Ultra-Wideband as a Backbone for Manufacturing Efficiency

Manufacturing has continually evolved with technology. From the rise of CNC machines to the introduction of robotics, each wave of innovation has pushed factories toward greater speed, precision and adaptability. The current wave, often described as smart manufacturing or Industry 4.0, is no exception. At its heart lies data: where products are, how machines operate and how materials move across the shop floor. 

Among the many technologies enabling this transformation, ultra-wideband (UWB) location systems stand out as a driver of efficiency and accuracy.

From tools to tracking: A case study in Trumpf’s transformation

One striking example of UWB adoption can be found at Trumpf, a supplier of machine tools and laser systems. The company has demonstrated how precise asset tracking can directly improve manufacturing outcomes by implementing real-time location systems across several of its facilities in Europe and the United States. Within months of deployment, Trumpf recorded measurable gains in on-time delivery, reductions in failure rates for sheet metal production and improvements in overall productivity. 

The success of this deployment highlights an essential reality about modern industrial environments. Factories have reflective metal surfaces, moving equipment and constantly shifting layouts. These conditions make asset tracking difficult. Traditional approaches such as RFID or Wi-Fi often struggle to deliver accurate or consistent results in these settings.

UWB, however, is designed to thrive in such complex environments. By operating across a broad spectrum of frequencies and using very short signal pulses, UWB can achieve centimeter-level accuracy even in multipath conditions where other systems falter.

Why UWB matters in Industry 4.0

Industry 4.0 is frequently described as a maturity model where organizations progress from basic digitization toward highly automated, self-optimizing operations. At the lower maturity levels, manufacturers can improve efficiency with simple data capture or automation. Real-time location data becomes increasingly essential as companies move to more advanced levels. 

An independent study by the Fraunhofer Institute emphasized that starting at level three of Industry 4.0 maturity, accurate and continuous location information is critical. By level four, which involves the use of advanced digital twins and autonomous processes, there is virtually no substitute for UWB's performance.

The reason for this is that accurate location data underpins many of the technologies associated with the smart factory. Digital twins, for instance, rely on precise measurements of where tools, products and machines are located at any given moment. Autonomous mobile robots need consistent positioning data to navigate crowded factory floors safely and efficiently. Augmented reality (AR) systems that guide workers through complex assembly or maintenance tasks require location accuracy to anchor virtual instructions to the correct physical objects. 

Even routine operations such as power tool management and predictive quality control depend on knowing exactly where assets are and how they are being used.

Other wireless technologies can provide general awareness but lack the accuracy and reliability to support tightly integrated processes. UWB distinguishes itself through its ability to maintain precision and resilience in harsh environments where multipath reflections are unavoidable. This makes it uniquely suited for industrial use.

Building scalable UWB systems

Introducing UWB into a factory environment often begins with small, targeted use cases. Many manufacturers start by tracking work orders or transport units, such as forklifts and automated guided vehicles. Once these early applications prove their value, deployments expand to include tools, raw materials, finished products, equipment and operators. This phased approach allows organizations to demonstrate return on investment in the short term while building the foundation for more advanced use cases in the future.

Strategic sensor placement plays a central role in scalability, as UWB systems rely on a network of anchors and tags that must be positioned to cover the factory floor effectively. 

The quality of coverage determines not only the accuracy of the system but also the number of applications it can support simultaneously. Planning deployments with scalability in mind ensures that the same infrastructure can eventually handle multiple use cases ranging from material tracking to AR-guided workflows.

This need for scalability is one reason why open standards are critical. Proprietary systems may solve individual problems, but risk creating isolated silos that are difficult to expand or integrate. Standards such as omlox define core zones and hubs that allow devices from different vendors to interoperate within the same localization environment. 

By building on these standards, manufacturers can adopt UWB solutions that are both future-proof and flexible.

The value of open standards

Trumpf’s work with omlox illustrates the importance of open collaboration in industrial technology. As a founding member of the consortium, the company helped establish omlox Core Zone, a framework that ensures interoperability between UWB devices and systems from different manufacturers. 

The value of this approach extends beyond Trumpf itself. For the broader industry, standards like omlox reduce vendor lock-in, simplify system integration and foster a more competitive ecosystem of suppliers.

For equipment providers and OEMs, standards open the door to innovation. Developers can design products that integrate into existing infrastructure, confident they will remain compatible as factories expand their systems. For manufacturers, standards assure that today’s investments will continue to generate value as technology evolves. The combination of open standards and scalable UWB hardware allows factories to move toward complete digital transformation without the risk of stranded investments.

Hardware examples of UWB in practice 

The success of UWB in industrial settings depends on the design of the chipsets that power it. Devices like Qorvo’s 3000-series UWB chipsets. These chipsets support real-time positioning with centimeter-level accuracy while maintaining signal integrity in the face of reflections and interference. Their performance enables various applications, from autonomous robot navigation to worker safety systems that prevent collisions between equipment and personnel.

The UWB deployments at Trumpf illustrate how such chipsets can form the backbone of scalable real-time location infrastructure. By combining UWB hardware with omlox standards, the company created an environment where digital twins, predictive quality management and AR-guided workflows draw on the exact source of accurate location data. This integration demonstrates the broader value of UWB — rather than solving one problem at a time, it establishes a common platform that supports multiple layers of the smart factory.

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