Tools, WIP, and people — visible across the plant.
Enforce safety, reduce tool loss, prove compliance.
Plants juggle thousands of tools, jigs, and work-in-progress units between cells. Carelens locates each one in real time, enforces zone safety, and audits compliance without slowing the line.
Plant 4 · Pune
Cell A1-A6 live
Tools out
62
3 overdue
Alerts
1
LOTO breach
LOTO breach · Cell A3
Badge W-118 entered locked-out cell. Work order WO-2204 only authorizes W-204 and W-209.
Floor activity
See allCell A1
Breach W-118
A2 → A3
A3 entry
Returned to crib
Where it shows up on day one
The questions Carelens answers for manufacturing teams from the first deployment.
Calibrated torque wrenches walk off — recalibration costs add up.
Every tool wears a tag. Tools must check back into the tool crib. Missing tools page the supervisor before the shift ends.
Unauthorized workers enter LOTO zones during maintenance.
Per-zone LOTO policy. Only badges on the work order can enter. Breach triggers buzzer + line-side display.
WIP gets lost between cells, missing the cycle time target.
Each WIP cart broadcasts its position. The MES sees flow in real time and surfaces stuck units automatically.
Shift attendance is a paper sheet that's wrong half the time.
Badges auto-clock-in when crossing the shift-line gateway. Payroll integration removes manual reconciliation.
Audits demand evidence of zone compliance.
Continuous logs of every badge crossing every zone, exportable as PDF for the auditor.
The hardware that ships with the platform
Pick the mix that fits your site — temporary or permanent, indoor or outdoor. Carelens supplies, commissions, and maintains everything below.
Rugged BLE tags for torque wrenches, jigs, fixtures.
- Industrial IP65 housing
- Heat-resistant variant
- 5-year battery
- Magnetic / clamp mount
ID-card BLE+UWB. Auto-clock-in at gateways.
- BLE + UWB
- Multi-week battery
- Drop / impact detection
- Lone-worker option
Anchors at cell, gate, tool crib.
- PoE / 24V DC
- Industrial enclosure
- Local zone logic
- OT-network safe
Battery-powered tag on every WIP cart.
- 3-year battery
- Drop sensor
- Tamper-evident
- Bulk-programming jig
What you get in the dashboard
Every signal from the hardware lands here. Roles, policies, alerts, reports — everything the manufacturing team needs in one place.
- Live shop-floor map with tools, badges, WIP
- MES / SCADA integration (OPC-UA, Modbus, REST)
- LOTO and calibrated-tool enforcement
- Shift attendance + payroll export
- OEE-grade utilization analytics per tool / cell
- Audit-ready compliance reports
Other industries we serve
Ready for a manufacturing pilot?
We ship the hardware, deploy on-site, and have you live in days — not quarters. Tell us your current pain points and we'll size the pilot.
- · Tailored hardware kit shipped to your site
- · On-site deployment and training
- · One human reply within a business day