How IPT-USP Achieved 60% Faster Inventory and 24/7 Asset Monitoring with SmartX HUB
Introduction
Customer Case: ZEISS — Manufacturing Yield Improvement
ZEISS is a global leader in optics and optoelectronics, with a presence in Brazil since 1913. Operating four vision centers in Brazil, ZEISS produces high-quality prescription eyeglasses and lenses where accuracy and quality are paramount. SmartX HUB's RFID solution was deployed to eliminate production errors and optimize the entire manufacturing process.
The Challenge
Enhancing the yield of eyeglass manufacturing was crucial to reduce waste and lower costs while maintaining product quality. Accuracy in prescription eyeglasses is non-negotiable — errors lead to customer dissatisfaction, complaints, and costly returns. Common mistakes included selecting the wrong lens type, material, or coating during production, and manual data entry consumed hours of production time daily.
The Solution
SmartX HUB integrated with ZEISS’s ERP to provide end-to-end RFID tracking across the production floor:
- 1 RFID Middleware managing the entire production tracking system.
- 40+ RFID readers installed at production stations for automated process control.
- 4 Zebra RFID handhelds for flexible, mobile scanning.
- 1 Smart BOX (RFID Cabinet) for batch verification.
- 2,000+ RFID orders processed daily, each tracked through every production step.
- ERP integration linking orders to material selection and controlling all production stages.
Implementation and Results
The implementation of SmartX HUB delivered measurable, transformative results for IPT:
- Boosted productivity by saving hours of daily manual data entry and reporting.
- Live factory visualization with real-time dashboards showing work-in-progress on the shop floor.
- Identification of production bottlenecks, enabling route optimization and JIT stock management.
- Significant cost savings through error reduction and process optimization.
Conclusion
ZEISS's deployment of SmartX HUB proves that RFID-driven manufacturing tracking can dramatically improve yields, reduce errors, and optimize production flow. When every order is tracked through every station, quality becomes a certainty rather than a hope.
For more details on this innovative project and other initiatives, visit our website and stay tuned for more updates on how our customers continues to lead in safety and operational excellence
About us
SmartX HUB delivers intelligent, real-time IoT and RFID solutions that empower organizations across manufacturing, logistics, healthcare, oil & gas, and more. By integrating smart technology with deep domain expertise, we help companies enhance operational efficiency, ensure compliance, and make data-driven decisions that improve safety, productivity, and asset performance.
From asset tracking and condition monitoring to workforce safety and supply chain automation, our scalable platform puts visibility and control at the core of every process—supporting sustainable, high-performance operations for the demands of the 21st century.
