Case Study: Ford Motor Company achieves real-time vehicle and parts visibility, faster fulfillment and major cost savings with Zebra RTLS

Company-Wide Real-Time Location System Drives Efficiency at Ford Motor Company

Ford Motor Company faced the challenge of tracking tens of thousands of parts and finished vehicles across large plants and yards, where misplaced items could halt production, delay deliveries and bloat inventory. Locating a single car among thousands or keeping line-side parts flowing under lean manufacturing practices required much faster, real-time visibility than traditional methods allowed.

Ford deployed Zebra’s wireless RTLS—including VTMS for vehicle tracking and WhereCall/WhereLAN/WherePort for parts and replenishment—at roughly 35 plants, using low‑power tags and ceiling antennas to pinpoint items to within about 10 feet. The system cut search times from hours to seconds, automated Kanban replenishment, delivered labor efficiencies and implementation savings of roughly $200,000–$500,000 per facility versus hardwired systems, installed in weeks, achieved near Six Sigma reliability and may reduce vehicle lot time by at least one day.

Ford Motor Company

Al Ver

Vice President of Advanced and Manufacturing Engineering