Intelligent Real-Time Kanban Automation Using Ultra-Wideband Positioning: Methodologies and Performance Evaluation

ABSTRACT: Traditional electronic Kanban (eKanban) systems depend on manual scans and offer only discrete material visibility, limiting responsiveness and automation in lean manufacturing environments. These operational bottlenecks are magnified in high-mix contexts, where delayed replenishment signals degrade flow stability, increase work-in-progress, and hinder sustainable material handling. Furthermore, vendor-specific systems lack interoperability for scalable automation, constraining the development of intelligent manufacturing solutions. This work investigates whether zone-based replenishment automation can be enabled through real-time locating systems (RTLS) using open interoperability standards, addressing a gap in empirical validation of such approaches. A middleware architecture was developed that integrates ultra-wideband (UWB) positioning, an Omlox-compliant location middleware (DeepHub), and a cloud-based eKanban system to replace manual triggers with geofence-driven order creation. The novelty of this study lies in demonstrating a fully automated Kanban signaling loop built on the open Omlox standard, providing vendor-independent RTLS interoperability and eliminating human intervention in replenishment signaling. This contributes new knowledge on how continuous location data can be converted into actionable replenishment events in a standards-based, modular manner, enabling more intelligent and autonomous material-flow control. A controlled proof-of-concept experiment simulating shop-floor conditions showed that the system achieved a 100% detection success rate, zero duplicate orders, and an average trigger-to-action latency of 2.7 s, while automatically recovering from authentication and WebSocket failures. These results provide the first empirical evidence that Omlox-compliant RTLS middleware can reliably support zone-based eKanban automation. The findings have direct implications for intelligent and sustainable manufacturing by demonstrating a scalable pathway toward interoperable, real-time material-flow systems that reduce manual intervention, avoid unnecessary handling, and lower work-in-progress. More broadly, the work addresses the current lack of empirical validation of open-standard RTLS integration within lean and sustainable production environments.