Whether you’re in metalworking, electronics, or general manufacturing, keeping track of materials, tools, and equipment can be one of the biggest time sinks on the shop floor. With complex workflows, thousands of moving parts, and constant deadlines, losing track of even a single order or gauge can mean wasted hours, missed shipments, or costly downtime.
That’s exactly the problem WISER Systems solves. And as we head to FABTECH 2025 (Booth #B10015), the leading trade show for metalworking and manufacturing, we wanted to highlight three real-world use cases from metal shops already using our system every day. We also have this content on video, at the end of the page.
Case Study #1: Tracking Work-in-Process (WIP)
A metal shop in Chicago manages around 5,000 active work orders at any given time, with approximately 10% cycling daily. To keep track of their work-in-process (WIP), they place WISER tags inside bins or containers holding metal parts like nuts, bolts, and screws.
Here’s how it works:
- Tagging and Assignment: Each bin is assigned a tag linked to a specific work order (e.g., “WO 1234”). The tag is dropped into the bin, and the work order is logged in WISER’s system.
- Real-Time Tracking: As bins move through processes like spin-dip coating or black oxide application, expediters can search for a specific work order using the WISER Tracker App. For example, searching “WO 1234” instantly reveals the bin’s location on the facility map.
- Streamlined Workflow: This eliminates the time-consuming task of manually searching a large shop floor, allowing workers to quickly locate and move bins to the next stage.
With 5,000+ work orders in motion at any time, this shop saves hours each day simply by knowing exactly where each order is at every stage.
Case Study #2: Tracking Gauges & Quality Control
In a metal shop near the Illinois-Indiana border, WISER’s system is used not for WIP but for tracking gauges and calipers critical to quality control. This shop, which ensures metal parts and welds meet precise tolerances, manages about 2,000 gauges floating around their facility.
Their challenge? With more than 2,000 gauges floating around, calibration schedules become a nightmare. These gauges require annual calibration to maintain accuracy, and locating them quickly is essential to keeping production on track.
Here’s how they use WISER:
- Tagging Gauges: Instead of tagging WIP, this shop places WISER tags on gauges and calipers (e.g., “Caliper 4567”).
- Customized Properties: You can add the Tag to a Group and have the tag show up in the group’s defined color. Not only that, but you can also customize 5 different properties and fill in any information you want (e.g. calibration due dates).
- Efficient Search: By searching for a specific gauge or calibration date, workers can instantly locate the tool on the facility map, avoiding hours of searching. For example, a search by data (e.g., 2025_9 for September) can find all the calipers that require calibration in September, so nothing is calibrated late.
- API Integration: WISER’s open API allows integration with existing systems like MES, ERP, or gauge tracking software, enabling seamless data sharing and automation.
This use case saves significant man-hours, ensuring gauges are found quickly and production continues without delays. While this example focuses on metal manufacturing, the concept applies to any industry tracking test equipment, such as electronics manufacturing.
Case Study #3: Tracking Tooling
This third shop specializes in stamping sheet metal parts. When a customer orders a specific part (e.g., “Part XYZ”), the shop needs to locate the corresponding tooling (e.g., “Die PZ002-3”) quickly to begin production. Every second wasted searching translates to lost revenue.
Here’s how WISER helps:
- Tagging Tooling: Each die or tool is tagged with a unique identifier (e.g., “PZ002-3”) and associated with a customer or part series in the WISER system.
- Flexible Search: Operators can search by tool name, customer, or series. For example, typing “PZ” or “Company 1” pulls up a list of relevant tools, accommodating workers on second or third shifts who may not know exact nomenclature.
- Color-Coded Groups: As mentioned before, items can be grouped (e.g., “Tooling”) and displayed in distinct colors on the map, making them easy to differentiate from other assets like WIP or gauges.
- Time Savings: Instant access to tool locations reduces downtime, allowing the shop to start stamping parts faster and meet tight production schedules.
This approach is especially valuable in high-pressure environments where speed is critical, and it’s applicable to any manufacturing facility managing specialized equipment or tooling.
Beyond Metal Shops
While these examples come from metal-focused facilities, the same principles apply across industries. Electronics manufacturers use WISER to track test equipment, job shops use it for WIP, and countless others rely on it to reduce wasted motion and keep operations running smoothly.
Visit our Use Cases page or our Case Studies Blog sections for more examples.
Visit us at FABTECH
We’ll be at FABTECH this year showcasing WISER’s real-time location solutions. If you’re attending, stop by our booth #B10015 to see live demos and explore how your facility could benefit.
Not going to the trade show or can’t make it? No problem.
If you are interested in talking with someone from WISER about how we can help at your facility, please feel free to reach out. You can contact us via our website, email, or phone.
We can share detailed case studies, arrange a demo or even arrange visits to similar shops (with their permission) to see the system in real-world settings.
