Case Study: Implementation of RealTrac Zonal Positioning for Work Permit and Personnel Control

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Initial Situation

At an industrial enterprise, strict access control to production zones was required. The work permit process was paper-based, with no real-time verification of whether employees were in authorized zones, and no centralized statistics on staff movements. The goal was to automate access based on electronic work permits and employees’ actual location.

Solution

RealTrac deployed a BLE-based system: automatic entry/exit registration, linking employee tags with active electronic permits, real-time violation alerts, and digital time logs for zone presence. The solution utilized PROD TAG 100 badges (integrated with ACS), PROD POINT 520 access points, and the RealTrac software platform integrated with the work permit management system.

Project Stages

1. Site survey and definition of controlled zones

2. Integration between RealTrac and electronic work permits

3. Pilot project in one workshop with validation of entry/exit events

4. Scaling the solution across the entire enterprise

Results

• 100% automation of work permit control

• Reduced permit processing and entry verification time by ~40%

• Eliminated unauthorized access to restricted zones

• Comprehensive reporting for employees and zones over any chosen period

Conclusion

RealTrac’s BLE zonal positioning solution (PROD TAG 100 + PROD POINT 520) fully digitized the work permit process, improved safety, and reduced administrative workload.

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