A lean approach to eliminating manual search and identification waste in server repair operations using a GPS-assisted hybrid tracking system

This study developed a prototype hybrid tracking system intended to reduce manual search and identification waste in server repair operations. Unlike pure GPS-based systems, which are unreliable in indoor environments due to signal obstruction, the proposed system integrates GPS, Bluetooth, and Cellular (GSM/LTE) connectivity to provide practical indoor localization capability. The problem originated from the current repair workflow where technicians spend working hours searching for server machines and manually verifying identification numbers before actual repair work can begin. Using baseline data from one 8-hour work shift, the study found that out of 275 missing server machines, only 88 units were located while 187 units remained unfound—a retrieval rate of only 32.00%. The remaining 187 units often spilled into subsequent workdays, compounding the operational backlog. To address this problem, the study proposed a system that binds a hybrid tracker to a server machine through its unique serial number and allows the user to locate the machine using a command sent via a mobile application, triggering a fast-blinking RGB LED alert and an audible beep to eliminate manual search waste. The study employed a developmental-descriptive design and relied on frequency counts and percentage analysis. The findings confirm that the current process contains Lean-related waste—specifically motion and waiting—and that a hybrid tracking approach is a practical intervention for improving machine traceability in repair operations. The study is limited to prototype development and baseline analysis, but it provides a solid foundation for future implementation and time-based performance evaluation.