Case Study: Allied Glass achieves real-time production visibility and reduced defects with Lighthouse Systems' Shopfloor-Online MES

Allied Glass gets a clear view of bottle production with Shopfloor-Online MES

Allied Glass, a manufacturer of premium glass bottles operating two factories in Leeds and Knottingley with a capacity of about 13 million bottles per week, needed better shop-floor visibility and faster, more accurate defect trending to protect product quality and reduce costly rejects. To replace paper-based processes and improve root-cause analysis, Allied upgraded to Shopfloor-Online MES (version 4) from Lighthouse Systems to capture defect data, track production runs, and link defects to specific moulds and sections.

Lighthouse Systems deployed Shopfloor-Online across both sites and integrated it with Allied’s PRISM ERP and the Otto measuring machine, delivering real-time dashboards, automated production order downloads, and drill-down reporting to pinpoint issues by machine, mould or section. The result was faster problem identification and resolution, on-demand incisive reports, reduced rejects and customer complaints, and improved throughput and quality — enabling Allied Glass to proactively target resources and drive process improvements across its production of millions of bottles weekly.

Allied Glass

Richard Johnson

Continuous Improvement Manager