Case Study: Film Coating Manufacturing Company achieves real-time downtime visibility and improved OEE with Lighthouse Systems' Shopfloor-Online

Film Coating Manufacturer Achieves Higher Productivity with Clear Downtime Data Visibility

Film Coating Manufacturing Company, a producer of precision coatings for electronic and decorative applications, struggled with limited visibility of machine downtime and relied on manual Excel-based recording across large, PLC-controlled multi-stage coating lines running 24/6–7. They needed real-time operator alerts, easy event annotation, robust downtime analysis, OEE reporting and a path to integrate job- and run-level data with their ERP. After evaluation they chose Lighthouse Systems and its Shopfloor-Online solution.

Lighthouse Systems implemented Shopfloor-Online, linking directly to PLCs to automatically capture stop events, reasons and production meters while allowing operators to annotate and reclassify events and capture process parameters (temperatures, tensions, feed rates). The system delivered real-time dashboards, historical downtime analysis and OEE calculations; operators save time, initial stoppages fell quickly and sustained performance improvements followed as engineers used the data to drive fixes. Lighthouse Systems continues rolling out the solution and plans ERP and Quality module integrations.