Case Study: I Holland achieves reduced waste and increased production capacity with Lighthouse Systems' Shopfloor-Online

I-Holland Puts Shop Floor Data at the Heart of Growth Plans

I Holland, based in Nottingham, is a world‑leading manufacturer of precision tablet forming tools that needed better shop‑floor information to support an ambitious management target of 50% production growth over five years. With little automated reporting in place, Lighthouse Systems first provided SPC‑Light and in April 2004 replaced it with the enterprise‑wide Shopfloor‑Online MES to deliver the real‑time visibility and control required across orders, machines and inspections.

Lighthouse Systems implemented Shopfloor‑Online integrated with the ERP, later added PLC data capture (2007) and a Complaints & Concerns module (2009), and deployed operator workstations for direct SPC and measurement input. The results included cutting historical extra throughput waste from 10–15% to almost nothing, substantially reduced lead times, increased effective capacity (enabling priority deliveries), improved traceability and faster customer responsiveness, and stronger operator‑led continuous improvement.

I Holland

John Woloszczak

Operations Director