Case Study: PET Bottles Supplier Manufacturing Company achieves better quality control with Lighthouse Systems

Leader in PET Bottles Increases Customer Satisfaction Through Improved Quality Systems

PET Bottles Supplier Manufacturing Company, operating as Constar in the case study, needed to replace cumbersome paper-based quality control processes across its UK, European, and US facilities. The manual system was error-prone, allowed data falsification, and led to forgotten checks, making it difficult to maintain consistent quality and keep customer complaints under control. The company worked with Lighthouse Systems and its Shopfloor Online MES software to improve visibility and accuracy of quality data.

Lighthouse Systems implemented Shopfloor Online to automate quality checks, capture SPC data, and connect measurements from gauges and CMMs directly to the system across closures, bottles, and pre-forms. The result was better process control, fewer logging errors, quicker identification of production issues, reduced waste and stoppages, and lower customer complaints. Constar also gained faster access to historical production data for comparison and setup, helping streamline operations and improve overall quality performance.