Case Study: Chassis Systems Ltd achieves improved shop-floor efficiency, accuracy and quality with Lighthouse Systems Shopfloor-Online

MES System Delivers Shop Floor Efficiency to Chassis Manufacturer

Chassis Systems Ltd (CSL), a joint venture between Dana and GKN that manufactures chassis for Land Rover Discovery and Range Rover Sport, faced a precision-quality challenge: more than 200 parts and 700 welds per chassis required extensive manual measurement and inspection recording, making analysis slow and error-prone. To gain real-time visibility and reduce manual effort, CSL turned to Lighthouse Systems and its Shopfloor-Online solution.

Lighthouse Systems implemented Shopfloor-Online in three phases—CMM data integration, wireless roving inspection with rugged tablets, and end-of-line quarantine—automating alerts, replacing PDF/manual reporting, and providing a full audit trail. The rollout freed operator time, increased CMM sampling throughput by about 50%, enabled minute-by-minute inspection reporting, improved fault containment and repair tracking, and helped CSL move closer to consistent in-spec production—demonstrating clear operational and quality gains delivered by Lighthouse Systems.