Case Study: Ceres Power Holdings PLC achieves production scale-up and real-time traceability with Lighthouse Systems' Shopfloor-Online

MES System Scales Up Production for Fuel Cell Manufacturer

Ceres Power Holdings PLC, a UK leader in fuel cell technology, was moving from small‑scale trials to larger volume production but found its paper‑based and spreadsheet‑centric systems unable to support growing complexity, traceability and real‑time visibility needs. With a new ERP in place, Ceres selected Lighthouse Systems and its Shopfloor‑Online MES to provide a flexible, scalable manufacturing platform that could handle batch, automated and manual assembly while adapting rapidly to ongoing product and process changes.

Lighthouse Systems implemented Shopfloor‑Online in three phases (Materials Preparation, Cell Production, Assembly), building ERP interfaces, barcode scanning and configuring routings, BOMs and quality/traceability checks. The solution removed spreadsheets from the shop floor, improved WIP and inventory visibility, reduced scrap from aged WIP, made data immediately available for faster decision‑making, and put Ceres Power Holdings PLC in a position to scale production to meet its strategic goals.

Ceres Power Holdings PLC

Ananda Mello-Costa

Quality Manager