Case Study: Rexam achieves consistent quality and rapid traceability across 19 European plants with Lighthouse Systems' Shopfloor-Online

Rexam focuses on quality at all European production plants with new software from Lighthouse Systems

Rexam, the world’s number one beverage can manufacturer producing more than 50 billion cans a year, needed to tighten and standardize quality control across 19 European plants that had outgrown their legacy systems. Seeking a web‑based, multilingual, operator‑friendly system that would integrate with SAP and machine downtime data and support lean shop‑floor working, Rexam selected Lighthouse Systems and its Shopfloor-Online solution.

Lighthouse Systems deployed Shopfloor-Online across all 19 plants, integrating with SAP and downtime feeds to present the correct checks, provide SPC charts, alarms, multi‑lingual operator screens and automatic customer certificates. The rollout standardized reporting, improved process capability, reduced customer complaints, removed a manual 30‑minute certificate assembly task through automatic reporting, and delivered two‑hour traceability and real‑time alerts—giving Rexam faster responses and measurable quality and efficiency gains.

Rexam

Bill Neilson

Customer and Operations Quality Director