Case Study: SunPower achieves ~40% output increase and doubles line capacity with Lighthouse Systems (Shopfloor-Online MES)

SunPower improves traceability, compliance and efficiency with Shopfloor-Online MES

SunPower, a global leader in solar PV manufacturing, faced rapidly rising demand, falling panel prices and strict traceability and compliance requirements (including a 25‑year warranty and US import duty rules) as it opened a new Ensenada plant. To stay competitive while increasing throughput and reducing cost per watt, SunPower turned to automation and an MES-based smart manufacturing approach using Lighthouse Systems’ Shopfloor-Online MES.

Lighthouse Systems implemented Shopfloor-Online integrated with PLC/OPC and Oracle ERP, embedding the MES deep into automated lines with scanners, sensors and serial‑based traceability, plus 24/7 support. The result: capacity per line roughly doubled and overall output increased by about 40%, direct labor and throughput time fell ~40%, and cost per watt dropped ~6%, while delivering full traceability, faster NPI and compliance with import and warranty requirements.

SunPower

Nikhil Padhi

Manufacturing Project Manager