Big ticket manufacturers turn to small specialist factory systems

Lighthouse, which only launched its web browser and Microsoft-based ShopFloor Online MES (manufacturing execution system) three years ago, claims it’s further evidence that big-name manufacturers are finally investing in joined up systems where it matters – on the plant floor. And it claims that benefits achieved aren’t just the classic improvements in factory operations – like better OEE (overall equipment analysis) and downtime analysis-led machine maintenance – and business visibility of the shop floor and WIP (work in progress). They’re also process and product quality enhancements, automated traceability, better tool management, increased plant and resource flexibility and sustainable lean manufacturing improvements. Most important, they’re being achieved at significantly reduced cost overall compared to the status quo of piecemeal systems with multiple databases under individual control, all with attendant maintenance, upgrade and integration overheads. “Until recently most operational managers haven’t known any different: they haven’t challenged their existing factory systems. They’re just the way things are done,” observes Lighthouse director Tim Barber. “But the bigger manufacturers are now seeing the problems – the gaps in their knowledge, the delays in reports from different systems, the costs and constraints.” Nissan is a good example. The site in Sunderland is now a Lighthouse user in powertrain and latterly also assembly, and has been credited with helping with the speedy and successful launch of the Qashqai small four by four.