Lighthouse Systems is a global provider of manufacturing execution system software delivering real-time manufacturing operations management.


Established in 1990, Lighthouse Systems’ HQ is in the UK with operations in Europe, the USA and Asia.
Our MES / MOM solutions - based on Shopfloor-Online™ - help to measurably improve efficiency, output, compliance and customer satisfaction.
Directly and through our partners, we serve medium and large businesses from a wide range of sectors across the discrete, batch and process industries - in more than 50 countries worldwide.Lighthouse Systems is 100% focused on helping organisations digitally transform their manufacturing operations with MES.

** https://www.lighthousesystems.com/about

Overview Lighthouse



What is MES software?

Gartner defines Manufacturing Execution System (MES) software as a system “to manage, monitor and synchronizes the execution of real-time, physical processes involved in transforming raw materials into intermediate and/or finished goods”.
MES software delivers complete, accurate and accessible data enabling manufacturers to address the relentless drive for cost reduction and efficiency gains in today's manufacturing environment.
 Shopfloor-Online™is Lighthouse Systems' modular enterprise-level MES system to support digital transformation.

What are the benefits of Shopfloor-Online™ MES?

1. Get real-time visibility for real-time management

Paper, spreadsheets, standalone databases, measuring systems and SCADA systems are no longer able to provide the data required to drive today’s manufacturing enterprise. MES software replaces these fragmented systems to seamlessly connect the top floor and the shop floor, creating an unbroken thread of critical data across all manufacturing operations. MES software delivers:

  • Critical analysis in real-time, such as performance and quality indicators, displayed in a highly visual graphic format that mimics the process
  • Operator empowerment with the tools to react faster when issues arise
  • Benchmarking of machines, production lines, production runs, plants and drive improvement

2. Reduce operational costs

MES enables increased control on all production inputs.

  • Direct labor costs: the MES monitors the machines and progress of jobs and alerts operatives when needed, so operator time is released for other tasks, saving direct labor costs
  • Indirect labor costs: operations data is automatically collected from the machines and equipment, improving accuracy and saving hours of operator time
  • Material costs: real-time process control optimizes the quantity of material used to meet specifications; meanwhile real-time production counting can prevent over-making
  • Energy costs: constant automated monitoring of energy usage by all plant equipment will quickly help identify faults and drive optimization of equipment utilization

3. Drive efficiencies

MES supports performance improvement plans.

  • Throughput and asset utilization: with accurate downtime data - when, where and for how long - improving machine / line / plant performance
  • Change-overs: MES alerts key personnel when a job is nearly completed; with the scheduling functionality the MES software supports better planning as well as reaction to unplanned events such as material shortage or equipment breakdown
  • Cycle-time: the MES software tracks OEE (overall equipment effectiveness), enabling operations personnel to focus on cycle-time improvement activities based on accurate information

4. Improve agility and flexibility

MES increases competitiveness as it enables:

  • Fastest New Product Introduction (NPI)
  • Smoother integration of new processes, factories and personnel
  • Greater integration with the supply chain

See how Shopfloor-OnlineTM helped Nissan reduce NPI by over 50%
>>>Nissan Qashqai case study

5. Standardize operations and enforce best practice

MES software provides the framework for standardizing, enforcing and controlling the process.

  • Routings and workflows enforce the process and ensure control
  • Integration of the MES with machines and equipment removes the need for manual data collection, increasing accuracy and security
  • Dashboards show real-time performance of shifts, production lines and plant

Shopfloor-OnlineTM  provides the solid foundation required by manufacturing organisations to enable the Smart Factory.

6. Improve regulatory compliance

Quality Assurance and Control is often dealt with by departmental applications but it is best when it can be integrated within MES to improve:

  • Conformance
  • Responsiveness
  • Traceability
  • Compliance
  • Overall quality metrics

Shopfloor-OnlineTM provides a complete quality management software suite
See how Shopfloor-OnlineTM facilitates traceability and quality compliance for a leading electronic assembly manufacturer

>>>Gtech case study

7. Leverage MES for your digital transformation

If your organization’s manufacturing sites are running multiple legacy applications, then consolidating them within a single platform will bring many benefits:

  • Better control: a simpler infrastructure will give you better control over manufacturing IT
  • Reduce direct costs: IT resources are no longer needed to maintain home-grown applications
  • Material cost: elimination of paper on the shop floor and physical storage space
  • Host the MES software in the corporate data center or in the cloud
  • Ensure business continuity with an out-of-the-box MES application, built on standard technologies and supported worldwide.

Shopfloor-Online MES Modules



From Point Solutions to Enterprise Platform: a modular, expandable MES solution to help you achieve Manufacturing Excellence

The Shopfloor-Online MES software platform comprises 26 independent modules across the 4 main areas of manufacturing operations, as defined by the ISA-95 model.It is possible to select only the modules needed to meet an initial requirement, but over time more modules can be added as the scope increases, to build a comprehensive Enterprise MES system.





** Can click link in each area (4 area)