Chassis Systems Ltd Enhances Production Efficiency with Lighthouse Systems Shopfloor-Online
Customer Company Size
Large Corporate
Region
- Europe
Country
- United Kingdom
Product
- Lighthouse Systems Shopfloor-Online
Tech Stack
- Wireless Network
- Rugged Tablet PCs
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Productivity Improvements
- Customer Satisfaction
Technology Category
- Functional Applications - Manufacturing Execution Systems (MES)
- Networks & Connectivity - Wireless Local Area Network
Applicable Industries
- Automotive
Applicable Functions
- Quality Assurance
- Process Manufacturing
Use Cases
- Machine Condition Monitoring
- Predictive Maintenance
- Remote Asset Management
Services
- System Integration
- Software Design & Engineering Services
About The Customer
Chassis Systems Ltd (CSL) is a joint venture between Dana and GKN, formed to produce chassis structures for Land Rover's Discovery and Range Rover Sport models. As a high-volume producer of complex, high-value parts, CSL places a strong emphasis on quality assurance. The company operates in the automotive industry, focusing on precision manufacturing processes that involve over 200 parts and more than 700 welds per chassis. Ensuring the quality of each product is crucial, and CSL has implemented procedures to measure and record inspection data across the production line. Historically, much of this data recording was done manually, which was time-consuming and prone to errors. CSL sought to improve efficiency, accuracy, and quality in its production processes by leveraging advanced technology solutions.
The Challenge
Chassis Systems Ltd (CSL) faced challenges in ensuring the quality of chassis structures for Land Rover's Discovery and Range Rover Sport models. The production process involved over 200 parts and more than 700 welds, requiring precise quality control. Historically, data recording was manual, making analysis cumbersome and time-consuming. CSL needed a solution to improve data visibility, automate processes, and increase inspection throughput. The manual system was inefficient, requiring operators to generate PDF documents for alerts, which consumed time and resources.
The Solution
CSL implemented Lighthouse Systems Shopfloor-Online to enhance data visibility and automate processes. The system's modular design allowed for future functionality additions, such as downtime analysis and maintenance management. Phase one focused on improving CMM data visibility, freeing up engineers' time and increasing inspection throughput by 50%. The system automated alerts for out-of-specification readings, eliminating manual PDF document generation. Phase two involved providing patrol inspectors with rugged tablet PCs connected to Shopfloor-Online over a wireless network. This allowed real-time reporting of visual inspections, replacing the manual catalog approach. Inspectors could now log checks and faults immediately, reducing training requirements and improving accuracy. Phase three ensured end-of-line quality checks, with faults input into Shopfloor-Online for detailed reporting and containment until repairs were made. The system provided a complete audit trail, enabling fault frequency and corrective action reporting.
Operational Impact
Quantitative Benefit
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