Film Coating Manufacturer Improves Productivity via Automated Downtime Tracking

Case studies

MES

Film Coating Manufacturer Improves Productivity via Automated Downtime Tracking

Case study shows how Shopfloor-Online automated downtime capture and OEE analysis for a precision film coating line, replacing manual Excel logging.

Published

June 4, 2026

Read time

3 min read

Source

A film coating manufacturer replaced manual Excel-based downtime recording with Lighthouse Systems Shopfloor-Online. The MES automatically extracts stop events and reasons from PLCs while allowing operator annotations for material, labor, or order issues. Real-time dashboards and historical analysis tools enabled process engineers and managers to identify recurring losses, calculate OEE, and drive sustained reductions in unplanned stops across 24/7 operations.

Key takeaways

Automated PLC data capture replaced error-prone manual Excel downtime logs

Operators annotate events with material, labor, or quality reasons the PLC cannot detect

Real-time OEE, availability, and downtime reports available to operators and management

Process parameter logging (temperature, tension, feed rate) revealed hidden performance issues

Phased rollout supports future ERP integration and quality module expansion

Market overview

SCR methodology note

Vendor landscape

Leaders

Implementation considerations

Important consideration

Original Source

Vendors mentioned in this report

No items found.