From Machine Data to Global SMT Standardization

A lighthouse SMT facility achieved 297% ROI and 50+% downtime reduction, helping drive more than $750K in annual savings across dozens of SMT lines globally

A global manufacturer operating a multi-site SMT network sought to improve OEE, reduce downtime, and establish a standardized approach to performance management across facilities worldwide.

One lighthouse facility became the first fully implemented deployment and quickly emerged as the model for global rollout. Across seven SMT lines, the deployment delivered $277K in annual net savings, achieved a 297% ROI with a 4.0-month payback period, increased OEE from 62.8% to 72.6%, and reduced downtime by more than 50%, decreasing average downtime from 3.45 to 1.65 hours per line per day.

The site also achieved 99.8% downtime labeling adoption, creating the operational visibility and data consistency needed to scale improvement across the SMT network.

Building on the success of the lighthouse deployment, the manufacturer expanded Arch across multiple facilities worldwide. Today, Arch supports dozens of SMT lines globally, delivering more than $750K in annual savings with a 192% ROI. Every site is ROI positive, with downtime labeling consistently above 95%, creating a common foundation for sustained OEE, downtime, and changeover improvement.

From Machine Data to Global standardization

HIGHLIGHTS:

$277K

annual net savings across seven SMT lines

297% ROI

with a 4.0-month payback

downtime reduction, from 3.45 to 1.65 hours per line per day

OEE improvement, from 62.8% to 72.6%

reduction in major downtime, from 15% to 8%

downtime labeling adoption

The Challenge

The manufacturer needed a scalable way to improve OEE and reduce downtime across SMT operations, starting with consistent, reliable data.

Fragmented connectivity limited access to machine data
Inconsistent downtime tracking reduced visibility into losses
Limited insight into OEE drivers slowed improvement efforts
Engineering teams relied on delayed, manual analysis
No repeatable model existed for scaling improvements across sites

Without a consistent data foundation, the organization lacked the visibility needed to systematically improve OEE across facilities.

The Arch Approach

The lighthouse facility implemented Arch to connect equipment, standardize downtime data, and enable real-time improvement.

Connected and stabilized SMT equipment data across lines
Standardized downtime labeling across operators and shifts
Embedded real-time performance analytics into daily operations
Automated issue and job creation through operational system integrations
Established deployment standards to support global rollout

This approach created a scalable operating model that accelerated OEE, downtime, and changeover improvement across sites.

Key Outcomes

Improving Equipment Performance

Increased OEE from 62.8% to 72.6%
Reduced downtime per line from 3.45 to 1.65 hours per day
Reduced major downtime from approximately 15% to 8%

Building a Reliable Data Foundation

Achieved 99.8% downtime labeling adoption
Enabled consistent, line-level root-cause analysis
Standardized performance measurement across lines and shifts

Delivering Financial Impact

Delivered $277K in annual savings
Achieved 297% ROI with a 4.0-month payback period
Demonstrated measurable business value

Creating a Scalable Operating Model

Established a lighthouse deployment model for the broader SMT network
Enabled repeatable rollout of performance improvements across global sites
Expanded Arch beyond SMT into additional manufacturing processes

Strategic Lessons

Start with a high-impact use case: Downtime visibility delivered rapid ROI and built momentum for broader improvement
Build a lighthouse site with local ownership: Local expertise accelerated adoption and knowledge transfer across facilities
Make performance actionable in real time: Live visibility enabled faster response and sustained downtime reduction
Standardize before scaling: Common definitions and workflows created a repeatable framework for network-wide deployment