FROM LOCAL SUCCESS TO GLOBAL ADOPTION:

How a Leading Electronics Manufacturer Scaled Downtime Reduction with Arch Systems

A global automotive parts OEM partnered with Arch Systems to reduce downtime at a Lighthouse factory in China. Starting with traditional tracking, the company generated $3.7 million in hard savings over a two-year period. Building on that success, the team began scaling downtime analytics globally and piloted Arch’s AI-powered Automated Downtime Labeling at the lead site.

In high-speed, high-mix environments, misclassified or uncategorized downtime can hinder improvement efforts. Arch’s Automated Downtime Labeling automatically identifies the true source of disruption, removing manual burden from operators and accelerating corrective action.

With both downtime capabilities in place, the company enabled global rollout without disrupting operations and is now expanding Automated Downtime Labeling to additional factories worldwide.

HIGHLIGHTS:

$3.7M+

$3.7M+ hard savings from Lighthouse factory; additional savings expected globally

70% automatic downtime classification from shopfloor machine data and easy AI voice labeling for the rest

100% global adoption of Arch’s downtime tools following pilot success

Zero disruption to operations

during deployment—fully parallel to existing systems

The Challenge

Scaling downtime reduction beyond one successful site required overcoming several hurdles:

Varying site maturity: Other factories lacked the same level of digital readiness.
Behavioral and system barriers: Change resistance and reliance on homegrown tools hindered adoption.
Need for scalable adoption: Following strong results, the customer requested a low-friction, enterprise-ready solution from Arch.

The Arch Approach

Arch Systems deployed a two-tiered strategy to drive adoption and scale insights:

Advanced labeling at the Lighthouse: Arch deployed Automated Downtime Labeling, improving data fidelity and accelerating root cause detection in fast-paced environments.
Traditional tracking across global sites: Other factories adopted Arch’s downtime tracking tools, replacing legacy systems due to their ease of use and rapid deployment.
Non-disruptive rollout: All solutions were deployed without requiring any production downtime.

Key Outcomes

Lighthouse Proven Success, Automation to Expand

Automated Downtime Labeling and traditional tracking enabled the lead factory to generate over $3.7M in hard savings. The manufacturer plans to extend AI-powered Automated Downtime Labeling to additional factories.

Enterprise-Wide Adoption

All factories transitioned off legacy systems and adopted Arch’s downtime tracking, thanks to its intuitive interface and low operational burden. Dramatic improvement in data integrity and quality during downtimes drove adoption globally.

Standardization and Ongoing Improvement

With consistent tools and trusted data across sites, the manufacturer is now driving continuous improvement and operational excellence worldwide.

Strategic Lessons

Automation unlocks adoption: AI-driven labeling removed the manual burden that had previously stalled progress, enabling scalable global expansion.
Simplicity drives scale: Global teams embraced Arch’s downtime tools because they were easy to use, not because they were mandated.
Frictionless integration accelerates impact: Parallel deployment ensured fast time to value with no operational risk.
AI maturity is a journey: Piloting advanced tools at one site before scaling enterprise-wide enabled both cultural readiness and technical refinement.
Good data leads to good decisions: Automating downtime classification minimizes human error and ensures the right teams act on the right problems—fast.