Data-Driven Decisions:

How a Global Manufacturer Used Arch to Recover $10M+ in High-Value Components

Faced with excessive waste from its global network of placement robots, a leading contract manufacturer turned to Arch Systems to uncover hidden recovery opportunities. By integrating real-time attrition data with part cost insights, Arch surfaced over $10 million in high-value components that were previously unrecovered. The result: smarter recovery decisions, reduced material waste, and a measurable improvement in cost efficiency across global production sites.

manufacturing-data-analytics-cost-recovery

HIGHLIGHTS:

$10M+

Recovered in valuable components

Real-time integration of attrition + part cost data
Improved decision-making on when recovery adds value
Reduced waste without overspending on low-value parts
Powered by Arch insights across global SMT operations

“Arch brings rich data-based analytics, visualizations, and intelligent actionable insights to optimize our operations and performance.”

— VP of Asset Management

The Challenge

Without clear, data-backed guidance, the manufacturer struggled to prioritize component recovery effectively, leading to overlooked high-value parts and wasted effort on low-value ones. Key operational challenges included:

Loss of high-value components across a global network of placement robots
No visibility into recovery ROI at the part level
Unnecessary expense spent recovering low-value parts
Lack of scalable intelligence to guide recovery decisions

The Arch Approach

Arch combined real-time attrition data with cost analytics to focus recovery efforts where they would have the greatest financial impact. The Arch platform deployment featured:

Arch analysis of placement robot attrition data
Integration of component-level cost data to prioritize recovery
Real-time dashboards to guide high-ROI decisions
Embedded insights to reduce wasted effort on non-critical parts
A scalable model supporting consistent execution across global sites

Key Outcomes

Real-Time Insight Into Component Losses Unlocked Actionable Data

Arch identified high-value components being lost during pick-and-place operations that previously went unaddressed.

● Surfaced >$10M in unrecovered component value
● Enabled visibility into where waste had gone undetected
● Provided clear signals to improve material retention

Smarter Recovery Decisions Improved Cost Efficiency

By integrating cost analysis with real-time attrition data, Arch helped teams focus recovery efforts where they mattered most.

● Avoided excessive recovery of low-value parts
● Redirected labor and automation to maximize ROI
● Reduced total recovery costs while increasing component value capture

Data-Driven Practices Standardized Across Sites

The platform’s insights created consistent global guidelines for intelligent recovery and performance monitoring.

● Empowered site-level and enterprise-level teams with unified analytics
● Created a repeatable, scalable approach to optimizing component use
● Strengthened digital operations with smarter material flow controls

Strategic Lessons

This case illustrates how combining real-time manufacturing data with financial insight can unlock significant value, turning what was once routine material loss into a strategic opportunity for savings and efficiency.

Key takeaways include:

Value visibility changes behavior: You can’t optimize what you can’t measure
AI delivers actionable context: Arch provided clarity on where recovery truly mattered
Smart recovery is not just about more, but better: Focus efforts where ROI is highest
Line-level intelligence scales enterprise-wide: Arch enabled a global shift in recovery efficiency
Technology + expertise = transformation: Arch combined speed, insight, and guidance to drive results