Empowering Efficiency:

Reducing Attrition with Guided, Intelligent Actions with Arch

At a key production site, a global contract manufacturer deployed Arch’s Action Manager to tackle high attrition rates on SMT lines. The pilot focused on enabling real-time detection and response to line-level issues, improving material utilization, and accelerating root cause resolution. Within the first week, the site saw a 12% reduction in attrition, translating to an estimated $65,000+ in annualized savings at one site, with plans for broader adoption already underway.

attrition-reduction-manufacturing-optimization

HIGHLIGHTS:

Attrition reduction within the first week

$5K+

Per line monthly savings

$65K+

Per site annualized savings

Real-time alerts for problem machines and component locations
Action Manager integrated with existing factory infrastructure
Pilot success expected to expand across additional lines and areas

The Challenge

High attrition on SMT lines was leading to excess material waste and lower production efficiency. Without real-time insights, the team struggled to identify patterns and implement timely corrective actions. Key operational challenges included:

Excessive material loss due to unmonitored attrition
No real-time alerting or visibility into line-level issues
Manual bottleneck identification and delayed resolution
Limited insight for planning future Continuous Improvement(CI) or predictive maintenance

The Arch Approach

To close the data-action gap, the customer piloted Action Manager, part of the Arch Platform, on two SMT lines using Fuji and ASM equipment. The pilot deployment featured:

Use of the attrition module with a 0.3% threshold for event detection
Targeted alerts delivered directly to operators for rapid response
Real-time monitoring of machine and component-specific issues
Cause and resolution tracking to enable future process improvement
Integration with existing IT infrastructure to streamline reporting and analysis

Key Outcomes

Attrition Reduced by 12% in One Week

Guided, intelligent actions enabled immediate impact on the lines.

● Attrition reduction aligned with target of 0.3%
● Lower material waste and more stable production flow
● Triggered real-time interventions by on-the-floor operators

Measurable Cost Savings and Line Optimization

Early results highlighted the broader business case for scaling the solution.

● $5,500 per line in monthly savings projected across similar lines
● $65,000+ in annualized savings per site
● Improved machine performance without major hardware changes

Foundation for Broader Action Manager Expansion

The pilot success provided a replicable model for further deployments.

● Action Manager now planned for additional lines and production areas
● Data infrastructure enabled future CI and predictive maintenance strategies
● Strengthened collaboration between IT, ops, and engineering teams

Strategic Lessons

Reducing attrition doesn’t require overhauling equipment. It requires targeted, real-time guidance that empowers teams to act decisively.

Key takeaways include:

Real-time alerts reduce material loss: Operators responded to issues before waste accumulated
Pilot programs prove value fast: A one-week rollout yielded measurable savings
Targeted thresholds drive action: A 0.3% attrition flag helped operators focus
Integrated tools scale faster: Built-in compatibility supported rapid deployment
Guided actions enable smarter production: Action Manager made improvement tangible and repeatable