From Manual Reports to Real-Time Insight

How a Global Electronics Manufacturer Modernized Asset Decisions and Avoided $14 Million in Capital Expenditures with Arch

A global electronics manufacturer transformed its asset management program with Arch’s Factory Intelligence Platform. By automating real-time data collection across more than 50 factories and ensuring KPI accuracy through advanced validation, the company gained the confidence to redeploy idle equipment rather than invest in new capacity, avoiding over $14 million in capital expenditures across its top five customer accounts in one year alone.

HIGHLIGHTS:

$14M

$14M CapEx Avoided by reallocating existing assets instead of purchasing new machines

Real-Time Accuracy You Can Trust: 95%+ accurate shopfloor data, self-healing and auditable to ~100% of actual machine facts

50+

50+ Global Sites Connected through automated real-time data collection

Daily Insights Replacing Bi-Monthly Reports,
accelerating confident decisions across operations

The Challenge

Manual reporting and fragmented data made it impossible for the company’s asset management team to accurately measure utilization or act quickly on insights.

Site teams manually consolidated spreadsheets from more than 50 factories, producing utilization reports only every two months.
Connectivity gaps and inconsistent machine data introduced uncertainty in KPIs, eroding trust in strategic decisions.
Leadership needed a reliable, automated foundation to ensure visibility, accuracy, and timely insight into asset performance across the global network.

The Arch Approach

Arch deployed a managed data connectivity and analytics program within its Factory Intelligence Platform designed to deliver both data accuracy and global visibility.

Automated Data Collection: Machines across all sites were connected for continuous, near-real-time reporting.
Managed Connectivity Service: Arch continuously monitored uptime, flagged missing or invalid data, and maintained KPI reliability.
Dual Data Validation: Real-time data was automatically cross-checked against each machine’s local historical log, the ultimate “ground truth,” ensuring 95%+ accuracy in live data and self-healing validation to reach ~100% alignment with shopfloor facts.
Certified KPIs and Audit Workflows: Site teams could review, audit, and suggest corrections to real-time data, building confidence in system accuracy while maintaining transparency across regions.

Key Outcomes

$14 Million in CapEx Avoided

Precise utilization analysis revealed opportunities to reallocate idle or underused assets, eliminating the need for new equipment purchases in one year alone. Detailed analytics tracked machine and sub-component performance, such as heads, feeders, and modules in pick-and-place systems or jigs and racks in ICT testers. This allowed the team to redeploy not just whole machines but high-value parts where they were needed most. This level of visibility required rich, part-level data rather than simple on/off signals.

Trusted, Real-Time Data Accuracy

Dual-source validation and managed connectivity ensured data accuracy above 95% in real time, with automated audits maintaining alignment to near 100% of actual shopfloor records. This reliability gave asset managers confidence to act on the data, “right-sizing” equipment and avoiding costly missteps driven by outdated or uncertain reports.

Faster, Confident Decision-Making

What once took two months of manual consolidation now occurred daily, allowing asset managers to respond immediately to changing customer demand. As product life cycles shortened and customer requirements evolved faster, the company’s ability to make rapid, trusted decisions became a competitive advantage.

Strategic Lessons

Data accuracy drives ROI: Validated, real-time KPIs prevent misleading conclusions and ensure capital is deployed wisely.
Automation accelerates action: Replacing manual workflows with continuous analytics shortens decision cycles and increases agility.
Connectivity is the foundation of trust: Managed connectivity ensures uptime, validation, and reliability across global systems.
Insight outperforms investment: Visibility into true utilization avoids unnecessary spending while improving operational performance.