Reducing Attrition and Downtime:

How a Global Automotive Electronics Manufacturer Unlocked Nearly $3M in Annual Efficiency Gains with Arch Systems

A global automotive electronics leader was facing significant operational challenges: high attrition rates were causing component waste, and excessive downtime was disrupting production on critical SMT lines. By deploying the AI-powered ArchFX platform, the manufacturer identified root causes, automated task resolution, and drove corrective action in real-time. Within months, they realized $2.8M in annual savings and expanded Arch across all SMT sites worldwide.

manufacturing-optimization-global-efficiency

HIGHLIGHTS:

$2.8M+

Annualized savings

Downtime reduction at a lighthouse site

ArchFX deployed across all SMT production sites
Enabled real-time visibility and task automation
Arch AI used to drive root cause detection and attrition tracking

The Challenge

As production volumes increased, the manufacturer faced mounting efficiency losses tied to two key issues: component attrition and unplanned downtime. These hidden costs not only disrupted workflows but also stood in direct conflict with the company’s strategic cost-containment and quality goals.

Key operational challenges included:

High component attrition across SMT lines, leading to excessive material waste.
Frequent downtime events at key sites, severely impacting throughput.
Limited real-time visibility into line-level issues and causes.
Reactive issue resolution, delaying impact and driving cost.

The Arch Approach

To gain control over these persistent challenges, the manufacturer partnered with Arch Systems to implement an enterprise-ready, AI-powered solution. The ArchFX platform brought transparency, intelligence, and automation to the customer’s SMT operations.

Arch Systems delivered a phased, AI-powered deployment featuring:

Arch AI for real-time attrition monitoring and root cause analysis.
Automated detection of high-risk lines using integrated SMT data.
Unified dashboards and alerting across all connected SMT lines.
Global scalability to deploy ArchFX across current and future sites.

Key Outcomes

Attrition Reduction Drove $600K in Savings

With Arch AI continuously monitoring material usage and loss, the manufacturer pinpointed previously untracked sources of component attrition.

● Enabled site-level teams to act on specific waste trends.
● Reduced unnecessary component usage through root-cause-driven process changes.
● Resulted in $600K in annualized savings across all SMT facilities.

75% Downtime Reduction Yielded $2.2M in Savings

At one key production site, ArchFX enabled faster detection and response to line stoppages. AI-driven visibility helped operators act before small issues escalated.

● Downtime reduced by 75% at the lighthouse site.
● Enabled continuous improvement through data-driven maintenance and task resolution.
● Resulted in $2.2M in annualized savings from recovered uptime.

Enterprise-Wide Rollout Validated Long-Term Value

Based on the results, the manufacturer expanded ArchFX across their entire SMT operation and made it a standard for new sites.

● Full deployment across all SMT sites globally.
● Ongoing use of Arch AI to guide daily decision-making.
● Supports continuous improvement and future scalability across the organization.

Strategic Lessons

AI-powered factory intelligence drives measurable outcomes when deployed with the right platform and partnership. Arch Systems helped this manufacturer go beyond visibility to action; reducing costs, increasing uptime, and setting the stage for sustainable efficiency gains.

Key takeaways include:

Dual-impact wins matter: Solving both attrition and downtime multiplies ROI.
AI transforms insight into action: Arch AI identified root causes that manual review missed.
Speed to impact: Downtime and waste reductions were achieved within months.
Standardization at scale: A single platform now drives consistent practices globally.
Strategic partnerships unlock value: Arch combined technology with expert-led deployment.