Securing the Future:

A Data-Driven Path to Manufacturing Excellence at a Global A&D Leader with Arch

To modernize its machine data infrastructure and scale digital transformation, a global aerospace and defense manufacturer partnered with Arch. By replacing fragmented scripts and site-specific agents with the Arch Platform, the company established standardized, secure connectivity across sites and launched scalable factory analytics. The result was improved process control, enhanced quality visibility, and lowered costs for future data initiatives, supported by a GovCloud-enabled architecture aligned with stringent security and compliance needs.

HIGHLIGHTS:

Standardized connectivity across all sites
GovCloud architecture ensured data security and compliance
Lowered cost of future data projects through platform reuse

Improved process control, quality yield, and root cause analysis
Supported a global OEE strategy and reduction of rework on critical products

The Challenge

The manufacturer’s efforts to scale Industry 4.0 were hindered by a patchwork of custom scripts and local agents used to collect machine data. Key operational challenges included:

Lack of standardization across factories and systems
Inefficiencies and rework in custom integrations
Limited real-time insight for root cause analysis
Fragmented infrastructure that blocked scalable analytics
Inability to support digital thread initiatives across supply chains

The Arch Approach

The company partnered with Arch to implement a secure, scalable machine data infrastructure and analytics layer across its entire operation. The Arch Platform deployment featured:

Implementation of a standard machine data architecture
Selection of a new MES to support future growth
Overhaul of machine data integrations and middleware
Launch of a GovCloud-enabled infrastructure for secure analytics
Elimination of disparate tools with a unified platform for data access

Key Outcomes

Standardized Connectivity Lowered Long-Term Costs

The Arch Platform eliminated the need for custom-built data tools at each site, enabling reuse and reducing project startup time.

● Provided a repeatable infrastructure for future data projects
● Lowered total cost of ownership across factory deployments
● Improved ROI by eliminating custom connector maintenance

Secure and Scalable Analytics Infrastructure Deployed

GovCloud integration ensured compliance with defense-grade security requirements while enabling modern enterprise analytics.

● Launched scalable analytics without compromising data security
● Supported multi-site collaboration and centralized reporting
● Established a clear path for enterprise-wide deployment

Quality, Efficiency, and Process Control Improvements

Access to unified data enabled the organization to optimize operations and reduce costly defects.

● Improved process control and first-pass yield
● Enabled faster root cause analysis across plants
● Supported a global OEE strategy with more reliable benchmarks
● Reduced scrap and rework on high-stakes products

Strategic Lessons

Scaling smart manufacturing across a global enterprise requires more than tools. It requires a flexible, secure, and standardized data infrastructure that drives both immediate gains and long-term agility.

Key takeaways include:

Standardization saves time and cost: One platform supports many factories
Security cannot be an afterthought: GovCloud support met critical compliance needs
Data reuse matters: A unified infrastructure accelerated future projects
Real-time data drives better quality decisions: Unified insights improved root cause analysis
The right partner drives transformation at scale: Arch delivered speed, security, and sustainability