Unleashing Efficiency:

How a Leading EMS Provider Skyrocketed OEE with Arch

To address performance gaps on its SMT lines, a global EMS provider implemented the Arch Platform to identify and resolve root causes of downtime. Arch’s insights enabled changes to inspection protocols that eliminated unnecessary disruptions and boosted both machine availability and OEE. Within four months, the customer achieved a 140% improvement in machine availability and a 97% improvement in OEE, unlocking new levels of efficiency and positioning operations for long-term success.

HIGHLIGHTS:

Improvement in machine availability (from 19.6% to over 48%)

Improvement in OEE (from 14.2% to over 28%)

Identified root cause of excessive downtime during first article inspections
SOP changes reduced unnecessary line stoppages
Insights delivered through real-time Arch Platform data

The Challenge

The customer faced recurring issues with low machine availability and suboptimal OEE across SMT lines, limiting production throughput and efficiency. Key operational challenges included:

Poor availability on SMT lines, measured as low as 19.6%
OEE baseline of just 14.2% across key lines
Production interruptions due to overly broad inspection protocols
Limited visibility into root causes of downtime

The Arch Approach

To drive targeted performance improvement, the manufacturer deployed the Arch Platform to monitor machine behavior in real time and uncover inefficiencies. The Arch Platform deployment featured:

Baseline performance analysis across SMT lines
Real-time downtime tracking and root cause identification
Discovery of unnecessary downtime tied to first article inspection procedures
Recommendations to revise SOPs for smarter inspection logic
Continuous monitoring to track the impact of changes

Key Outcomes

Root Causes Uncovered and Actioned

Arch exposed a key inefficiency: the entire production line was being stopped during first article inspection, even when only one board was affected.

● Downtime traced directly to inspection process missteps
● Arch insights helped teams isolate non-critical stoppages
● Inspection logic refined to match actual quality control needs

SOP Revisions Delivered Measurable Gains

By changing when and how the line was stopped, the customer preserved quality standards without sacrificing uptime.

● SOPs revised to halt lines only when introducing a new product
● Enabled more continuous production without compromising inspection
● Created a balance between quality assurance and machine efficiency

OEE and Availability Surged Within Four Months

Measured from January to April 2024, performance improvements were dramatic and sustained.

● Machine availability improved from 19.6% to over 48%
● OEE improved from 14.2% to over 28%
● Gains exceeded 140% and 97% respectively, across key lines

Strategic Lessons

The right visibility can drive the right decisions. When manufacturers pair real-time data with process refinement, the results are fast, scalable, and measurable.
Key takeaways include:

Small changes drive big impact: Procedural updates delivered measurable efficiency gains
Availability is the foundation for OEE: Downtime reduction led to higher overall effectiveness
Inspection protocols must fit the context: Line stoppages were restructured to match operational needs
Real-time insight speeds up SOP improvements: Data enabled fast adjustments to key workflows
The Arch Platform supports continuous optimization: Ongoing visibility drives sustained performance gains