Planning Optimization
Spot Drift. Route Recovery. Stay On Track.
Plan vs. Actual: Close the Gap
Factories rarely fail at making products. They fail at making them on plan. Outdated cycle times, crew variation, and small delays compound into missed shifts and overtime.
Arch changes that.
Our AI-native platform connects plans to actual in real time, spotting drift as it happens and routing recovery actions to the right people instantly. Site managers stay ahead of slippage, planners adapt schedules dynamically, and leaders gain confidence that every shift is on track.
core capabilities
Planning Optimization for Today’s Factory
Real-Time Attainment Visibility
Monitor plan versus actual throughput live, across lines and shifts.
Micro-Stop Detection
Uncover hidden time losses that don’t appear in downtime logs.
Fast Recovery Routing
Automatically alert and assign owners for rapid issue closure.
Adaptive Planning
Leverage Arch AI to forecast schedule risk and recommend job re-sequencing.
Unified KPI Framework
Track attainment, DLE, and throughput consistently across sites.
SMART PLANNING FOR MANUFACTURING
Planning Optimization in Practice
Plan vs. Actual Tracking
Measure attainment in real time by linking job context and run/stop data to production plans.
Schedule Recovery / Mid-Shift Adjustment
Detect schedule slippage early and trigger reallocation or re-sequencing to recover output.
Labor & Resource Allocation
Balance crews and workloads using live productivity signals and predictive insights.
Changeover Optimization
Identify and reduce setup and transition losses between jobs or products.
Capacity Planning & What-If Analysis
Simulate alternate production plans to assess throughput and delivery impact.
Standardized Attainment Reporting
Roll up shift, product, and site performance using a unified KPI framework.
Case Study Spotlight:
How a Leading Electronics Manufacturer Scaled Downtime Reduction with Arch Systems
HIGHLIGHTS:
$3.7M+
Zero disruption to operations
during deployment—fully parallel to existing systems
A global automotive parts OEM partnered with Arch Systems to reduce downtime at a Lighthouse factory in China. Starting with traditional tracking, the company generated $3.7 million in hard savings over a two-year period. Building on that success, the team began scaling downtime analytics globally and piloted Arch’s AI-powered Automated Downtime Labeling at the lead site.
Arch Enables Smarter, Connected Manufacturing
Experience AI-driven enterprise workflow transformation, end to end in the factory.
Equipment & Process Optimization
Eliminate losses.
Maximize performance
Planning
Optimization
Deliver on plan.
Every shift.
Product Quality & Compliance
Catch defects.
Prove compliance.
Equipment & Process Optimization
Eliminate losses. Maximize performance
Planning
Optimization
Deliver on plan. Every shift.
Product Quality & Compliance
Catch defects. Prove compliance.
Ready to Get More from Every Product Run?
Arch helps factories reclaim hidden capacity, delay unnecessary investments, and sustain continuous improvement. Let’s talk about planning optimization and how your factory teams do more with less.
