Case Study: Flex achieves 297% ROI and 50%+ downtime reduction with Arch Systems

Flex achieves 297% ROI and cuts SMT downtime 50% with Arch Systems

Flex, a global manufacturer, faced challenges in improving overall equipment effectiveness (OEE) and reducing downtime across its multi-site SMT network. Their operations suffered from fragmented connectivity, inconsistent downtime tracking, and a lack of a scalable model for performance improvement. To address this, they partnered with Arch Systems to implement its solution for connecting equipment and standardizing data.

Arch Systems implemented a solution that connected and stabilized SMT equipment data, standardized downtime labeling, and embedded real-time analytics into daily operations. This approach delivered significant results, including a 297% ROI, a 4.0-month payback period, and over $277,000 in annual savings at the initial site. OEE increased from 62.8% to 72.6%, while downtime was reduced by more than 50%. The success of this lighthouse deployment led Flex to expand Arch Systems across dozens of lines globally, achieving over $750,000 in annual savings and creating a standardized foundation for continuous improvement.

Flex