Case Study: Flex achieves 20.6% availability improvement with Arch Systems AI downtime classification

Flex boosts injection molding availability 20.6% in 5 weeks with Arch Systems

A world-class global electronics and plastics manufacturer, Flex, faced significant operational challenges in its injection molding operation for healthcare devices. Despite having over 60 machines, the site lacked visibility into machine status and downtime causes, relying on manual interpretations and tribal knowledge from experts. This led to inconsistent data that masked opportunities for improvement. To address this, they partnered with Arch Systems to implement its Factory Intelligence Platform.

Arch Systems deployed its AI-powered downtime classification and real-time process visibility tools, which automatically standardized data and triggered proactive maintenance actions. This solution eliminated dependency on tribal knowledge and provided a unified view of the entire machine fleet. As a result, Flex achieved a 20.6% improvement in equipment availability in just five weeks, unlocking over $1.2 million in annual savings and realizing a 15x ROI, which triggered a global expansion plan.

Flex