Case Study: Flex improves SMT line utilization with Arch Systems

Flex cuts 12% of downtime from missing material with Arch Systems

A North American electronics manufacturer, Flex, faced significant operational challenges due to hidden component attrition on its SMT production lines, which silently created material shortages and was responsible for approximately 12% of downtime. Without a reliable way to measure these losses or connect them to specific machine issues, the company struggled with inaccurate material forecasting and could not systematically improve its line utilization. To address this, Flex turned to the Arch Factory Intelligence Platform from vendor Arch Systems.

Arch Systems implemented its platform to deliver real-time visibility into machine performance and component attrition. The solution identified root causes, such as a critical placement head with a 1.95% attrition rate, and enabled faster maintenance response. As a result, Flex reduced materials-related downtime and improved utilization on the Arch-enabled production lines during the pilot, while non-instrumented lines remained flat or declined. Arch provided the data-driven foundation for smarter materials planning and operational performance.

Flex