Case Study: a North American Steel Manufacturer achieves $330K in annual throughput gains with Arch Systems

North American Steel Manufacturer unlocks $330K in annual throughput with Arch Systems

A North American steel manufacturer faced a challenge with high-frequency planned changeovers on its pickling line, where up to 180 events per day caused significant lost capacity. With limited visibility into the micro-steps of the process, they could not identify the root causes of variability. They partnered with Arch Systems, which deployed its Factory Intelligence Platform to digitize and analyze the changeovers.

Arch Systems used AI-driven root cause analysis to break down the process, identifying flattener jog retries as a key source of delay. This enabled a 12-second reduction per changeover, recovering 35 minutes of production time daily. For the manufacturer, this translated to an additional 5 coils per day and approximately $330,000 in annual recovered throughput on a single line, with a total potential of $1.3M when scaled across four lines.