Empowering Efficiency:

Reducing Attrition with Guided, Intelligent Actions with Arch

At a key production site, a global contract manufacturer deployed Arch’s Action Manager to tackle high attrition rates on SMT lines. The pilot focused on enabling real-time detection and response to line-level issues, improving material utilization, and accelerating root cause resolution. Within the first week, the site saw a 12% reduction in attrition, translating to an estimated $65,000+ in annualized savings at one site, with plans for broader adoption already underway.

HIGHLIGHTS:

12%

Attrition reduction within the first week

$5K+

Per line monthly savings

$65K+

Per site annualized savings

  • Real-time alerts for problem machines and component locations
  • Action Manager integrated with existing factory infrastructure
  • Pilot success expected to expand across additional lines and areas

The Challenge

High attrition on SMT lines was leading to excess material waste and lower production efficiency. Without real-time insights, the team struggled to identify patterns and implement timely corrective actions. Key operational challenges included:

  • Excessive material loss due to unmonitored attrition
  • No real-time alerting or visibility into line-level issues
  • Manual bottleneck identification and delayed resolution
  • Limited insight for planning future Continuous Improvement(CI) or predictive maintenance

The Arch Approach

To close the data-action gap, the customer piloted Action Manager, part of the Arch Platform, on two SMT lines using Fuji and ASM equipment. The pilot deployment featured:

  • Use of the attrition module with a 0.3% threshold for event detection
  • Targeted alerts delivered directly to operators for rapid response
  • Real-time monitoring of machine and component-specific issues
  • Cause and resolution tracking to enable future process improvement
  • Integration with existing IT infrastructure to streamline reporting and analysis

Key Outcomes

Attrition Reduced by 12% in One Week

Guided, intelligent actions enabled immediate impact on the lines.

  • ● Attrition reduction aligned with target of 0.3%
  • ● Lower material waste and more stable production flow
  • ● Triggered real-time interventions by on-the-floor operators

Measurable Cost Savings and Line Optimization

Early results highlighted the broader business case for scaling the solution.

  • ● $5,500 per line in monthly savings projected across similar lines
  • ● $65,000+ in annualized savings per site
  • ● Improved machine performance without major hardware changes

Foundation for Broader Action Manager Expansion

The pilot success provided a replicable model for further deployments.

  • ● Action Manager now planned for additional lines and production areas
  • ● Data infrastructure enabled future CI and predictive maintenance strategies
  • ● Strengthened collaboration between IT, ops, and engineering teams

Strategic Lessons

Reducing attrition doesn’t require overhauling equipment. It requires targeted, real-time guidance that empowers teams to act decisively.

Key takeaways include:

  • Real-time alerts reduce material loss: Operators responded to issues before waste accumulated
  • Pilot programs prove value fast: A one-week rollout yielded measurable savings
  • Targeted thresholds drive action: A 0.3% attrition flag helped operators focus
  • Integrated tools scale faster: Built-in compatibility supported rapid deployment
  • Guided actions enable smarter production: Action Manager made improvement tangible and repeatable