Obsolescence is an unavoidable part of any manufacturing endeavour. No matter how well your company has planned, some factors are more challenging to consider in advance than others.
In the era of Industry 4.0, new technology continues to revolutionise the manufacturing industry. Industry professionals view it as the latest industrial revolution, hence the Industry 4.0 moniker. Big data and computing technologies are the front-runners in innovations proving value to manufacturers. It is more crucial now than ever to remain on the leading edge of new technology. Upgrading equipment to provide greater efficiencies will provide a greater return on the investment.
Obsolescence in manufacturing, as defined by the International Institute of Obsolescence Management, occurs when parts, services, and resources previously available are no longer produced by the original equipment manufacturer (OEM). It may also occur when the OEM has gone out of business. While the part, service, or resource may be difficult to come by, it is still needed. Therein lies the rub.
Every component comes with a life cycle, and it is impossible to repair or replace components that are no longer obtainable or extremely expensive to source from reputable suppliers that specialise in obsolete parts. The inevitable result is downtime in production, which impacts the bottom line.
One of the biggest contributors to obsolescence is new technology. While it brings with it enhanced features for components, modules, software, and subsystems, new technology creates compatibility issues with older software and hardware. Other contributing factors include:
Obsolescence increases costs for through-life support. Manufacturers are forced to strategically estimate current and future demand for components for vital equipment that are being discontinued. Predicting this kind of demand is difficult and can result in inefficiencies.
Nearly 70 per cent of companies faced with obsolescence admitted to lacking full awareness of when vital equipment required repairing, replacing, or upgrading.
Manufacturers that hope to avoid the pitfalls of obsolescence need to focus on several crucial points as part of an obsolescence strategy.
Manufacturers are advised to develop an obsolescence strategy to help lower the risks. There are three main aspects of obsolescence management, on which focus should be placed: a report of on-site components, risk analysis of those components, and identifying a specialist supplier to help plan and secure replacement parts.
If the COVID-19 global pandemic taught the manufacturing industry anything, it was that it pays to plan ahead. For manufacturers, planning involves having a solid relationship with a middleman who can source hard-to-find parts. The availability of resources and obsolete components can mean the difference between continued production and prolonged shutdowns that result in a profit loss. Middlemen can locate alternative supply chains and help mitigate the risk of obsolescence.
Components should be assessed based on whether they can survive a further occurrence of downtime. Locate external companies that provide year-round on-site emergency repair services whose emergency technicians can help manage repairs. It is imperative to group industrial parts based on their risk of becoming obsolete. Stockpile replacement parts in order of importance. Special quotes and last-time buy notices often accompany components that are about to become outdated. Be sure to account for warehouse space costs associated with storing spare parts.
Manufacturers should analyse existing components to determine which need replacing before an immediate need for an upgrade occurs. It is better to purchase any new or used parts in advance rather than waiting until they are needed, only to discover they are obsolete.
Even with a strategy in place to address obsolescence risks, it is impossible to plan for every scenario. Manufacturing companies must identify a level of obsolescence that is tolerable to their bottom line and build their plan around it.
Once all of the above information is compiled, centralise it in a safe location. Creating a spreadsheet that details the condition of critical parts, how likely they are to break, and where to obtain replacement parts (either from storage or a direct supplier) is all most manufacturing facilities need.
Obsolescence management is not a one-off review. Periodic reviews of the strategy and assessments of all critical systems and components must be conducted. Larger manufacturing facilities find it helpful to hire someone to oversee their obsolescence management efforts. Regardless of whether you assign an in-house staff member to conduct the reviews or hire an outside agency, regular reviews and updates can eliminate costly repairs and produce long-term savings.
Radwell provides full-service assessments of all electronic equipment and offers consignment stock and full repair capabilities to keep your facility running 24/7. Contact us online or by calling 01782 576800 to find out more.