Posted to News on 4th Dec 2025, 12:00
What happens when a critical component goes obsolete?
Industrial machines are built for long service lives, but the electronic components inside them often aren't. Drives, PLCs, HMIs, servo amplifiers and communications modules typically follow much shorter product lifecycles. As a result, it's increasingly common for a machine to be running reliably while the parts it depends on are no longer manufactured or supported, as the experts at CJS Automation explain.
When a critical component fails, and no direct replacement is available, the impact is immediate. A single discontinued module can halt production entirely, creating urgent pressure to find a compatible replacement or a repair option to get the system running again.
When obsolescence hits, downtime is immediate
A machine may operate without issue for years until the moment a legacy drive or controller fails. If the OEM no longer supplies that component, teams may quickly face a range of challenges:
- Production stops while the search for replacements begins
- Limited availability means sourcing can take longer than expected
- Re-engineering may be required, such as updating software or modifying control panels
- Compliance considerations may arise in regulated industries
- Costs increase, especially if downtime affects customer deliveries
A new global report from ABB, developed in partnership with Sapio Research, found that 83 per cent of industry decision-makers say unplanned downtime costs at least $10,000 per hour, with many reporting significantly higher costs.
For these reasons, obsolescence is now regarded as an essential maintenance and lifecycle-management issue rather than an occasional inconvenience.
Why obsolescence happens
The reasons why obsolescence happens are straightforward but often overlooked. The lifecycle of electronic automation components rarely aligns with the much longer operational life of the machines they support. Many plants run equipment for 15-25 years or more, while electronic components may only be produced for a fraction of that time.
Additionally, technology evolves steadily. Updated platforms, newer processors, different communication options and changes in manufacturer product lines all contribute to older components eventually being discontinued.
The practical options when support ends
When a component reaches end-of-life, maintenance teams typically explore several avenues to restore operation:
1. Source obsolete or hard-to-find components - Specialist suppliers such as CJS Automation provide access to both current ranges and discontinued automation parts. This is often the quickest way to secure a like-for-like replacement with minimal disruption.
2. Use refurbished or reconditioned parts - Refurbished drives, PLCs and HMIs provide a reliable route to keep older machines running. Many are thoroughly tested and warrantied, giving maintenance teams confidence without requiring redesign of systems.
3. Repair the existing unit - Repairs can return a failed module to operational condition and may be the most cost-effective approach, particularly when original parts are no longer available.
4. Identify compatible alternatives - Sometimes, a different model, or even a different brand, can be integrated as a functional equivalent. This may require rewiring, reprogramming or mechanical adaptation, but it restores long-term support options.
5. Migrate to a new platform - If obsolescence is widespread across a machine's architecture, some organisations choose to plan a phased or complete migration to modern equipment.
Planning ahead matters most
A proactive approach can significantly reduce the pressure when a part becomes obsolete. Useful steps include:
- Identifying which components are nearing end-of-life
- Holding critical spares where appropriate
- Establishing relationships with legacy-component specialists
- Exploring repair and refurbishment options before failure occurs
- Creating upgrade pathways for key systems
With these plans in place, obsolescence becomes a manageable part of the machine lifecycle strategy.
A small part with a big impact
When a critical component goes obsolete, it highlights the gap between the longevity of industrial machinery and the shorter lifecycles of electronic automation parts. But with preparation and support from suppliers experienced with legacy components, manufacturers can keep their equipment running reliably long after official OEM support ends.
