Electronic control components have evolved on a massive scale, but many systems are much older and are now classified as obsolete. In the event of a failure within such a control system, replacement products may not be readily available, so what are the options?
“Industrial processes have relied on electronic controls for decades and, as the technology has advanced, these controls have also become more complex and, usually, more compact,” explains Brian Park, service centre manager for Sulzer Glasgow. “As competition in this sector has increased, some of the original equipment manufacturers (OEMs) have gone out of business, leaving end users with some considerable challenges in the event of a failure.”
Staying operational
For many businesses, the easiest option is to replace the control equipment with a more modern equivalent that also offers new features, improved efficiency and takes up less space. Although this may not always be the most cost-efficient solution, the long-term benefits and the improved availability of spares will reduce the total cost of ownership.
However, some industrial sectors, such as nuclear, military and oil & gas, have very strict protocols regarding the replacement of components, meaning that retaining proven systems and keeping them operational is essential. “In such situations, it is necessary to replicate existing components, ideally from existing drawings, but often with no reference material, which can prove to be quite a challenge,” Park adds. “Since programmable logic controllers (PLCs) took on the mainstream role of process control in the 1980s, the complexity, size and general design have changed immeasurably. However, some of this pioneering equipment is still in service and the end users need to have spare parts available to minimise any downtime. One failed card could prevent a million-pound machine from operating, so creating more spare parts is a proactive method of maintenance management.”
Re-manufacture often the best solution
This can be illustrated by a recent example from the oil and gas industry where the control system for a reciprocating compressor had failed and needed to be repaired at the earliest opportunity. The initial inspection showed a multiple card failure had rendered the sequence control inoperative, the power supply card was missing and components, such as the semiconductors, dated back to the 1990s.
The scale of the challenge was increased by the fact that the OEM was no longer in business, leaving no spares and no replacement products, while the client needed the control panel back in service as soon as possible. “In many applications a new controller could be created from modern components, offering more functionality, reliability and all from a more compact enclosure,” Park says. “However, as specifying new equipment for the oil & gas industry can be a very drawn-out process, this meant the best solution would be to re-manufacture the electronic circuits, down to component level and to the original specification. With the necessary expertise and facilities, our Glasgow Service Centre was contracted to design and make the new cards.”
The repair process itself can be used to generate design drawings, source obsolete semi-conductors and create test procedures for final testing. The complete reverse engineering procedure can replicate printed circuit boards (PCBs) and, where necessary, hand-drawing the circuit diagram for both design and future use.
“In this case, once the new cards had been tested and installed, the client requested additional spare cards to be manufactured, as well as other cards to be remanufactured to ensure future availability of spare parts,” Park continues. “In this way, any similar failures that occur can be resolved by the on-site maintenance engineers with a minimum of downtime.”
Similar situations arise in the nuclear industry, as well as military applications, where there is a requirement to prove functionality at the beginning, document the whole process and witness functionality at the end, before the new components are signed off and accepted. “In such circumstances, we can provide a cost-effective alternative that can significantly prolong the service life of electronic controls and deliver on-going support,” Park says. “In this way, applications that require obsolete electronics to be repaired or replaced can be effectively maintained using a preventative servicing regime. In addition, for those industries that allow, it is possible to incorporate more modern technology and software into existing control packages, increasing productivity and flexibility.”
Designing with obsolescence in mind
It’s fair to say that the smartphone is to blame for many everyday technologies – including the calculator, the torch and the camera – slowly entering the realms of obsolescence. However, not even this disruptive technology can go on ruling our lives forever: a 2015 study by Ericsson found that one in two people believe smartphones will be obsolete by 2021 (http://bit.ly/2hfWL6D). With tech life-cycles becoming shorter, it is important for product designers to plan in advance for component obsolescence to maximise the lifespan of their products.
There are many requirements that need to be assessed when designing a product. The initial considerations in the development path are simple: what is the product and what is the function? Once the designer has established the basics, they can move on to material choice, manufacturing method, production numbers and cost forecast. A more difficult thing to assess is product lifecycle. If a designer cannot control all aspects of their component supply chain, obsolescence will affect the working life of the product.
“Lifecycle is becoming an increasingly important factor in product design, because of the increased speed of obsolescence by newer technologies, market trends and as a result of planned obsolescence,” says Jonathan Wilkins, marketing director of industrial automation equipment supplier EU Automation. “Technology lifespan is shrinking and forcing designers to change products,” he points out.
The challenges of obsolescence are best addressed at the design stage. This involves analysing procurement information and avoiding the selection of parts close to obsolescence. A strategic approach by forecasting and planning can make a big difference to optimising product lifecycle.
“Manufacturers typically send out notifications such as product change, end of life or discontinuation, last time buy and last time ship notices,” Wilkins explains. “These can be used to by designers to mitigate the risk of obsolescence; but, because the notifications are not always accurate or complete, this approach alone is not enough.
“A designer can break down the bill of materials for analysis at component level to filter out low-risk components and assess the risk for the remaining ones. This way, the designer can weigh up the likeliness of component obsolescence against the impact it will have
on the product’s end performance.”
Some predict that the flexibility offered by 3D printing as production methods could, to some extent, counteract the acceleration of obsolescence by providing companies with a more personalised and flexible manufacturing. NASA has tested 3D printing in the International Space Station (https://go.nasa.gov/2zthYUW) to allow on-demand manufacturing and reduce the need for costly spare parts. Similarly, Daimler Trucks is planning to use 3D printing to produce spare parts (http://bit.ly/2zJ221V).
“3D printing could take off as a popular way to replace, repair or restore obsolete, or hard-to-source parts in some industries,” says Wilkins.
However, for the time being, he advises, the technology remains cost-prohibitive and has significant production limitations. For industrial automation systems, obsolescence is less of a concern.
“It’s not possible to access spare parts in the same way in every industry, so it’s important to be proactive, flexible and strategic with obsolescence management.”
Design engineers should select parts and components with obsolescence in mind. Sharing information and making predictions will prove vital, as will understanding of the lifecycle of products and systems. Using forecasting and strategic planning helps firms manage product lifecycle. When it comes to designing for obsolescence, prediction is key – what will replace the smartphone, however, is anyone’s guess.
Box out: Seven steps to heaven
What do jazz luminary Miles Davis and obsolescence managers have in common?
If your answer is that they’ve both been inducted into the Rock and Roll Hall of Fame, then you’d be wrong. The real answer is that they both have seven steps to heaven.
For anyone who may be unaware of Miles Davis’ back catalogue, one of his greatest hits was Seven Steps to Heaven, taken from his 1963 record of the same name. The album was recorded in a period of transition for Davis; health problems forced him to move away from live shows and integral members of his backing band left to follow their own solo careers.
However, a band is like an automated system and Davis knew he didn’t need a complete overhaul to carry on making beautiful music, just a few well-fitted replacements.
So, what are the seven steps to heaven when it comes to effective obsolescence management in industry?
Step 1: System assessment
The initial step is to assess your automated system - how long have parts been on the market? Are they already obsolete? When are software updates released? These are all questions you need to ask when starting to put together a strategic obsolescence management plan.
Step 2: Resource planning
Managing obsolescence, like making music, is an art form. It’s very difficult to be good straight away -
it takes hard work, planning and practice. However, if it is done correctly, obsolescence management can save companies from resorting to unnecessary and costly system upgrades, but only if the proper resources are in place.
You need to weigh up whether it would be beneficial for your company to hire a dedicated obsolescence manager, as well as the requisite management tools. Above all, a reliable automation spares supplier is a key component. Knowing who to call when a part breaks down could be the difference between a day of downtime or a week.
Step 3: Basic risk analysis
In a factory, critical applications are things that a company simply cannot operate without. These should be a main area of focus when you put together an obsolescence plan.
It’s imperative to analyse the components of critical systems as well and to estimate the likelihood of these breaking down. You can do this quite easily by asking some simple questions, such as how many original equipment manufacturers (OEMs) make a compatible product? What’s its lifespan? How critical is the part to the overall system?
Step 4: Obsolescence risk
Industrial parts need to be grouped, based on their risk of becoming obsolete, because, once this happens, sourcing replacements becomes more difficult. If you identify the components in your system that are obsolete - but also essential in keeping your systems running - you can start stockpiling replacements.
Step 5: Supplier planning
Based on your analysis of how critical a part is to your process, the speed at which it will wear and its risk of becoming obsolete, you should draw up a plan of where you can source these parts from and how quickly. For example, if a supplier doesn’t regularly hold a specific obsolete VSD in stock, then they will have to source that from a third party, which could be located half way around the world.
Working with an industrial automation parts supplier like EU Automation means you are safe in the knowledge that, when a part does break down, they will have the stock and the contacts to secure obsolete replacements for you quickly.
Step 6: Putting together a database
All the data you collect regarding parts should be recorded and kept up to date. However, it doesn’t mean that you must spend a lot of time and money on a fancy database system. It could be something as simple as creating a spreadsheet, cataloguing status, time it would take to source a replacement, risk of the part breaking down and the details of suppliers with the component already in stock.
Step 7: Reviewing and updating
Effective obsolescence management is a full-time job; it takes careful management to keep automated systems pitch perfect. Once a plan has been established, it’s important not to let things slip, which means ensuring records are updated regularly.
The key to obsolescence management is preparation. By implementing the systems and procedures described in this article, you could save money and reduce downime. Don’t be too rash to write off an entire system when a part breaks down. Take a tip from Miles Davis and get on those seven steps to heaven.