With a thorough MRO strategy, routine maintenance and replacement part ordering will quickly become a relatively seamless process. However, no MRO strategy is perfect—and the issue of needing discontinued, obsolete equipment parts will inevitably arise.
Obsolete parts are not the same as parts that have reached the end of their lifecycle. End-of-life parts are those that have been worn out over time and need to be replaced. Obsolete parts, on the other hand, are those that have been discontinued by the original equipment manufacturer (OEM) due to new technologies or more-advanced iterations of equipment. There are several factors that might create the need to locate discontinued or obsolete parts:
- Discontinued machinery: If a manufacturer stops making a machine because they are introducing an updated version of that old machine—it is likely that the manufacturer will also stop making its replacement parts at some point as well.
- Unprofitable parts: As machines that have been discontinued are found less frequently in facilities, third-party replacement part manufacturers will eventually phase out the parts for those machines from their product line.
These situations can put manufacturers in a bind, as their outdated equipment may still be operational and useful. However, finding legacy parts for this machinery can be exceptionally challenging due to supply chain instability, longer lead times and consolidation among OEMs. This means manufacturers may be forced to deal with extended downtime, premium pricing on the secondary market and increased scrap risk from using inferior substitute parts. All this adds up to make proactive sourcing of obsolete parts a critical component of a reliability program. As product cycles continue to accelerate and infrastructure gets older, the problem will only get worse.
Finding replacements for obsolete OEM parts
As an alternative to trying to find obsolete industrial machine parts for aging equipment, some manufacturers buy new machinery instead. This is not always the most cost-effective or practical route (in fact, there are many ways you can affordably upgrade your current assets)—especially if the machinery you currently have still has some years left.
In order to work around and anticipate issues with obsolete equipment parts to ensure you have the parts readily available for your current assets, it’s wise to have a parts sourcing strategy in place for those discontinued by the manufacturer. It’s also important to think about forecasting for aging assets, including MTBF analysis, failure-mode reviews and lifecycle assessments. This will help prepare you for the possibility of needing obsolete parts, so you won’t be caught by surprise. Any critical, high-risk components should be stockpiled proactively to minimize downtime. Proactive preparation helps avoid costly mistakes—like purchasing counterfeit parts from unverified sources or navigating unclear documentation—keeping your operations reliable and secure.
Below are a few examples of where you can source obsolete machinery parts:
- Online electronic component brokers: You’re likely to be able to locate replacement parts online for some time after they are discontinued because most brokers will not sell out of their inventory of obsolete industrial equipment parts immediately. Digital marketplaces and AI-powered broker platforms simplify parts sourcing—but they also introduce risks, including counterfeit components from unverified sellers. Depending on your inventory space and plan, you may want to consider purchasing extra parts to extend the time you have access to them. If you don’t want to spend hours crawling the web and comparing prices, consulting a supply chain and procurement vendor is an option.
- The manufacturers themselves: The manufacturer may still have surplus replacement parts after discontinuing a machine, along with rebuild kits and retrofit packages. Many also will provide documentation or legacy support services. Contact the manufacturer and inquire about availability. There also may be a possibility that the OEM has licensed parts production out to approved remanufacturers. Be sure to note, however, that lead times have increased across the industry, so the sooner you can start planning the better.
- Part repair/remanufacturing: If you are unable to locate a new source of replacement parts, the repair and remanufacturing of existing parts may be the best option. Advanced Technology Services part repair services are able to bring failed parts back up to speed—extending their useful life at significant cost savings versus buying new. This also may help you meet your ESG goals by reducing waste and material consumption.
- 3D printing/additive manufacturing: Electronic component fabricators are often able to reproduce replacement parts. Additive manufacturing is being used more frequently in conjunction with traditional remanufacturing processes. If you can locate a vendor willing to fabricate parts for you, you will have access to a new source of replacements. Be aware, however, that pressure-bearing or structural components should not be printed unless they can be certified by the OEM as being within specifications.
Proactive strategies to avoid discontinued part emergencies
Thanks to digital transformation, there are a number of strategies manufacturers can employ to prevent the type of unplanned downtime that comes from needing obsolete components. These include:
- Using CMMS/EAM systems to keep track of the lifecycle of critical parts and systems
- Failure mode ranking through reliability-centered maintenance practices to prioritize procurements
- Critical spare analysis and stocking levels
- Regular communication with OEMs for updates on product lifecycles
- Adopting predictive analytics to optimize spare-parts inventories
Digital tools for obsolete part identification
Manufacturers have access to numerous digital tools and workflows to help them locate obsolete components or suitable replacements. For example, digital twin software can create a 1:1 virtual model of a machine and all its components, giving technicians the opportunity to test a replacement part’s fit and performance without needing to take the actual machine apart. Many suppliers now feature AI-enabled tools that can suggest cross-compatible components when the need arises. Cloud-based MRO databases for legacy equipment make it easier for technicians to search for the details they need to find and procure the right components, as well.
Is a broken or obsolete part causing you downtime? If so, contact us today to learn more about our time-sensitive, quality repair services that can save you 40-60% over the cost of buying new. ATS repairs thousands of parts every year, with fast turnaround for emergency needs. We refurbish hard‑to‑find and obsolete components to reliable working condition, offering a cost‑effective alternative to sourcing through brokers, OEMs or online marketplaces.
