Electronic products can remain in service long after some of their components become obsolete. Over time, parts may be discontinued, suppliers may change, and newer technologies may replace original components. Changing environmental or material regulations such as RoHS, REACH, and PFAS requirements may also affect component availability.
Key Takeaways
- Electronic components may become obsolete years before the products using them reach the end of their service lives.
- Component lifecycle management tracks availability, obsolescence risk, supplier changes, and potential alternatives.
- Early planning gives OEMs more options than reacting after a component is discontinued.
- Obsolescence can affect production, repair programs, regulatory requirements, and the total lifecycle cost of a product.
- Supply-chain, engineering, and aftermarket teams should work together throughout the product lifecycle.
- Obsolete components may enter the broker market, increasing the risk of counterfeit parts.
- Design reviews can identify single- and sole-source components before they become a problem.
For OEMs building products with long service lives, those changes can create sourcing problems, unexpected redesigns, and interruptions in production or aftermarket support. Component lifecycle management helps identify and address those risks before a disappearing part becomes an urgent problem.
What Is Component Lifecycle Management?
Component lifecycle management is the process of monitoring the electronic and electromechanical parts used in a product from initial design through production and long-term support. That means looking beyond whether a component can be purchased today. OEMs also need to consider where the part is in its lifecycle, how many manufacturers can supply it, whether suitable alternatives exist, and what would happen if that component disappeared.
This is closely related to diminishing manufacturing sources and material shortages, commonly called DMSMS. The Defense Logistics Agency defines a DMSMS issue as the loss or impending loss of manufacturers or suppliers for items, raw materials, or software. Its updated DMSMS guidebook emphasizes proactive management throughout a system’s lifecycle rather than waiting for obsolescence to create a shortage. For an OEM, that proactive approach can make the difference between a planned component transition and an emergency redesign.
Why Do Long-Life Products Face a Greater Obsolescence Risk?
The electronics industry changes quickly. Many commercial components are developed for markets where products are replaced every few years. That timeline does not always match products in aerospace, defense, medical devices, life sciences, or industrial applications. An aircraft system or piece of laboratory equipment may remain in use long after the processors, memory, connectors, or other components in its original design are no longer in regular production.
Regulations Can Also Drive Component Obsolescence
New technology is not the only reason components become obsolete. Regulations can also affect the materials manufacturers use. RoHS, REACH, PFAS, and similar requirements can lead manufacturers to change or discontinue components. This creates another source of obsolescence risk for OEMs.
The longer a product remains active, the greater the chance that part of its bill of materials will change. Spartronics works with OEMs that manufacture many of these types of complex, highly regulated electronic products. Planning for component availability is therefore not limited to the original production run. It can affect repairs, spare parts, and sustaining engineering years after a product reaches the field.
What Happens When a Component Becomes Obsolete?
An end-of-life notice does not automatically mean an OEM has to redesign its product. It does mean the team has decisions to make.
Depending on the situation, options may include:
- Purchasing enough inventory to support projected future demand.
- Qualifying an alternate Form, Fit, or Function (FFF) component or supplier.
- Qualifying an alternate component or supplier.
- Redesigning part of the assembly.
- Updating software or firmware to support a replacement.
- Revalidating or retesting the product after a change.
- Planning a broader technology refresh.
The earlier the risk is identified, the more options the OEM generally has.
How Component Obsolescence Increases Counterfeit Risk
Once authorized sources can no longer supply a component, OEMs may have to look to the broker market. This can increase the risk of counterfeit or suspect parts entering the supply chain. Early lifecycle planning can reduce this risk. Teams have more time to secure authorized inventory or qualify alternatives before supply disappears.
This is one reason component engineering and risk analysis are part of Spartronics’ supply chain management services. Monitoring component availability and working with a broad supplier network can help teams make sourcing decisions before a shortage begins affecting production schedules.
Why Is a Last-Time Buy Not Always the Complete Answer?
A last-time buy can be useful when a manufacturer announces that a component will be discontinued. The OEM estimates future requirements and purchases enough material to support the remaining product lifecycle. The difficulty is estimating how much will actually be needed.
Demand can change. Products may remain in service longer than expected. Repair rates may increase as fielded equipment ages. Stored components also have to be managed properly. Buying too little may only postpone the problem. Buying too much can tie up capital in inventory that may never be used.
What Are the Storage Risks of a Last-Time Buy?
Electronic components have finite shelf lives. This makes proper storage a major consideration when planning a last-time buy. Over time, component leads can oxidize and reduce solderability, while moisture can build up in stored components. These issues can create problems when the parts are eventually used in production.
A long-term supply of microchips may require specialized, climate-controlled storage and moisture management, which can add significant costs to an LTB strategy. These storage requirements should be considered before purchasing years of inventory.
That is why lifecycle management should consider expected production, field service requirements, existing inventory, alternate parts, and the realistic remaining life of the product before deciding how to respond.
How Can Component Changes Affect Regulated Products?
For regulated products, replacing an obsolete part may involve more than finding something with similar specifications. A component change can affect testing, documentation, configuration control, and potentially regulatory requirements. Medical devices are a good example. The FDA notes that changes in a device’s components, design, or manufacturing process can require additional evaluation and, depending on the significance of the change, regulatory action. Its guidance on modifications to 510(k)-cleared devices specifically recognizes that supply-chain changes can drive product modifications.
That makes early warning especially valuable. If engineering and quality teams know a component is approaching end of life, they have more time to evaluate alternatives, conduct required testing, and update documentation correctly. Spartronics supports this process through value-added and sustaining engineering alongside manufacturing, quality and supply-chain teams.
Component Lifecycle Management Continues After Production
The challenge does not end once new-product manufacturing slows down. OEMs may still need to repair equipment, provide replacement assemblies or maintain spare-parts inventories for years. A component that is no longer required for regular production may remain critical to supporting installed products.
Spartronics’ aftermarket solutions include obsolescence management, sustaining engineering, refurbishment, repair, and spare-parts support. Maintaining visibility into component status helps OEMs plan how products will be supported through the rest of their useful lives rather than addressing each shortage independently. This can be particularly valuable when downtime is costly or replacement of an entire system is impractical.
How Can OEMs Be More Proactive About Component Obsolescence?
Effective lifecycle management starts well before a discontinuation notice arrives. During product development, teams can evaluate whether critical components have multiple sources, consider anticipated lifecycle status, and identify parts that could be difficult to replace later.
Identify Single- and Sole-Source Components During Design Reviews
Design reviews should identify components that depend on a single or sole source. Teams can then look for opportunities to qualify multiple sources. Adding approved sources during the design stage gives OEMs more options later. If one manufacturer discontinues a component or experiences a supply disruption, another qualified source may already be available.
Spartronics’ manufacturing readiness process includes upfront evaluation of components, designs, and supply-chain risks before products move further into production.
Product lifecycle tools can help teams track component status, manufacturer notices, sourcing risks, and other changes across a BOM. Agile, e2open, and SiliconExpert are examples of tools available for this type of monitoring. Spartronics uses SiliconExpert.
Once the product is active, the BOM should continue to be monitored. Engineering, procurement, manufacturing, and aftermarket teams can then respond to emerging risks together instead of treating obsolescence as a purchasing problem after inventory has already disappeared.
Protect the Full Product Lifecycle With Spartronics
Long-life electronic products require a manufacturing strategy that extends beyond the initial production run. Spartronics supports OEMs throughout the product lifecycle with component engineering, supply-chain management, sustaining engineering, obsolescence management, manufacturing, and aftermarket services. By identifying component risks earlier and planning for changes, OEMs can protect production continuity and continue supporting products already operating in the field.
Learn more about Spartronics’ full range of electronics manufacturing services or contact Spartronics to discuss lifecycle support for your product.
