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What is obsolescence?
Obsolescence describes the state in which electronic components, assemblies, or complete systems are no longer available or have been discontinued by the manufacturer. The term originates from the Latin to become obsolete and means „to become obsolete“ or „to fall out of use.“ In electronics development, obsolescence primarily occurs when components are no longer produced, are replaced by new generations, or their supply chains disappear.
In many technical applications – such as industrial plants, measurement systems, rail technology, or defense electronics – the lifespan of an entire system is often between 10 and 30 years. Electronic components, on the other hand, frequently have significantly shorter product life cycles. Microcontroller, memory, power semiconductors, or communication chips are already discontinued after only a few years. This creates a structural problem: a device may still be needed even though individual key components are no longer available.
Typical examples of obsolescence in electronic assemblies include:
- Microcontroller or processors that are discontinued by the manufacturer
- Memory modules (Flash, DRAM, EEPROM) whose housings or interfaces are no longer produced
- Analog or Power ICs being replaced by new semiconductor generations
- special sensors or RF components offered by only a few manufacturers
- discrete components or connectors with modified housing shapes or pinouts
Components with high functional significance for the system are particularly critical. For example, if a central Microcontroller or a FPGA discontinued, a simple replacement is often not possible. Differences in peripherals, memory organization, pin assignments, or toolchains then lead to hardware and software adjustments becoming necessary.
Causes of obsolescence
Obsolescence arises from various technical and economic developments along the supply chain.
A common reason is the technological advancement of the semiconductor industry. New manufacturing technologies, smaller structure sizes, or new architectural concepts lead to older component generations disappearing from the market. Manufacturers focus their production capacities on new products.
Another factor is the economic decisions of component manufacturers. If a component reaches only low production volumes or a production line is discontinued, a discontinuation (End-of-Life, EOL) often occurs.
Changes in the supply chain can also trigger obsolescence. These include, for example:
- Setting a housing variant
- Elimination of a sub-supplier
- new regulatory requirements (e.g., RoHS amendments)
- Transition of manufacturing processes
The information about such changes is usually provided via Product Change Notification or Product Discontinuation Notification the manufacturer.
Measures for obsolete components
If a component is discontinued or can no longer be procured, several technical and organizational measures are available. Which strategy is sensible depends on the component's role in the system and the planned product lifecycle.
Replacement with compatible components (second source)
If alternative manufacturers exist, a functionally compatible component can be used. The prerequisite is that the housing, pin assignment, and electrical properties are sufficiently similar. This strategy is particularly possible with discrete components or standard ICs.
Redesign of individual circuit parts
If no compatible replacement is available, a portion of the hardware can be adapted. For example, a new voltage regulator, a different memory module, or an alternative interface can be integrated. This often requires modifications in the Circuit diagram and in the PCB layout.
Platform or controller migration
Porting central components like microcontrollers or SoCs to a new hardware platform may become necessary. This involves adapting software, drivers, and sometimes even hardware architecture.
Last-Time-Buy and Stockpiling
When discontinuations are announced, manufacturers often offer a so-called Last-Time-Buy Companies can procure and store larger quantities to ensure production or maintenance over several years.
Assembly or System Redesign
If multiple key components are affected simultaneously, a complete redesign of the electronics may be required. This involves modernizing the entire hardware platform.
Refurbishment and repair strategies
In some industries, existing assemblies are repaired or reconditioned. This includes, for example, replacing individual components or refurbishing assemblies from existing devices.
Pick and place services
Obsolescence Management
Obsolescence management encompasses all organizational and technical measures by which companies control the risks of discontinued components throughout the entire product life cycle. In long-lasting systems, obsolescence is ideally considered during development. This includes, for example, the selection of widely used components, modular hardware architectures, and early assessment of component life cycles.
Software Tools for Obsolescence Detection
Specialized databases and software tools are often used today for the early detection of component risks. These systems collect information about electronic components, their life cycles, and changes made by manufacturers. The goal is to identify risks in Bills of Materials (BOM) as early as possible.
A well-known example is the platform Octopart. These systems aggregate data from various sources, including manufacturer information, distributors, inventory levels, and technical data sheets. Developers and buyers can use them to check if a component is still in production, what its current availability is, and what alternative components exist.
