The Late-Night Search
It’s 11pm on a Thursday. Production is down, alarms are flashing, and someone’s scrolling through eBay listings for a twenty-year-old Siemens PLC module. The same part that once arrived next-day from the manufacturer is now only available from a seller overseas, labelled “untested – no returns.”
Sound familiar?
The Treasure Hunt
We’ve all been there, chasing that one obsolete HMI or drive that’s keeping an entire line from running. It’s no longer engineering; it’s archaeology, sifting through grainy photos and vague descriptions, hoping “used but working when removed” actually means what it says.
The Realisation
That late-night panic is a symptom of a much bigger issue: automation obsolescence. It’s not just a broken part, it’s a reminder of how dependent your operation has become on technology that’s quietly slipped past its support lifecycle.
The Hidden Danger of Obsolescence in Automation Systems
Automation keeps modern manufacturing running precise, efficient, and reliable. Yet one risk is often ignored until it’s too late: equipment obsolescence.
When a PLC or HMI fails and the manufacturer no longer supports it, businesses face downtime, inflated costs, and compliance risks that can cascade through production.
Why Obsolescence Is So Often Overlooked
In many factories, legacy automation systems run day after day without complaint. As long as the line moves, it’s easy to assume all is well.
This “if it isn’t broken, don’t fix it” mindset is understandable, but dangerous. Over time, manufacturers grow comfortable with familiar systems, unaware that spare parts are vanishing and software updates have stopped.
When the inevitable failure arrives, the problem becomes urgent and costly.
The Risks of an Obsolete PLC or HMI
⚙️ 1. Lack of Spare Parts
When a product line is discontinued, sourcing a replacement becomes a nightmare. Components disappear from stock, third-party sellers price-gouge, and what’s left are used, untested parts with no warranty.
⏱️ 2. Downtime Costs
Every hour of downtime is lost revenue. Hunting for old modules or patching together temporary fixes can cost hundreds of thousands of pounds in lost output and missed orders.
🧯 3. Safety & Compliance Issues
Older systems lack modern cybersecurity and safety features. Running outdated equipment can expose your business to risk, from data breaches to health & safety violations.
🔌 4. Integration Challenges
New automation hardware uses different software, protocols, and programming environments. Replacing one obsolete unit often triggers a wider upgrade, introducing complexity, delays, and additional cost.
🔧 5. Rising Maintenance Costs
Even when you keep an old PLC running, maintenance costs escalate. Engineers familiar with legacy systems are retiring, and spare parts are drying up. Routine jobs become time-consuming, high-risk fixes.
How to Stay Ahead of Obsolescence
Avoiding these risks starts with a proactive lifecycle strategy, not a reactive scramble when something fails.
1. Assess and Document Equipment Health
Create an up-to-date inventory of your PLCs, HMIs, and drives. Note their support status, firmware versions, and upgrade paths.
Our digital asset management platform — ECS Vault — makes this process effortless by storing software backups, version control, and obsolescence data in one secure place.
2. Embrace Preventive Upgrades
If your system is nearing end-of-life, plan the transition before it becomes an emergency.
ECS Projects can support migration and upgrade programmes with minimal disruption, ensuring compatibility and compliance.
3. Build a Contingency Plan
Keep critical spares and establish reliable remote-support options.
Our patented ECS Connect service provides 24/7 PLC fault support, with engineers able to connect within the hour — reducing downtime from days to minutes.
4. Invest in Staff Training
Ensure your engineers understand both legacy systems and modern replacements. ECS provides training and workshops to help teams prepare for technology transitions.
Conclusion
Obsolescence isn’t just about ageing parts, it’s a business continuity risk.
When critical PLCs or HMIs fail, the true cost isn’t just the replacement component, but lost production, safety exposure, and operational stress.
By taking a proactive approach, documenting your assets, planning upgrades, and implementing robust support, you can turn obsolescence from a looming threat into a controlled, managed process.
Don’t wait for the late-night search to begin.
Stay ahead of obsolescence. Keep your lines running.
Let ECS help secure the future of your automation.
