How to Manage Obsolescence in Industrial Automation and Cut Downtime

In today’s fast-paced manufacturing and industrial sectors, obsolescence is more critical than ever. From PLC systems and industrial control panels to automation hardware, HMI software and SCADA networks, companies face growing risks from outdated equipment. Failure to manage obsolescence can result in costly downtime, reduced efficiency and even compliance failures.

What is Obsolescence in Industrial Automation?

Obsolescence occurs when automation equipment such as a PLC, industrial drive or control system module is no longer supported by the manufacturer. This typically means:

• Spare parts are difficult or impossible to source.

• Software updates and security patches are discontinued.

• Technical support and training materials are no longer available.

  
  

Well-known examples include legacy PLC platforms such as Siemens S5, Rockwell PLC-5 or Schneider Modicon Quantum which are now end-of-life.

Why Obsolescence Must Be Tackled

1. Cut Downtime

Old and unsupported PLC controllers, HMIs and drives are far more prone to failure. Without a clear strategy to manage obsolescence, a single component fault can stop an entire production line and cut productivity for hours or even days.

2. Maintain Supply Chain Security

When automation hardware becomes obsolete, sourcing spare parts often means turning to grey-market suppliers. This increases costs and brings the risk of counterfeit or unreliable components.

3. Improve Cybersecurity

Outdated SCADA systems, HMI software and network devices often lack modern cybersecurity updates. Tackling obsolescence by upgrading to supported industrial Ethernet, OPC UA and secure PLC platforms reduces vulnerability to cyber-attacks.

4. Boost Efficiency and Performance

Modern platforms such as Siemens S7-1500, Rockwell ControlLogix, Beckhoff TwinCAT and Schneider Modicon M580 deliver faster processing, larger memory and built-in diagnostics. Upgrading helps boost efficiency, save energy and enhance long-term productivity.

5. Meet Compliance and Safety Standards

Obsolete equipment may not meet the latest safety standards such as ISO 13849, IEC 61508 SIL or UL 508A. A structured plan to manage obsolescence ensures continued compliance with safety and quality regulations.

Obsolescence Strategies

A clear strategy is essential to manage obsolescence effectively:

• Audit existing automation assets: Identify all PLCs, drives, HMIs and field devices in use.

• Classify risk levels: Prioritise high-risk equipment close to end-of-life.

• Plan phased upgrades: Migrate from obsolete platforms (e.g. Siemens S7-300 to S7-1500, Rockwell SLC 500 to CompactLogix).

• Use virtualisation and digital twins: Simulate upgrades before deployment.

• Partner with automation experts: Work with system integrators specialising in PLC migration and control system modernisation.

  
  

Summary

Tackling obsolescence is not just about replacing old equipment, it is about protecting productivity and ensuring resilience. Companies that manage obsolescence proactively can cut downtime, boost efficiency, strengthen cybersecurity and maintain compliance. Whether it means upgrading PLCs, modernising HMI and SCADA platforms or refreshing industrial drives, a forward-looking approach ensures competitiveness and long-term success.