End of life retrofit

An end-of-life retrofit within industrial automation does not have to be done all at once. With a smart, phased approach, the renewal can be spread over multiple moments, which keeps production interruptions to a minimum.

An end-of-life retrofit within industrial automation does not have to be done all at once. With a smart, phased approach, the renewal can be spread over multiple moments, which keeps production interruptions to a minimum.

End of life retrofit

Machines that have performed reliably for years will eventually reach an age where an end-of-life retrofit becomes increasingly urgent. Replacement parts are becoming increasingly difficult to obtain, as components are no longer produced or manufacturers end support. This creates new challenges, especially when these machines play a vital role in the production process.

In addition, the life cycle of electronic components and control systems is often shorter than that of mechanical components. This increases the risk of long-term downtime. When critical components are no longer available or supported, failures can lead to significant delays and rising costs for maintenance and repair.

In these situations, it becomes increasingly difficult to accurately predict the Mean Time Before Failure (MTBF). At the same time, the Mean Time To Resolve (MTTR) and the Mean Time To Failure (MTTF) increase. The sum of risks and costs can ultimately be higher than the investment in a well-prepared retrofit.

An end-of-life retrofit therefore offers a smart and sustainable solution for outdated machines. By renewing critical components such as control systems, the lifespan can be extended considerably. Moreover, a retrofit does not have to be carried out in one go. By dividing the process into multiple phases, production remains operational as much as possible, stagnations are minimized and the machine park is prepared for the future step by step.

Machines that have delivered stable performance for years eventually reach a point where an end-of-life retrofit is no longer a strategic choice but a technical necessity. As electronic components and control hardware enter the end-of-support phase, the availability of critical parts decreases exponentially. Component obsolescence, outdated firmware, and the loss of supplier support cause increasing risks within the operational chain. This poses a growing challenge for engineers, especially when the systems in question occupy a core position within an automated production environment.

The discrepancy between the lifespans of electrical and mechanical subsystems increases the risk of unplanned downtime. The unavailability of I/O modules, CPUs, or servo drives can lead to system degradation and uncontrolled downtime. At the same time, maintenance costs rise due to reduced availability of expertise and the need for custom repairs or reverse engineering of outdated hardware.

In this context, accurately modeling parameters such as Mean Time Before Failure is becoming increasingly complex. Mean Time To Resolve and Mean Time To Failure are increasing due to longer diagnosis and repair processes and limited access to documentation or software tools. From a reliability engineering perspective, this creates an unfavorable balance between risk, maintenance capacity, and lifecycle costs, making retrofit the most economically and technically rational option.

An end-of-life retrofit allows existing installations to be reengineered with modern control architectures, improved signal processing, and future-proof communication protocols. Through the phased implementation of new PLC platforms, remote I/O structures, and optimized HMI interfaces, the engineer can significantly extend the installation's lifespan without lengthy production downtime. This not only preserves the machinery but also prepares it for further digitalization and integration into next-generation industrial networks.

Frequently Asked Questions

What is a retrofit and why is it important?

A retrofit is the process of modernizing existing machinery by replacing outdated components or adding up-to-date technology. This is important because it extends the life of machinery, reduces the risk of breakdowns, and increases efficiency without having to purchase a completely new machine.

How do I know if my machine needs a retrofit?

You may consider a retrofit if your machine is experiencing frequent breakdowns, spare parts are hard to come by, or the manufacturer no longer offers support. An increasing Mean Time To Resolve (MTTR) and risks of downtime can also be signals that a retrofit is needed.

Can a retrofit be carried out in phases?

Yes, a retrofit does not have to be done all at once. It is possible to divide the process into multiple phases, depending on your needs and production planning. This way, your production is minimally disrupted while the machine is gradually modernized.

How much does a retrofit cost compared to a new machine?

The cost of a retrofit is usually considerably lower than investing in a completely new machine. In addition, you save on additional costs, such as installation, training and possible production downtime that come with a new installation.

What happens to my production during a retrofit?

With well-organized planning, retrofits can be performed during planned downtimes, minimizing the impact on your production. With a phased approach, your machine remains largely operational while components are replaced incrementally.

What are the long-term benefits of a retrofit?

A retrofit makes your machines more efficient and reliable, with a lower chance of failures. You benefit from modern technologies, improved energy efficiency and lower maintenance costs. In addition, a retrofit allows you to increase production capacity and keeps your machine park future-proof for longer.

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