Industrial automation is facing a severe test of technological iteration. The current pace of technological advancement in the industrial sector is unprecedented, putting both hardware and software in automation systems under pressure to become obsolete. As the core control unit for machinery and production processes, programmable logic controllers (PLCs) face a particularly acute obsolescence problem. The retirement of old PLCs not only creates significant financial pressure but also leads to operational disruptions and strategic decision-making difficulties, making it a complex issue that manufacturers must comprehensively address. A thorough understanding of the actors involved, their nature, when they occur, the impact levels, and the underlying causes is crucial for maintaining market competitiveness and stable operations.

PLC Lifecycle and Impact Areas

PLC obsolescence directly impacts all manufacturing companies employing automated production, regardless of size. When equipment manufacturers like Lenze gradually terminate technical support and parts supply for older models, companies face the consequences. PLCs typically go through five distinct lifecycle stages: product launch, market growth, spare parts availability, gradual market withdrawal, and complete phase-out. With technology upgrades and manufacturer strategy adjustments, users' window for obtaining spare parts may shrink to six months to a year, after which they face the dilemma of being completely unmaintainable.

The Dual Financial and Operational Pressures of Obsolescence

The most direct challenges posed by PLC obsolescence are both financial and operational. Maintenance costs for older systems rise rapidly, and the scarcity of compatible spare parts drives up prices. Furthermore, systems based on outdated technology architectures are more susceptible to sudden failures, resulting in unplanned downtime, emergency repairs, and production losses that severely impact business profitability. Furthermore, the programming languages and hardware technologies used by older PLCs are becoming less widely understood, making it difficult for companies to find suitable technicians. This forces companies to invest more in employee training or hire expensive external experts, further increasing operational burdens.

A Multi-Pronged Solution and Technological Evolution

To address these challenges, manufacturers need to adopt a strategy that combines technology upgrades, supply chain adjustments, and long-term planning. One viable approach is to move toward more scalable automation solutions, such as integrated PLCs that combine a controller with an HMI panel (such as those offered by Unitronics). This type of equipment eliminates the complexities of external wiring and communication configuration. By completing logic design and interface development on a unified software platform, it significantly reduces the difficulty of long-term maintenance and future upgrades. For existing legacy systems, companies can leverage the support of third-party professional service providers and adopt diversified procurement channels to maintain the operation of core equipment, thereby buying time for system migration.

A strategic management approach that turns crises into opportunities

The key to addressing the costs of PLC obsolescence is not to resist technological upgrades, but to mitigate their negative impact through systematic management. Manufacturing companies need to continuously track the lifecycle status of existing automation equipment, establish smooth communication mechanisms with suppliers to obtain product planning information, and develop transition plans as early as possible. By investing in next-generation integrated control systems and building internal professional technical teams, companies can transform potential operational crises into planned technological iterations, ultimately ensuring continued production efficiency and profitability amid the wave of intelligentization.