Legacy Applications: A Partnership for Long-Term Legacy Sustainment

What you'll learn:

• LEMs can provide options and shoulder the burden.
• LEMs can help plan for the future.
• Collaboration is the solution.
• What application OEMs should avoid when looking for support options for legacy products.

Because everyone is an OEM to someone, it's helpful to categorize different types of OEMs. GDCA is a LEM that typically works with two types of OEMs: "embedded electronics OEMs" (AKA embedded OEMs) and "application OEMs."

We've previously explored embedded OEMs' focus on bringing embedded computers to market. These "embedded" computers differ from typical IT (information technology) computers in that they’re "embedded" into capital equipment, which then performs physical functions.

Nowadays, almost everything has an embedded computer—from consumer appliances like toasters and refrigerators to commercial "applications" such as industrial robots, medical devices, airport baggage scanners, trains, defense systems, etc. And they’re all made by "application OEMs."

Application OEMs purchase and use embedded circuit cards and systems to develop their products. Legacy equipment manufacturing emerged in response to a need from application OEMs working in commercial markets.

When embedded OEMs stop making older computer designs, the companies that use those parts in their own products are in trouble. Their supply chains start to crumble, and they scramble to get the last remaining parts. If they can't find the parts they need, they're forced to make expensive and difficult upgrades to their systems.

This is where LEMs can be a lifesaver. LEMs offer options beyond just scrambling for last-minute parts or expensive upgrades.

Providing Options and Shouldering the Burden

The ways LEMs can help depend on application OEMs' unique situations. This mainly involves whether they’re using commercial-off-the-shelf (COTS) products from an embedded OEM or embedded computers that they've designed themselves in-house (Fig. 1).

For COTS products, LEMs help application OEMs rebuild broken supply chains. They act as a bridge between customers and suppliers, finding mutually beneficial solutions when there's disagreement about legacy support.

LEMs can become a new source of supply for discontinued products. They may even convince the original manufacturer to continue supporting older products.

For companies with in-house designed computers, many of which may contain obsolete components, LEMs offer a complete solution. They can take over the entire manufacturing process, ensuring a steady supply of the necessary components without burdening internal teams.

In all situations, LEMs work across the entire supply chain. They provide application OEMs with computer assemblies that are identical to the originals, breaking the costly cycle of forced upgrades due to component obsolescence.

Planning for the Future

Electronics obsolescence is a certainty and a natural part of any embedded computer board's lifecycle, and planning for it is essential. An LEM can help with this planning by predicting and proactively resolving future obsolescence issues before they become problems.

LEM plans involve an economic evaluation of options that are only sometimes available to the application OEM on their own. That could include establishing a new source of supply (NSOS) or simply contacting the embedded OEM on the customer's behalf for support.

Often, application OEMs prefer establishing an NSOS. In this case, the LEM rebuilds and maintains the product supply chain for application OEMs, ensuring a smooth transition from the embedded OEM.

A technology refresh/upgrade is sometimes necessary for an application to integrate new capabilities or upgrade obsolete hardware. An LEM can assist an application OEM with this process by bridging the gap and providing manufacturing and repair support for critical systems until the refresh is complete.

Collaboration is the Solution

LEMs have industry-wide relationships and an in-depth understanding of electronics manufacturing, engineering, and supply-chain risk management. This helps application OEMs gain a much deeper understanding of which parts are at risk for obsolescence, what options exist to combat obsolescence, and how products can be sustained for as long as they're needed (Fig. 2).

Sometimes, the embedded OEM will have enough old stock to offer another “last-time buy” (LTB) or supply their customer with replacement parts for at least part of the card's lifecycle. LEMs can help serve as knowledgeable liaisons and encourage collaboration for sustainment, which will result in the application OEM getting the parts that they need.

What Application OEMs Should Avoid When Looking for Support Options for Legacy Products

Far more options are available for supporting legacy products than many realize, some of which go beyond working with a legacy equipment manufacturer. However, it’s always important to consider all your options and understand what to avoid when looking for support. Here are a few suggestions on what not to do.

1. Avoid partial solutions

Refrain from settling for a partial solution, no matter what path you take to support the embedded systems critical to your products.

When supporting critical embedded systems, it's crucial to avoid settling for short-term solutions. If a product is needed for 10 years, the chosen support strategy must provide for that duration, not just a few years.

While a temporary band-aid solution might seem attractive initially, it will inevitably create significant long-term support challenges. Putting off finding a sustainable solution will limit available options. As supply chains weaken and original equipment manufacturers shift their focus, obtaining necessary support becomes increasingly difficult.

2. Don’t try to tackle legacy sustainment alone

The importance of collaboration has been emphasized throughout this article, and its critical nature can’t be overstated. In reality, no individual or team within a company possesses the necessary time and resources to effectively and sustainably manage the support requirements of a legacy product.

Each member of the team has existing responsibilities, and diverting their attention from these core duties would result in a significant waste of time, resources, and financial resources. This diversion would inevitably detract from the focus on current or new product development, which are crucial for generating valuable returns on investment.

Moreover, this approach would limit available options, as it removes the possibility of outsourcing the service and necessitates internal management of the legacy product support.

3. Don’t procrastinate

One of the most detrimental approaches to addressing obsolescence is to ignore it. Unfortunately, this is the de facto strategy adopted by a significant number of OEMs when it comes to sustaining legacy products. For many, prioritizing the support for soon-to-be-obsolete products doesn’t rank high on their list of immediate concerns. Consequently, it often fails to receive much attention…until it’s a fire.

Furthermore, many organizations cling to the hope that they can secure another LTB from the embedded OEM, relying on past experiences where such requests were fulfilled. However, this approach is neither sustainable nor reliable, as there’s no guarantee that the OEM will grant another LTB.

Moreover, delaying the implementation of a legacy sustainment strategy significantly diminishes available options and hinders the ability to source the necessary system components. Over time, supply chains continue to degrade, materials become increasingly scarce, and manufacturers cease production of parts once demand dwindles.

Therefore, proactive engagement with legacy sustainment planning offers the greatest potential for success and a wider range of viable options—and it saves time (Fig. 3).

4. Don’t rely on asking the OEM for another last-time buy

As has been said, “Hope is not a strategy.”

Regarding last-time buys, requesting additional LTBs from the OEM constitutes an undesirable practice. Past success in securing LTBs doesn’t guarantee their continued availability. LTBs aren’t infinitely feasible for OEMs, particularly as the product ages. These temporary and tactical solutions offered by OEMs are precisely that—temporary measures.

Once these options are exhausted, no further alternatives may remain. Therefore, it’s imperative to pursue a long-term solution that will provide the necessary support over the extended lifespan of the product.

5. Don’t wait until the last minute

This warning extends beyond mere procrastination. It highlights the perils of last-minute planning, a common predicament that often results in frantic efforts to mitigate the consequences of unforeseen circumstances.

Waiting until the final moment to secure support for a legacy product inevitably leads to a frenzied scramble to acquire the necessary resources.

Instead of succumbing to this reactive approach, it’s imperative to proactively develop and implement a plan to support components at risk of obsolescence several years prior to the anticipated last-time buy.

Conclusion

Legacy equipment manufacturers have much to offer application OEMs and their customers, providing the necessary support for critical embedded systems rife with obsolete components.

They bridge the yawning chasms in broken-down supply chains for obsolete embedded boards; offer services to plan for future obsolescence of critical, at-risk components; and provide application OEMs with far more options than an expensive upgrade.

LEMs can be valuable partners in the face of looming obsolescence issues both now and in the future. They can shoulder some of that burden so that application OEMs can focus on what matters most for their businesses and missions.

The most important thing to remember is that many options are available when combating electronic obsolescence. As a result, folks can consider their options before jumping into a disruptive technology upgrade.

The earlier a company begins to address its legacy support challenges, the greater the range of available options they have.