Feature: Automotive
highest share of driver-monitoring systems in use. To meet existing and future regulatory requirements, automotive manufacturers will need to install sensors that help ensure sufficient safety-related redundancies. As a consequence, more sensors will be built into the car’s seat, steering wheel and dashboard to continuously track and trace drivers’ vitals such as respiration rate, blood pressure and heart rate, among others. At this stage it is worth noting that these components have
significantly shorter lifecycles than those traditionally used in the automotive sector. Te average lifespan of current electronics ranges from 1.5 to 13 years, but most only survive four to five years, requiring manufacturers to reconsider their obsolescence management plans. Moreover, as newer sensors reach the market, those already in use
become obsolete sooner. For instance, ultrasound sensors may soon be overtaken by camera- or lidar-based parking assistant systems. Overall, sensor obsolescence brings huge challenges to most automotive manufacturers.
Ongoing changes To keep up with the times and bypass the issue of sourcing legacy parts, manufacturers can commission an entirely new system, in the so-called rip-and-replace approach, for interoperability, efficiency and synchronisation with emerging technologies. However, the disadvantages are just as evident. Not only is
the initial investment oſten cost-prohibitive, but loss of profits caused by the necessary downtime to replace equipment and retrain employees can be enough to put smaller plants out of business. Moreover, at a time when manufacturers worldwide are struggling to reduce the amount of waste that fills up landfills, the rip-and-replace approach is certainly not the best option for the environment. In light of this, manufacturers are doing their best to cope with
obsolescence by stocking large inventories of key parts and taking advantage of last-time-buy options. However, both strategies have shortcomings. Last-time-buys require large upfront investments to purchase a sufficient number of components that may or may not be used in the future. Manufacturers also need to estimate the total usage of these components, and this is not always easy, especially when the quantity and quality of available data for predictive maintenance are inadequate. In addition, the long-term storage of electronic components requires dedicated warehousing space, especially for sensitive components that might be easily damaged by environmental factors such as heat and humidity.
Strategic approach Obsolescence is the natural consequence of technological progress, with no option of eliminating it completely, but, there are steps that can be taken to minimise its negative consequences. On automotive production lines, the first step is to assess the
current state of equipment by performing a comprehensive system audit. Manufacturers can start by assessing how old their machines are and how long their components have been on the market. Te answer should then be compared with the life expectancy
Rapid changes to automotive design mean that manufacturers are under unprecedented pressure to modernise their production lines
data provided by the OEMs. Tis will help maintenance teams determine the life stage of core machines and their components, to better assess of how long they will serve the plant. Manufacturers can then make a list of components that are already obsolete or near their end of life. Te second stage involves risk analysis. In this phase,
manufacturers can assess which applications to prioritise in their obsolescence management plan and establish a dedicated budget for their upkeep. Finally, based on the analysis of how critical a part is to core
processes, the predicted speed at which it will wear out and its risk of becoming obsolete, manufacturers can plan where to source these parts and how quickly. In this phase, it is essential to liaise with a reliable parts supplier. Since failure of any key component could affect the whole assembly line, timely replacement is essential to avoid unplanned downtime. Terefore, when an obsolete component breaks, calling the right partner can make the difference between a couple of hours or several days of downtime.
The design stages Regarding vehicle components, engineers should ideally plan for obsolescence during the design phase. Analysing procurement data and avoiding parts that have been on the market for several years is a good beginning to minimise the risk of obsolescence. Although assessing product lifecycle is not easy, access to procurement information can offer the designer more control over the complex automotive supply chain. Simulation and digital twinning can also be used to visualise each stage of production and design in the most efficient way, eliminating unnecessary redundancies that increase the risk of obsolescence. Te first electric car dates back to 1881, developed by French
electrical engineer Gustave Trouvé, aſter he improved the design of a small Siemens electric motor and incorporated a newly-developed rechargeable battery. Since then, we have seen so much innovation, which will continue apace. With careful planning and the assistance of a specialist in obsolete parts, auto makers can stay ahead of the game and remain competitive for years to come.
www.electronicsworld.co.uk December 2021/January 2022 39
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