22nd FVI Expert Breakfast

🔌 “Component obsolete – production stops!” How a single part can bring entire plants to a standstill – and what you can do about it.

At the 22nd FVI Expert Breakfast on May 23, 2025, we’ll tackle a topic almost everyone knows but few approach systematically: Obsolescence in maintenance.

🔍 Spare parts that no longer exist. 📉 Components that were never documented. ⛔ Opaque supply chains, silent failure risks. 👉 And then? Downtime.

🎙 Our guest: ➡️ Carsten Finke, Managing Director of INSpares GmbH, shares real-world experience:

Why you often don’t even know what you’ve got

Why transparency is the most powerful lever against obsolescence

How to shift from “crisis mode” to proactive strategy

📅 When? Friday, May 23, 2025, 09:30–10:30 CEST 🌍 Where? Online – live & interactive

👥 Moderation: 🎤 Marcel Hahn – Moderator & Tech-Enabler 🎤 Jens Reißenweber – Maintenance Consultant & Scout for Perfect Production

💡 What to expect: ✅ Why many machines include obsolete parts from day one ✅ How companies can identify risks – before it’s too late ✅ Real stories, practical insights, and clear strategies

📌 Spoiler: The dead end is coming – but you don’t have to drive all the way there.

Summary

• Obsolescence Management Carsten, Marcel, and Jens discussed the importance of obsolescence management in industry. Carsten emphasized the need for transparency regarding installed components to enable strategic decision-making. Jens pointed out that the issue is becoming more urgent, especially as retrofit is the new investment.

  • Definition and Significance: Carsten explained that obsolescence management involves managing discontinued parts. It’s not a problem if a part becomes obsolete – as long as you don’t rely on it. In industrial settings, where parts are complex and interconnected, failure can have major consequences.
  • Real-World Example: Carsten shared a case where a client discovered in 2019 that parts in a new plant were already unavailable. This led to production downtime and highlighted the need for effective obsolescence management.
  • Retrofit as a Solution: Jens highlighted retrofitting – modernizing existing systems – as a key strategy, especially relevant when investing in new equipment isn’t feasible.

• Transparency and Lifecycle Data Carsten stressed the importance of transparency regarding installed components and their lifecycle data.

  • Component Inventory: All installed components must be identified to create transparency – including manufacturer, configuration, and installation context.
  • Lifecycle Tracking: Tracking component lifecycles enables early reaction to discontinuations and proactive planning.
  • Customer Example: Repeated case: a new plant (2019) already included obsolete components – leading to downtime.

• Procurement Challenges Jörg and Klaus highlighted the challenges SMEs face in sourcing components and managing lifecycle data.

  • External Support: Jörg noted that SMEs often struggle without external help. Service providers can increase transparency and support lifecycle monitoring.

  • Monitoring Processes: Klaus emphasized the need for structured processes to track lifecycle data. His company uses a database that flags lifecycle changes and discontinuations.

• Strategic Planning and Budgeting Carsten and Jens underscored the importance of strategic oversight in obsolescence management.

  • Bird’s-Eye View: Strategic decisions require a comprehensive view of the facility – identifying critical components, planning inventory, and setting priorities.
  • Flexibility: Jens stressed the need for adaptable strategies and budgets to respond to unexpected failures or market shifts.

• Digitization and AI Support Tina presented two use cases where digital tools and AI help address obsolescence.

  • AI for Information Retrieval: AI can extract needed data from digital records – helping technicians find the right parts faster.
  • 3D Printing and Machining: Tina described how these technologies are used to reproduce unavailable parts – allowing legacy equipment to remain operational.

• Collaboration with Service Providers Roland and Horst emphasized the need for cooperation with external experts.

  • Service Provider Support: Roland noted that obsolescence management is not the core business of manufacturers – external specialists are often essential.
  • Public Transport Approval: Horst pointed out that system approvals in public transport are a major challenge – and obsolescence must be considered already at procurement.

• Experiences and Best Practices Hans-Christian and Marcel shared hands-on insights into dealing with obsolescence.

  • Strategic Reserves: Hans-Christian recalled how companies used to keep reserves of critical spare parts – a key tactic to avoid downtime.
  • Data Digitization: Marcel emphasized digitizing data assets to create transparency and prepare for obsolescence. Technologies like digital twins can help ensure spare part availability.