Across British manufacturing, many older machines continue to perform reliably long after their expected service life.
For production managers, keeping proven equipment running can appear far more cost-effective than investing in a complete system replacement
The problem begins when a legacy drive, motor or feedback device suddenly fails.
When older automation components become obsolete, the true cost is rarely the part itself. The greater expense comes from unplanned downtime, lost production, emergency sourcing, and the pressure placed on maintenance teams to restore output quickly.
In some cases, a single failed component can stop an entire production line for days, if not weeks.
Many manufacturers no longer support ageing machinery or discontinued automation products, leaving engineers searching for replacement parts with uncertain availability and long lead times.
A recent example involved a food manufacturer during the busy Christmas production period. An AGV responsible for transporting products to cold storage suffered an unexpected drive failure, bringing a critical part of the operation to a halt. With approximately 75,000 mince pies needing to be moved urgently, every hour of downtime increased the risk of production delays.
Fortunately, motec held a compatible replacement drive in stock. The unit was dispatched immediately, allowing the AGV to be repaired and returned to service within 24 hours. What could have become a major disruption during a peak manufacturing period was resolved before significant production losses occurred.
This is where specialist support becomes critical. With more than 40 years of experience in motion control and automation, motec supports customers with sourcing, repair and replacement options for legacy systems that still offer operational value.
Because motec is independent, replacement solutions can be selected from multiple manufacturers rather than forcing a complete redesign around a single brand. This enables businesses to extend machine life while avoiding unnecessary capital expenditure.
Legacy equipment can remain commercially viable for many years, but the risks and hidden costs of component failure should be understood before production is disrupted.
To help manufacturers identify potential vulnerabilities before they become costly breakdowns, motec offers system surveys and legacy automation health assessments for UK-based end users.