Machine Obsolescence Management
In many industrial plants, machines are older than part of the team, and key components are no longer available on the market. The lack of a modernization plan puts the technical department under constant pressure, and the risk of a serious failure or prolonged downtime increases every year.
The most common problems faced by companies include:
- unavailability of spare parts and technology,
- unplanned and costly downtimes,
- lack of data on the actual condition of assets,
- lack of an early warning system for signs of aging,
- pressure from management to maintain production continuity amid rising costs.
At Operivo, we have developed a unique method for managing machine aging that allows for a transition from reactive problem-solving to conscious and predictable future planning.
How do we operate?
- Early detection of aging signs – we identify symptoms of aging (e.g., difficulty obtaining parts, decline in manufacturer availability, technical signals).
- Risk Assessment – we determine which elements of infrastructure are most at risk of failure and where the lack of parts is a critical threat.
- Life cycle analysis – we assess how long specific devices can safely operate and what actions will extend their lifespan.
- Modernization and investment planning – we create a roadmap of actions: from prolonging the life cycle, through technical modifications, to planned restorative investments.
- Implementation and training – we support your team in implementing the strategy and provide training to ensure knowledge remains within the organization.
The effect? Machines operate longer, potential risks are detected and controlled at an early stage, and investment decisions become predictable and business-justified.
3 levels of analysis
Strategic Machine Analysis
Risk Map
Make investment decisions based on facts. A detailed analysis of machines with a risk map will show which assets are most exposed and where the investment will yield the greatest effect.
Obsolescence Management Maturity Assessment
Check if your aging management approach is effective. The process audit is an organized diagnosis and workshop that turns ad-hoc reactions into planned decisions.
Self-Assessment
Obsolescence Management
Check how your company is handling the risk of aging machinery. Fill out a free self-assessment and receive a report with initial tips in just a few minutes.
Obsolescence Management
Maturity Assessment
The maturity assessment of the obsolescence management process allows you to check whether your organization manages the aging of machines in an orderly and predictable manner, or merely reacts to current problems. During the audit, Operivo specialists analyze the consistency of your management system – from monitoring the status of manufacturer support, through the availability of parts and competencies, to compliance with regulations and investment strategy.
The result is a diagnosis of gaps in the process, a decision-making workshop with your team, and clear recommendations on how to move from ad-hoc responses to a conscious, systemic approach. This is a step that transforms obsolescence from an "invisible enemy" into a fully controlled process – with specific priorities and a plan for the coming years.
Details of our process are described in our free eBook.
Strategic Machine Analysis
Risk Map
Strategic analysis of machines and production lines is the most detailed level of assessment in the Operivo approach. We focus on specific assets – devices and lines that are critical for production continuity. Each machine is evaluated in at least five dimensions: manufacturer support status, availability of spare parts, regulatory compliance, digital compatibility, and availability of service competencies.
The result of the analysis is an objective risk map, showing which devices pose a real threat to the business. Through scoring and prioritization of investments, management receives a clear basis for making CAPEX decisions: what to modernize, what to maintain, and what to replace. It is a tool that transforms uncertainty into informed planning – with specific action scenarios and their costs.
Operivo Sp. z o.o.
Aleja Jana Pawła II 27
00-867 Warsaw
+48 533 373 200
europe@operivo.com
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