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Case Study: Future-proof hardware design
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Overview:
This case study explores how our innovative approach to hardware re-design provided Mesh Global with a robust, sustainable solution during unprecedented supply chain disruptions. Focusing on future-proof hardware design and supply chain sustainability, we transformed a critical challenge into an opportunity for cost savings and growth.
Don’t let supply chain disruptions and obsolete components derail your business. Let’s talk about future-proofing your products!
Ben Mazur
Managing Director
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Introduction
Mesh Global, a multi-disciplined systems integrator (renowned for its bespoke design and manufacturing services across mechanical, electrical, electronics, software, and hydraulic disciplines), faced a significant hurdle with obsolete components and fragile supply chains. Ignitec® delivered robust solutions and hardware services through innovative engineering, extensive industry knowledge, and a commitment to sustainable, future-ready designs. Our expertise in future-proof hardware design set the stage for a collaboration that resolved immediate issues and paved the way for Mesh Global’s long-term business sustainability.
If your business is experiencing similar challenges and you’re looking for a tech partner to help resolve them, we can help!
The Problem
The need for future-proof hardware solutions has become paramount in an era of rapid technological change and global supply chain disruptions. Due to supply chain fragility, Many industries struggle with obsolete components, increased downtime, and escalating costs. For Mesh Global, the obsolescence of critical hardware components threatened their ability to fulfil customer commitments and maintain market competitiveness, underlining the urgency for a re-design that could withstand present and future challenges.
Future-proof hardware design solutions
Businesses employ “future-proof hardware design” strategies to ensure their products remain viable, scalable, and resilient despite supply chain disruptions and component obsolescence. Here are some key strategies:
- Modular and scalable design: Systems with a modular architecture allow individual components or subsystems to be upgraded or replaced without re-designing the entire product. This flexibility is vital when specific components become obsolete or are subject to supply shortages. Building in scalability from the start means the hardware can be expanded or modified to meet evolving performance requirements or integrate newer technologies over time.
- Component standardisation and generic substitution: Instead of relying on specialised, proprietary parts, companies opt for standard, widely available components. For example, replacing obsolete relays with generic high-power MOSFETs can help mitigate supply chain risks. In addition, standardised parts make switching suppliers or substituting components easier if certain parts become scarce or outdated.
- Redundancy and safety enhancements: Incorporating redundant components in critical design areas increases the hardware’s reliability. If one component fails or becomes obsolete, its redundant counterpart can ensure uninterrupted operation. Furthermore, designing with safety and operational buffers in mind allows hardware to cope with unexpected stresses, reducing the risk of failure due to unforeseen supply chain issues.
- Supply chain diversification and risk management: Businesses diversify their supply chain by establishing relationships with multiple vendors instead of depending on a single supplier. This approach helps maintain a steady supply of components even if one supplier faces disruptions. Sourcing components locally can reduce the risks associated with global supply chain vulnerabilities, such as geopolitical tensions or pandemic-related disruptions. Lastly, keeping a buffer inventory of critical components can provide a temporary cushion during supply shortages, giving time to adjust production or find alternatives.
- Continuous market and technology monitoring: Regularly monitoring market trends and technological developments allows companies to anticipate when components may become obsolete. This foresight enables timely redesigns before critical shortages impact production, making integrating new, more sustainable components into existing designs easier.
- Open architecture and standardised interfaces: By utilising open standards and well-documented interfaces, hardware systems become more adaptable to change. Open architectures allow for easier integration of third-party components, reducing dependency on any single supplier and ensuring that new technologies can be integrated as they become available without necessitating a complete overhaul of the hardware.
- Collaborative Partnerships: Collaborating with technology partners and industry experts such as Ignitec® can provide insights into emerging risks and innovative solutions. Such partnerships often lead to shared expertise, crucial for developing resilient, future-proof hardware solutions.
Are outdated hardware and obsolete components slowing you down? Call us for more information on how we can audit and re-design hardware, overcome supply chain disruptions, and boost efficiency.
Case Study: Subsea hardware solution for Mesh Global
Mesh Global is a multi-disciplined systems integrator covering Mechanical, Electrical, Electronics, Software & Hydraulic Disciplines. They offer a bespoke design and manufacturing service to both end users and as well as manufacturers. The challenges they faced, component shortages and obsolescence, including supply chain disruptions during the pandemic, required that they find a reliable and knowledgeable partner for a swift hardware re-design.
These strategies inspired Ignitec to implement a comprehensive hardware re-design for Mesh Global. Specifically:
- The problematic control PCB was overhauled: Obsolete relays were replaced with generic high-power MOSFETs and other easily substitutable components.
- By integrating dual redundancy into the design, we ensured that the product met high safety and reliability standards. This meticulous approach addressed immediate issues and rendered the system future-proof—capable of enduring future supply chain disruptions and evolving market demands.
Results
Industries that have adopted robust, sustainable hardware solutions have reported significant improvements in operational efficiency and cost reduction. In the case of Mesh Global, Ignitec’s Subsea Hardware Solution delivered multiple tangible benefits:
- Enhanced Reliability: The re-designed PCB eliminated dependency on obsolete components, ensuring continuous production.
- Future-Proofed: The solution is adaptable for future updates and modifications by using readily available, generic components.
- Cost Savings and Increased Sales: The updated design allowed Mesh Global to meet its order commitments, communicate effectively with customers, and ultimately boost sales while reducing long-term operational costs.
- Improved Supplier Engagement: Our active engagement with suppliers helps us stay informed about component shortages or upcoming changes in component availability, allowing us to anticipate alternatives and solutions to serve our clients better.
Impact & Lessons Learned
- Product resilience through innovation: The case demonstrates how a proactive re-design can mitigate risks associated with component obsolescence and supply chain disruptions.
- Sustainable practices: Integrating strategies from other industries, such as redundancy and modular design, can provide a competitive edge regarding reliability and cost efficiency.
- Future readiness: Investing in future-proof hardware design ensures businesses remain agile and responsive to market changes, supporting sustained growth and customer satisfaction.
Conclusion
The collaboration between Mesh Global and Ignitec® underscores the critical importance of future-proof hardware design in today’s volatile market. This case study is a compelling example for businesses looking to secure their supply chain and safeguard their technological investments, ensuring they remain competitive and prepared for future challenges.
If you’re looking for hardware re-design or solutions to keep you competitive for years to come, schedule a free and confidential consultation with an expert on our team.
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FAQ’s
Why is future-proof hardware design important?
Future-proof hardware design ensures long-term reliability, reducing the risk of obsolescence and supply chain disruptions. It allows businesses to adapt to changing technology, regulations, and component availability. This approach minimises costs, prevents downtime, and enhances product sustainability.
How can businesses prevent hardware obsolescence?
Businesses can prevent hardware obsolescence by designing with widely available, interchangeable components and avoiding proprietary parts. Regularly reviewing supply chain risks and adopting modular designs also help extend product life. Proactive redesigns incorporating emerging technologies can future-proof hardware against rapid industry changes.
What are the risks of using obsolete components?
Obsolete components increase the risk of supply shortages, higher replacement costs, and product failures. They can also lead to compliance issues if new regulations require updated technology. Businesses relying on outdated parts may face unexpected downtime and costly redesigns.
When should a company consider re-designing its hardware?
A company should consider re-designing its hardware when key components become obsolete or difficult to source. Supply chain disruptions, increased failure rates, or changing industry standards are strong indicators. Proactive redesigns can prevent costly last-minute changes and ensure long-term sustainability.
Which industries benefit most from future-proof hardware design?
Industries with long product life cycles, such as aerospace, medical devices, and industrial automation, benefit the most from future-proof hardware design. These sectors require reliable, adaptable technology to avoid costly upgrades and replacements. Companies in consumer electronics and automotive industries also use this approach to stay ahead of technological advancements.
Who is responsible for ensuring hardware remains future-proof?
Engineering and product development teams are crucial in ensuring hardware remains future-proof. Procurement and supply chain managers also contribute by sourcing reliable components with long-term availability. Collaboration across departments helps create adaptable, resilient designs.
Why do supply chain disruptions impact hardware design?
Supply chain disruptions can limit access to critical components, delaying production and increasing costs. When manufacturers discontinue parts, businesses must re-design or source alternatives, often at a premium. A future-proof approach mitigates these risks by using widely available and adaptable components.
How does modular design contribute to future-proofing hardware?
Modular design allows for easier upgrades and part replacements, extending a product’s lifespan. It reduces dependency on specific components, making adapting to supply chain changes easier. This flexibility lowers re-design costs and improves long-term sustainability.
What role do alternative components play in future-proof hardware design?
Alternative components help maintain supply chain resilience by ensuring replacements are readily available. Designing with multiple sourcing options prevents production delays caused by discontinued parts. Using standardised, widely available components reduces long-term risks.
When should a company conduct a hardware audit?
A company should conduct a hardware audit when experiencing sourcing difficulties, increasing failure rates, or changing regulatory requirements. Regular audits, at least every few years, help identify vulnerabilities before they become critical. Proactive assessments can guide necessary redesigns to future-proof products.
Which technologies help future-proof hardware design?
AI-driven supply chain analysis, digital twins, and predictive maintenance help future-proof hardware design. These tools enable businesses to anticipate component shortages and test new designs before implementation. Advanced materials and energy-efficient components also contribute to long-term sustainability.
Who should be involved in a hardware re-design project?
A hardware re-design project should involve engineers, supply chain experts, and quality assurance teams. Procurement specialists ensure components are future-proof while compliance teams verify regulatory requirements. Cross-functional collaboration helps create a sustainable and adaptable design.
Why do some industries struggle with future-proofing hardware?
Industries with highly specialised components or strict regulatory requirements often struggle to future-proof hardware. Long certification processes can make it challenging to replace obsolete parts quickly. Dependence on proprietary technology also limits flexibility in sourcing alternatives.
How can companies reduce costs when future-proofing hardware?
Companies can reduce costs by choosing widely available components, designing modular systems, and negotiating long-term supplier agreements. Regular hardware audits help identify potential risks before expensive redesigns are needed. Investing in scalable designs reduces the frequency of costly upgrades.
What are the key challenges in future-proof hardware design?
Key challenges include predicting component availability, balancing cost with longevity, and ensuring compatibility with evolving technologies. Regulatory changes can also impact the viability of specific materials or designs. Businesses must continuously adapt their strategies to stay ahead of these challenges.
When do companies typically face hardware obsolescence issues?
Companies typically face hardware obsolescence issues when suppliers discontinue key components, or technological advancements render existing designs outdated. Industries with long product life cycles often experience this problem more acutely. Proactive planning and regular redesigns help mitigate these risks.
Which materials are best for future-proofing hardware?
Materials with long-term availability, durability, and compliance with evolving environmental regulations are best for future-proofing hardware. Lightweight composites, energy-efficient semiconductors, and corrosion-resistant metals are commonly used. Sustainable materials also help meet increasing regulatory demands.
Who benefits from a future-proof approach to hardware design?
Future-proof hardware design benefits manufacturers, suppliers, and end-users. It reduces maintenance costs, minimises downtime, and ensures products remain functional and relevant. Long-term reliability also strengthens customer trust and brand reputation.
Why do businesses need dual redundancy in hardware design?
Dual redundancy improves reliability by ensuring a backup system is in place if the primary component fails. This is especially important in critical applications like subsea systems, aerospace, and medical devices. It reduces downtime and enhances overall system resilience.
How can predictive maintenance support future-proof hardware design?
Predictive maintenance uses real-time data to anticipate hardware failures before they occur. This approach helps businesses replace components proactively rather than reacting to unexpected breakdowns. It extends the lifespan of hardware and prevents costly disruptions.
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