For aerospace and defense program managers, engineering leaders, and supply chain teams, keeping a long-life system in production can be just as challenging as getting it there in the first place.
Aerospace and defense systems are often designed to remain in service for years, or even decades. The electronic components inside them may have considerably shorter lifecycles.
That disconnect creates a challenge for OEMs: component obsolescence is not simply a sourcing issue. It is a lifecycle risk that can affect production, cost, qualification, service commitments, and ultimately program continuity.
In the defense industry, this challenge is often addressed as Diminishing Manufacturing Sources and Material Shortages (DMSMS). DMSMS encompasses the loss—or impending loss—of manufacturers, suppliers, materials, or components needed to sustain a system throughout its lifecycle. The U.S. Department of Defense treats DMSMS management as a multidisciplinary, lifecycle activity focused on identifying risks, evaluating impacts, and developing mitigation strategies.
Managing that risk effectively requires more than finding a replacement part when an end-of-life notice arrives. It requires visibility, engineering expertise, and a disciplined approach to keeping the product viable for the long term.
Long-Life Systems. Shorter-Life Components.
The lifecycle of an aerospace or defense system can extend far beyond the commercial lifecycle of the components used to build it.
A component that was readily available when a product was designed may become obsolete, constrained, or difficult to source years later. When that happens, the replacement is rarely as simple as finding another part with the same basic specifications.
The change may affect the product’s electrical or mechanical performance, manufacturing process, qualification requirements, documentation, or regulatory compliance.
For programs with long service lives, component lifecycle management needs to be considered alongside product design and manufacturing—not after the fact.
Industry frameworks such as IEC 62402 provide a structured approach to obsolescence management across the product lifecycle, while SAE/GEIA-STD-0016A provides a framework for developing a DMSMS management plan.
The specific requirements may vary by program, but the underlying principle is consistent: identify potential issues early and give the program time to respond.
Why Obsolescence Becomes a Program Risk
An obsolete component can create challenges well beyond procurement.
A replacement may require:
- Engineering analysis and form-fit-function evaluation
- Qualification or validation
- Printed circuit board (PCB) or system redesign
- Changes to manufacturing processes or documentation
- New sourcing and supplier qualification
- Additional inventory planning
- Coordination across engineering, quality, manufacturing, and supply chain teams
The earlier a risk is identified, the more options a program has to address it in a deliberate, cost-effective way.
Waiting until a component is no longer available can limit those options. Earlier identification gives OEMs more time to evaluate alternatives, plan inventory, qualify replacements, or make a design change when necessary.
Finding a Replacement Is Only the Beginning
The objective isn’t simply to find a component that fits the specification. It’s to find a solution that works for the product, the manufacturing process, and the program.
That requires engineering and manufacturing teams to consider the broader impact of a component change.
Does the alternate meet the required electrical and mechanical characteristics? Can it be incorporated into the existing design? Will it affect PCB assembly or system integration? Does it introduce new sourcing or compliance considerations? What testing or qualification is required?
These questions are particularly important for complex products that combine PCB assemblies, cable and harness assemblies, electromechanical components, and higher-level system integration.
A lifecycle decision made at the component level can have implications across the finished product.
Engineering and Manufacturing Need to Work Together
Component obsolescence is easier to manage when the people evaluating the part understand how that part fits into the product and the manufacturing process.
At Intervala, component lifecycle management is supported by engineering expertise across electronics, electromechanical assemblies, manufacturing processes, and supply chain. That allows potential risks to be evaluated in the context of the complete product—not as a stand-alone purchasing decision.
The goal is to identify risk early, understand the available options, and help customers make informed decisions before an EOL event becomes a production problem.
That same approach supports quality throughout the lifecycle. Quality First Time, Every Time means considering how decisions made today can affect product performance and manufacturing quality down the road.
Supply Chain Resilience and Counterfeit Risk
DMSMS can also create pressure on the supply chain.
When a component becomes difficult to source, the available market may narrow quickly. That can increase lead times, costs, and sourcing complexity—and create additional risk around component authenticity and traceability.
For aerospace and defense programs, that last point matters. When authorized sources are no longer able to supply a component, organizations may face greater exposure to unauthorized or counterfeit material. DoD guidance specifically identifies counterfeit-part risk as a consideration when resolving DMSMS issues and points to standards including AS5553 for counterfeit electronic, electrical, and electromechanical parts.
A disciplined response means evaluating qualified sources and technically appropriate alternatives rather than simply purchasing what is available.
Material authenticity, traceability, documentation, and supplier qualification all need to remain part of the decision. The solution has to support the product’s technical requirements as well as the program’s quality and compliance expectations.
Building Resilience Before You Need It
Effective lifecycle management starts well before a component becomes unavailable.
That can include:
- Monitoring component lifecycle status and early warning signals
- Identifying high-risk components before an EOL announcement
- Evaluating qualified alternate components
- Developing strategic inventory plans
- Supporting alternate-source qualification
- Assessing opportunities to modernize or consolidate components
- Managing design changes when replacement is unavoidable
These activities are central to DMSMS management: identify the issue, assess its potential impact, evaluate available resolution options, and implement the solution that best supports the program’s lifecycle needs.
The benefit is not just avoiding a future disruption. It is maintaining flexibility and control as the program evolves.
For long-life aerospace and defense products, that kind of forward planning can make the difference between managing a change on your terms and reacting to one on someone else’s timeline.
That is where the right manufacturing partner can add value—not just when a component reaches end of life, but throughout the lifecycle of the product.
A Manufacturing Partner for the Full Lifecycle
The strongest manufacturing strategy does not end when a product enters production.
As programs evolve, OEMs may need support with component changes, supply chain challenges, engineering updates, manufacturing transitions, and aftermarket requirements. Having those capabilities connected can simplify decisions and reduce risk across the product lifecycle.
Intervala brings engineering, manufacturing, quality, and supply chain expertise together to support complex products from prototype through production and beyond. Our capabilities span PCB assembly, cable and harness assembly, electromechanical integration, system assembly, testing, and component lifecycle engineering. Intervala’s lifecycle engineering services include component lifecycle analysis, identification of obsolete or high-risk components, and ongoing support to extend product life and reduce the risk of costly redesigns.
Because when a system is designed for a long lifecycle, the components and manufacturing strategy supporting it need to be considered for the long haul, too.
Keep Your Program Moving
Whether you’re managing an existing DMSMS concern or looking ahead to potential component lifecycle risks, Intervala can help assess the challenge and identify practical paths forward.
Talk with our team about your component lifecycle and obsolescence risks.