What really happens when an industry runs out of spare parts?
In a factory, every second of downtime costs thousands of dollars. But temporary downtime isn’t the worst that could happen. Imagine if a critical machine broke down, and the part you need to fix it is not available anymore. It’s not back ordered, it’s not delayed – it’s totally unavailable. What happens then?
This isn’t just theory. All around the world, industries are going through a crisis because key spare parts are becoming harder and harder to find. That could be for many reasons – disruptions in the supply chain, manufacturers discontinuing old parts, global shortages… Whatever the case, companies are getting desperate to stay in business and keep the work going.
Some are creative and decide to use 3D printing for parts. Others go for something riskier, like contacting suppliers in the black market. Then there are those that tweak their machines to work without the parts they can’t find. Regardless of the amount of “creativity” these companies have, it’s clear that an industry that runs out of spare parts will face severe consequences.
Why do spare parts run out?
Spare parts don’t disappear overnight, but a mix of different issues can make them impossible to find. One of the reasons is disruptions in the chain of supply. A lot of industries depend heavily on countries like China and India for key components, but if there’s a delay in shipping, a port is congested, or there’s a shortage of raw materials, production slows down or completely stops. If there’s even one weak link in the chain, it can cause businesses to wait for months for parts they should have gotten in days.
Another cause is simply discontinuing older machines, which then causes the manufacturers to stop making replacement parts for them. This leaves businesses in a tough spot and forces them to look for second-hand components. And that’s always far from ideal. Geopolitical and economic factors are also part of the problem. Trade restrictions, sanctions, export bans, all of this can unexpectedly cut off access to supplies.
This combination of issues leaves industries scrambling, especially when essential components, like hydraulic pump parts, are short in supply.
What happens when spare parts run out
A business won’t shut down or accept the loss once they can no longer find spare parts. Usually, they go crazy trying to find solutions and while some are practical, others are downright scary.
Most of the time, the first step is to find another supplier. Third-party manufacturers, aftermarket parts, refurbished components, all of this can fill the gap. But it’s not without risks because there are plenty of counterfeit parts on the market and quality control is pretty much non-existent in those cases. And if you choose one bad component, that could cause even more damage.
When there’s no replacement to be found, innovation is the next best option. Some businesses turn to reverse engineering and use advanced manufacturing techniques like 3D printing to recreate the parts they need. This can be a lifesaver, but it’s not always simple. Some components are patented and others need specialized materials or pinpoint precision in manufacturing. Sometimes, these small-scale solutions simply can’t replicate what they need to.
One other option is to just keep the machines running without the missing part, which is when preventative maintenance becomes more important than ever. Engineers try to tweak anything that could be tweaked or they even repurpose other components to keep things running.
When all else fails, there’s parts cannibalization. It means that you need to dismantle a machine that’s either old or unused (or both!) and salvage what you can. This is a functional short-term solution, but in the long run, it simply isn’t sustainable. Sooner or later, you’ll have no more machines to strip for parts.
But some companies are even more desperate. Industries that have a lot of money hoard critical parts, make them even more scarce, and then drive up their prices. This forces smaller businesses to pay prices that are crazy inflated, but when there’s no other choice, what could you do?
Others contact unauthorized suppliers or even sources on the black market because that’s how desperate they are. In some cases, businesses within the same industry will work together and form emergency supply networks to share parts and keep everyone running.
All businesses have one thing in common – the longer the shortage lasts, the more desperate they become. The worst part is that what follows desperation are risky “solutions.”
Conclusion
So, what happens when spare parts are nowhere to be found? In short – nothing good. Businesses get so desperate trying to adapt that sometimes, they turn to something illegal just to keep afloat.
The real issue is that this problem won’t go away because the world runs on complex supply chains that are all interconnected and the companies that survive are the ones that have planned ahead. Not the ones that reacted to the shortage the fastest.