Enabling Form, Fit & Functional Replacement - So Redesign Activities Can Be Avoided

17 August 2023

Headquartered in Essen, Germany, Thyssenkrupp Elevator has an international reputation as a leading supplier of elevator systems.

The company portfolio comprises passenger and freight elevators, escalators and moving walkways, passenger boarding bridges, stair and platform lifts, plus bespoke service solutions to support the long-term operation of such equipment. Given the nature of the applications it serves, equipment may be deployed for several decades. Therefore an ongoing supply of key components is absolutely paramount. 

When semiconductor vendor NXP let customers know about an end-of-life (EoL) notice for the P80C592, Thyssenkrupp had to think about what the implications would be for its business. This 8-bit 8051 microcontroller unit (MCU), with built-in CAN controller and data conversion capabilities, features in several popular Thyssenkrupp equipment designs - and having to incorporate an alternative into these designs was certain to present a major engineering headache. The company engaged with Rochester Electronics, a specialist in solving supply chain and obsolescence problems (and an authorised NXP partner) to assist in the matter.

With fully detailed original design and test data being transferred from NXP, the Rochester team successfully replicated the P80C592 for Thyssenkrupp. This meant that it was not necessary to modify any of the software or hardware - thereby eliminating the need for costly redesign work and subsequent requalification effort. Long-term supply was assured, thus future-proofing equipment production. 

According to Olli Lehtonen, Cluster Manager for Electrics & Electronics for Thyssenkrupp; “Working together, Rochester and Thyssenkrupp were able to replicate, test and qualify this component within less than a year, from project start to mass production ramp-up. Collaboration with Rochester was seamless throughout the project, and the professionalism and open communication were key to the successful product replication program. This allowed us to continue to support our customers without going through expensive and time-consuming redesign.”

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