Component Alternative Cross-Reference Strategy for Product Resilience

Geopolitics, natural disasters, the global economy, and consumer demand continue to create volatility in the semiconductor supply chain, impacting component availability which effects your business continuity and time to market (TTM).

Prior to the pandemic component sourcing was mainly focused on cost management with market availability rarely being an issue. Now, we have entered a new era of product design, with factors such as component shortages, faster EOLs, and changing regulatory compliance requirements creating the need for a more robust and resilient product design. 

Having an electronic component cross-reference, replacement, and mitigation strategy is now a key ingredient to your overall supply chain resiliency. 

Pre-planning semiconductor crosses and being able to quickly find component alternatives, even if it requires engineering approval will help you manage the product lifecycle, control cost, and prevent a stop in your production.

Types of Electronic Component Alternatives …

There are three main types of replacements for off-the-shelf components in your design:

• Direct Drop-in Cross-Reference Replacements: This type of cross has the same packaging, pinout, and footprint as well as, parametric features for a given part number in your design. Meaning it can serve as a direct, interchangeable equivalent electronic component alternative in your product design with no need for any changes or a re-design.
• Same Footprint and Fit Cross-Reference Replacements: This type of cross has the same package and pinout of a given part number in your design but has some minor differences in the parametric features. There is a need for the design or component engineer to evaluate the component and ensure proper functionality of the overall design with this alternative in place. Once the engineering team approves the alternative, a design change may be required. It is important to note that if there are design changes, the original component may no longer meet the product’s requirements.
• Functional Cross-Reference Replacements: These component crosses have the same function of an approved component in your design, but not the same pinout and packaging therefore cannot be used interchangeably in the design. The design engineers have to evaluate the component and make design changes for these alternatives to be used in the product. 
  

The concept of component alternatives may seem simple, but it can be a complicated and time-consuming project. Consider the number of electronic components in a product design and then having to sift through thousands of data sheets to compare components such as MCUs, ICs, SRAMs, MOSFETs, Transistors, Capacitors, and Diodes to find the proper functioning cross-reference match. 

In general, it can be easier to find drop-in replacements for components, such as transistors and passives but for other components such as specialized ICs finding alternatives can take hours of research and a redesign is commonly needed.

Next Steps …

Regardless of the type of cross, component alternative selection requires several steps. Starting with the evaluation of data sheets, and comparing part specifications and critical attributes. Then find suppliers which have the part availability, vetting, and add them to your vendor list if needed. Finally, understand the pricing, lead times, and component lifecycle status to ensure production continuity. 

Sifting through hundreds of data sheets, contacting distributors for availability and pricing, and adding vendors and suppliers to your procurement process is all very time-consuming but should be part of your product lifecycle management. 

Digitizing your supply chain and utilizing tools that enable intelligent part selection and real-time access to the data you need will help business continuity, product resilience, and lifecycle management with increased efficiency and accuracy. Learn more by reviewing the Z2Data Cross-Reference Guide. 

In summary, consider the following measures as part of your Component Alternative Strategy:

• Create a robust and resilient design that includes component alternatives and crosses at the onset. 
• Use tools to monitor and receive alerts on potential component lifecycle changes, lead-time delays, and any other disruptions in your supply chain.
• Strengthen your procurement process and inventory management by diversifying and expanding your supplier and vendors (AVLs), reducing dependencies and potential disruptions. 
• Build agility in your procurement. 
• Ensure product compliance with access to data on REACH, RoHS, blacklist material, banned suppliers due to forced labor, and receive alerts on any relevant regulatory changes.  
  

A proactive approach to cross-referencing allows you to build a comprehensive supply chain risk mitigation strategy and supply chain resiliency.