Electronics lifecycle management services for sustained performance.

Extel’s Product Upgrades service delivers targeted hardware and software enhancements to extend the useful life and performance of your electronic systems. We provide modular upgrade kits and retrofit solutions, such as new circuit boards, updated processors or firmware, to add features, improve reliability and meet evolving regulatory standards.

This cost-effective lifecycle solution helps you meet financial and sustainability objectives by refreshing aging subsystems instead of undertaking costly redesigns.

In practice, our engineers work with your team to plan and execute upgrades that preserve performance: whether adding IoT connectivity to a controller or modernising a medical device to current safety regulations. This proactive approach maximises uptime and ROI across high-reliability markets like Defence, Aerospace, Medical and Industrial electronics.

• Hardware Retrofits: Replace or upgrade aging PCBs and modules with current-generation components to improve speed, efficiency and thermal performance.
• Firmware or Software Updates: Enhance system capability with validated firmware or software revisions (e.g. new protocols, encryption or UI improvements) that meet industry standards.
• Feature Enhancements: Integrate additional functionality (sensors, communications, HMI etc.) to satisfy new customer requirements or regulations without a full redesign.
• Standards Compliance: Implement design updates so that legacy products remain certified for their regulated environments.
• Lifecycle Extension: Plan technology refresh programs and last-time buy strategies to delay obsolescence, stretching product service life while maximising technology investment.

Effective proactive maintenance is essential for mission-critical equipment to minimise downtime and extend operational life. We offer scheduled servicing, calibration and condition-based monitoring to keep your electronics running at optimised performance.

By inspecting and maintaining systems before failures occur, we dramatically improve overall equipment uptime and reduce unexpected repair costs.

Industry data shows that preventive maintenance can boost uptime by 25–30% and cut repair expenses by up to 40%. Extel works with you to establish maintenance SLAs, checklists and KPIs so that each service visit maximises reliability and compliance.

• Scheduled Servicing: Routine inspections, cleaning, firmware validation and part replacement (e.g. batteries, fans) according to agreed intervals to prevent wear-and-tear failures.
• Predictive Monitoring: Use of sensor data and analytics to identify early warning signs (thermal shifts, vibration, signal degradation) and schedule maintenance before outages.
• Performance Reporting: Generate maintenance reports and KPIs (MTBF, uptime, test results) to inform continuous-improvement initiatives and budgeting.
• Maintenance Agreements: Formal SLAs with guaranteed response times and uptime targets. Our support contracts include warehousing spare parts and prompt dispatch to meet your uptime commitments.
• Regulatory Checks: Ensure all preventive maintenance meets the strict requirements of your industry, keeping equipment validated and audit-ready over long service lives.

Our service and repair capabilities ensure fast, reliable after-sales support for complex electronics. Extel provides full diagnostics and repair at the component and system level, backed by the traceability and quality controls required by high-reliability sectors.

We employ IPC-trained technicians and state-of-the-art test equipment (e.g. ICT, functional and environmental testing) to accurately pinpoint failures and restore boards or assemblies to “as-new” condition.

Every repair includes thorough validation and documentation: serialised tracking, test reports and failure analysis ensure complete transparency. We honour robust SLAs and KPIs, providing reliable turnaround times and consistent quality so you can maintain field uptime.

• Diagnostics and Testing: Comprehensive fault-finding using 3D automated optical inspection (AOI), in-circuit test, X-ray and functional test jigs.
• Component and PCB Repair: Specialised rework and replacement of components on multi-layer boards, including BGA and fine-pitch soldering, to avoid whole-board replacement.
• System Reassembly: Complete box-build assembly and integration services post-repair (including cable harnesses and enclosures), ensuring the repaired unit is production-ready.
• Quality Assurance: Rigorous inspection and calibration after repair to meet original product specifications. We maintain full documentation traceability (from arrival to final test) for audit and continuous improvement.
• Logistics and Support: Efficient incoming process and spare-parts management. We expedite repairs and exchanges so your critical systems are back in service as quickly as possible.

High-reliability, regulated products require proactive obsolescence management to stay ahead in the market and manage supply chain disruptions and major redesign costs. Extel continuously reviews the lifecycle status of all components in your design, using industry databases and supplier data to forecast part end-of-life months or even years ahead.

When a component is identified as at risk, we work with your engineers on validated alternatives or redesign paths that preserve form, fit and function. This includes coordinating last-time buys of critical parts, converting to newer component standards or altering BOMs to equivalents.

By planning these transitions early, we safeguard your certification and production timelines, ensuring legacy products remain serviceable throughout their intended life.

• Lifecycle Analysis: Regular BOM reviews and lifecycle forecasting for critical components. We flag expiry dates and changes in manufacturer status long before shortages occur.
• Last-Time-Buy Planning: Executing strategic inventory purchases for end-of-life parts through authorised channels, mitigating risk of grey market or counterfeit components.
• Alternate Sourcing: Engineering evaluation of substitute components and updating designs as needed. We maintain an open OEM-supplier dialogue to validate equivalency and manage qualification.
• Redesign and Requalification: If a direct substitute is unavailable, we conduct targeted redesigns under strict configuration control, minimising impact on system certification.
• Supply Chain Partnerships: Ongoing engagement with component distributors and OEMs to track market trends and ensure continuous supply of key technologies, keeping your long-lived products fully supported.