Should You Repair or Replace? How Tariffs Are Reshaping MRO Decisions in 2025
🏗️ Introduction: The New Cost of Downtime
In 2025, factory maintenance leaders are facing a tough question:
Should we repair that downed drive or replace it with a new one?
What used to be a simple price comparison has become more complicated due to:
- 📈 245% tariffs on Chinese electronics
- 🚢 Supply chain slowdowns
- 🛠️ Labor shortages for new installations
- 💵 Inflationary pressures on factory budgets
When a critical PLC or drive fails today, it’s no longer just about getting production back up—it’s about balancing cost, lead time, risk, and ROI.
🧠 This blog will help you make the right call—repair or replace—based on your situation, the part involved, and what’s happening in the market right now.
1️⃣ Why Replacement Isn't Always the Smartest Option in 2025
Tariffs Have Changed the Math
Replacing a faulty automation component used to be the fast fix. Today, it's often the costlier and slower option.
Here’s why:
- 🚫 Many common parts are now tariffed up to 245%
- 📦 Lead times are extending—especially for branded, authorized products
- 🔧 New installs require more labor for programming and wiring
“Customers often think replacing a $2,000 drive will solve their issue. But after tariffs, shipping, and install time, it could be closer to $4,000—and two weeks of waiting.”
When Replacement Still Makes Sense:
- ✅ The part is obsolete and not supported by repair facilities
- ✅ You’re upgrading to modern controls (e.g. converting 1336 PLUS to PowerFlex 750)
- ✅ Safety or compliance mandates a change
2️⃣ When Repair Wins: Cost, Speed, and Simplicity
Repairs are seeing a major resurgence in 2025—and for good reason. A high-quality repair partner can often:
- ✅ Fix a failed unit in days, not weeks
- ✅ Save you 40–70% over the cost of a new replacement
- ✅ Extend the life of legacy equipment without reprogramming
- ✅ Bypass tariffs entirely (service is not taxed like hardware)
Delta Automation’s Refurbishment Advantage
At Delta Automation, we offer in-house repairs and refurbished parts backed by a 2-year warranty. That means:
- Same-day shipping on tested refurbished parts
- Component-level board repairs on popular drives and PLCs
- Cleaned, tested, and certified units—ready to install
🔧 “We just saved a food processor over $9,000 by repairing a Siemens S120 that would have taken 6 weeks to replace—and it was back online in 48 hours.”
Common Parts We Repair or Replace:
- ✅ Allen-Bradley PowerFlex Drives
- ✅ Siemens S7 PLCs
- ✅ ABB ACS Series Drives
- ✅ Mitsubishi and Omron HMIs
- ✅ Servo amplifiers, encoder cards, and motor controllers
3️⃣ How to Decide: A Smart MRO Evaluation Checklist
🧰 1. Age of the Component
- 📅 < 5 years old → Consider repairing
- 🧓 > 10 years old → Lean toward replacement if outdated or unsupported
📈 2. Part Availability
- 🟢 In-stock domestically → Replacement may be viable
- 🔴 Long lead time or discontinued → Strong case for repair or refurbished
💵 3. Cost Comparison
| Option | Avg. Cost | Lead Time | Tariff Risk |
|---|---|---|---|
| New replacement | $$$$ | 4–12 weeks | High |
| Repair service | $$ | 2–10 days | None |
| Refurb unit | $$$ | 1–3 days | None |
🛡️ 4. Risk of Downtime
Will waiting create lost revenue or safety risks?
Can a repaired unit buy you time until a full upgrade later?
🧑🔧 5. Installation & Programming Burden
Will a new part require rewiring, new licensing, or control logic updates?
Is it plug-and-play or a custom integration?
✅ Decision Matrix Summary
| Situation | Best Option |
|---|---|
| Part is less than 5 years old | Repair |
| OEM lead time is > 4 weeks | Refurb or repair |
| You’re doing a full upgrade anyway | Replace |
| Tariffs make new parts >2x the cost | Repair or refurb |
| Part is discontinued but still critical | Repair |
| You need it running within 48 hours | Refurb or repair |
4️⃣ Refurbished vs. New: What the Data Shows
The idea of using refurbished parts was once a fallback. In 2025, it’s a strategic edge.
📊 Industry Trend: Refurb Demand Is Surging
- 🔺 Demand for industrial refurbishment services is up 38% YoY
- 🔺 58% of manufacturers plan to increase refurbished part use in 2025
- 📉 Lead time for new PLCs averages 8.5 weeks vs. 3.5 days for refurb stock
🔁 Why Refurb Makes Business Sense in 2025
- 🧾 Cost Savings: Refurbs average 30–60% cheaper than new
- ⏱️ Speed to Recovery: Often same-day shipping
- 🛠️ Legacy Compatibility: Minimal setup or configuration needed
- ♻️ Sustainability: Supports circular economy and green initiatives
A Tier 1 auto supplier recently replaced their entire PowerFlex 70 inventory with refurbished units from Delta Automation. The switch saved them $22,000 and six weeks of downtime.
✅ What to Look for in a Refurb Partner
- Component-level testing and diagnostics
- Warranty-backed repairs (Delta Automation offers 2 years)
- Inventory from multiple OEM brands
- Emergency support and rapid shipping
5️⃣ Why MRO Leaders Are Rebuilding, Not Replacing
More factory maintenance teams are realizing that rebuilding their systems piece by piece is smarter than full replacement.
5 Key Reasons for the Shift:
- 🔧 Maximize ROI on existing infrastructure
- 📉 Avoid long OEM lead times
- 💰 Preserve capital for future upgrades
- 🌱 Align with corporate sustainability goals
- 🔄 Build resilience beyond OEM channels
“Repair-first” isn’t a fallback. It’s the strategy forward for smart, tariff-proof MRO operations.
🧾 Final Thoughts: Make Repairs Your First Move, Not Last Resort
Tariffs have changed the game—but they’ve also revealed a smarter path forward. Repairing or refurbishing your automation components isn’t just a backup plan. It’s now a primary strategy for MRO efficiency, cost control, and operational resilience.
With a trusted repair and refurbishment partner like Delta Automation, you can:
- ✅ Slash downtime from weeks to hours
- ✅ Cut costs by 40–70%
- ✅ Protect against tariff inflation
- ✅ Extend the life of critical automation systems
- ✅ Avoid delays on PowerFlex drives, Siemens PLCs, ABB boards, and more
📞 Ready to Get Started?
Browse our refurbished inventory, submit your repair request, or contact our team to discuss the best MRO solution for your facility.
Delta Automation is here to keep your operations running—cost-effectively, reliably, and without the tariff stress.