Authentic Components Procurement: Avoiding Counterfeit Industrial Parts

Close inspection of die markings is often required to distinguish genuine components from high-quality counterfeits.

Introduction

Every engineer and procurement manager dreads a line stoppage due to a bad component. Counterfeit or recycled parts can mimic genuine ones but fail prematurely or even cause safety hazards. Alarmingly, industry reports note that the risk of unknowingly buying a counterfeit part increases by approximately 25% each year. This trend is exacerbated by global supply chain pressures and component shortages.

Procurement teams must therefore adopt smart sourcing strategies: sourcing from authorized distributors, verifying traceability, and implementing rigorous quality checks. This article addresses the pain of component authenticity, offering concrete guidance on securing your supply chain for Siemens and Allen-Bradley PLC lines and ensuring compliance with industry standards like AS6081.

1. The Counterfeit Challenge

Global electronics supply chains are vast and complex. In 2019, nearly 67% of reported suspect components came from companies outside China, indicating that counterfeiters operate worldwide. Counterfeit parts often appear genuine—in fact, many are actually recycled authentic parts that have been salvaged, polished, and remarked—making detection difficult.

A single fake PLC chip or I/O module can lead to weeks of troubleshooting. For procurement, the bottom line is clear: due diligence on suppliers saves massive costs later. Understanding the different types of fraud is the first step in prevention.

2. Authorized vs. Independent Distributors

Authorized Distributors

These distributors have official agreements with manufacturers. Parts come directly from the original source, meaning the authenticity risk is nearly zero. Authorized channels often list their inventory clearly and provide full manufacturer warranties. For example, trusting a supplier that carries genuine industrial automation components ensures that the chain of custody remains unbroken from the factory to your facility.

Independent (Franchised) Distributors

These firms source harder-to-find items globally. A reputable independent distributor inspects and verifies every component according to AS6081 standards. If you must use an independent source for obsolete parts, ensure they follow strict counterfeit mitigation processes, including visual inspection and documentation review. Check if they report to data exchanges like ERAI or are GIDEP members.

3. Inspection and Testing

When a part is critical or the source is not the original manufacturer, only lab testing can provide certainty. Techniques include:

• X-ray Imaging: To check die markings, bond wire integrity, and internal structure.
• Decapsulation: Chemical or mechanical removal of the package to inspect the actual silicon die.
• Electrical Testing: Verifying the part meets datasheet specifications.

Note that because most counterfeit parts are recycled, external markings can be re-applied with high precision. If you lack in-house labs, purchase from distributors who provide these testing services and always require traceability paperwork.

4. Key Practices for Procurement Teams

To secure the supply chain, procurement teams should standardize the following practices:

• Risk Assessment: Classify components by impact and obsolescence. High-risk parts deserve extra scrutiny.
• Chain-of-Custody: Demand manufacturer lot numbers and supply chain history. Accredited suppliers will provide trace documents.
• Certifications: Seek suppliers certified in AS6081 (for distributors) or AS5553 (for manufacturers). These demonstrate formal counterfeit avoidance programs.
• Documentation: Ensure each part has a certificate of conformity or agency label when applicable (UL, CE marking), and that packaging looks factory-new.

Table: Counterfeit Component Types and Mitigations

5. Long-Term Stocking for EOL Parts

When a component goes End-of-Life (EOL), procurement is most vulnerable. To prevent future counterfeit risk, consider a long-term stocking program. This involves purchasing the required quantity of an EOL chip directly from the OEM or a trusted partner and having them store it for you.

This strategy ensures you receive manufacturer-sealed parts over time, accompanied by full documentation.

Conclusion

Mitigating counterfeit risk requires vigilance at every step: qualified suppliers, thorough inspection, and strategic planning. By working only with reputable distributors—whether authorized or rigorous independents—and implementing verification processes, companies can ensure the integrity of their automation hardware. This protects not just equipment, but also employee safety and company reputation. In short, buy smart, verify thoroughly, and plan ahead to avoid the hidden costs of fake parts.

Call to Action

Explore our catalog to source genuine PLCs, sensors, and components from industry-leading brands. Contact Chipsgate’s procurement experts to discuss establishing a secure supply chain or long-term stocking contracts for your projects.

FAQ

Q: Why is buying from an authorized distributor important?

A: Authorized distributors get parts straight from the manufacturer or its official channel. This virtually eliminates counterfeits. They also provide complete traceability (lot numbers, certificates) so you know the part’s history.

Q: What should I do if a component is obsolete?

A: Plan ahead by stocking up before EOL, or use a reputable independent distributor with a verification process. Many customers use a long-term purchase agreement: buy a known-good inventory now for future needs.

Q: How can I tell if a part is counterfeit?

A: Some red flags include mismatched or sloppy markings, non-standard packaging, or missing documentation. However, since most fakes are high-quality, only lab tests (e.g., X-ray, decap) can confirm authenticity. If unsure, get a second opinion from a certified test lab.

Q: What certifications help with counterfeit avoidance?

A: Look for suppliers certified to AS6081 (authorized distributor standard) or AS5553 (manufacturing), and check industry watchlists like ERAI or GIDEP. Also, regulatory labels (UL, CE, CSA) add confidence when verified.

Further Reading / References

• Area51 Electronics – “4 Vital Best Practices to Mitigate Counterfeit Electronic Parts”.
• ERAI (Counterfeit Risk Database) – Regularly updated alerts on suspect parts.