The tell is behavioural, not technical. When supervisors start keeping a paper list "just in case", the device has already failed even if it still powers on.
Six signals worth acting on
- Failed reads have crept above roughly one in twenty attempts
- A queue forms at shift change that did not used to form
- The device is at or near its user or log capacity
- HR is manually correcting more than a handful of punches a week
- Firmware is no longer updated by the manufacturer
- It cannot talk to modern software — no ADMS, no API, export by USB only
Repair or replace?
A cracked sensor or a dead power supply is worth repairing on a device under four years old. A worn optical sensor on a five-year-old entry-level unit is not — the repair is half the price of a new terminal that reads faster and holds four times the users.
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