What Is Run to Failure Maintenance? (Benefits & Disadvantages)

Run to failure (RTF) maintenance is a reactive maintenance strategy in which equipment is purposely allowed to operate until it breaks down or reaches the point of failure. So, instead of performing preventive maintenance, equipment is repaired or replaced after it fails. This strategy is often used when the cost of maintenance exceeds the cost of replacement or when the equipment is non-critical, inexpensive or unserviceable.

Take office carpeting, for instance. Over time, it naturally wears out due to foot traffic, but maintaining it — by constant cleaning or patching — is often more expensive than simply replacing the entire carpet when it reaches a state of irreparable damage. In this case, RTF maintenance is ideal. Instead of routinely trying to maintain the carpet, it strategically makes sense to let it degrade until it’s unusable and can be replaced. 

When Should Run to Failure (RTF) Maintenance Be Used?

The best time to leverage RTF maintenance is when the cost of preventive maintenance outweighs the cost of repairing or replacing a piece of equipment after failure. Typically RTF maintenance is used for:

• Assets with short lifespans: Items like light bulbs or fuses that are inexpensive and have predictable failure times
• Disposable assets: Single-use or low-cost assets designed to be replaced once they fail, such as filters or packing materials
• Equipment with low failure risk: Machines or systems that rarely fail and don’t require frequent upgrades, making preventive maintenance unnecessary
• Nonessential equipment: Non-critical assets, such as office furniture or low-usage equipment, in which failure won’t make a significant impact on operations
• Equipment with random failure patterns: Pieces of equipment, such as certain electronic components, in which failure is unpredictable and preventive maintenance would not reduce the likelihood of breakdown

RTF Maintenance vs. Breakdown Maintenance

Both RTF and breakdown maintenance are considered corrective maintenance strategies that take place after a piece of equipment fails, but they differ when it comes to intent and planning:

RTF Maintenance

• Planned: Failure is expected, and the strategy is deliberately chosen for specific pieces of equipment.
• Controlled: Equipment assets are allowed to run until failure as part of the maintenance plan, typically for non-critical, inexpensive or disposable items.
• Cost-effective: RTF is used when the cost of regular maintenance exceeds the cost of replacing or repairing the equipment asset after failure (i.e., light bulbs or filters).

Breakdown Maintenance

• Unplanned: Failure is not anticipated and disrupts operations.
• Reactive: Repairs are made only when a breakdown occurs, often resulting in inconvenient and costly downtime.
• Higher risk: Since it’s not part of any planning, unexpected breakdowns can impact productivity and lead to emergency maintenance, especially for critical or complex equipment.

Another way to consider the differences is that RTF is a proactive maintenance strategy for specific equipment assets, while breakdown maintenance is an unintended and disruptive response to an unexpected event.

Advantages of RTF Maintenance

As we’ve established, RTF maintenance is a strategy in which equipment is deliberately operated until it fails, at which point repairs or replacements are made. While on its face this might seem counterintuitive compared to preventive or predictive maintenance strategies, there are specific situations where RTF is beneficial. In fact, a 2020 Plant Engineering study found that 51 percent of industrial facilities use a RTF maintenance strategy. That’s because key advantages include:

• Low maintenance costs (if any): RTF eliminates the costs associated with regular check-ups, repairs or part replacements up until the equipment fails.
• Time savings: By not scheduling or performing routine maintenance, RTF saves time that would otherwise be spent on inspections or upkeep, allowing personnel to focus on other tasks.
• Easy to implement: RTF is straightforward, requiring minimal planning and no predictive maintenance systems, making it easy to integrate with key pieces of equipment.
• Fully utilized equipment: Equipment is used to its full potential, maximizing the lifespan of the equipment before replacement or repair.

Note that RTF is typically used for non-critical equipment assets. For critical machinery, failures can lead to expensive downtime, safety risks and high repair costs, making RTF a less appropriate strategy in these cases.

Disadvantages of RTF Maintenance  

As we’ve mentioned, RTF maintenance can be effective in specific contexts, but it also comes with significant disadvantages. Some key drawbacks include:

• Less predictable downtime: Since failures are not planned, equipment can break down unexpectedly, leading to unplanned downtime that disrupts operations.
• Higher repair costs: Emergency repairs, especially during off-hours, can be expensive. Additionally, if the failure is severe, it may lead to higher costs for parts or labor.
• Shorter equipment lifespan: Running equipment until failure can result in excessive wear and tear, potentially shortening the overall lifespan of the asset compared to a more preventive maintenance approach.
• Potential safety concerns: Allowing equipment to fail, especially in high-risk environments, can pose safety hazards to employees or cause collateral damage to other systems.

Given these disadvantages, RTF is generally best suited for non-critical, inexpensive equipment where the consequences of failure are minimal. For more important equipment assets, preventive or predictive maintenance strategies are usually more effective in maintaining operational efficiency and safety.

8 Steps to Implementing an RTF Maintenance Strategy

Implementing an RTF maintenance strategy involves careful planning and execution to ensure that letting equipment run to failure doesn’t negatively impact operations. Follow these steps to implement it effectively:

1. Select equipment in which RTF makes sense: Identify non-critical, low-cost or disposable pieces of equipment that can be allowed to fail without major operational disruption.
2. Document equipment details: Record key information such as manufacturer, model, expected lifespan and maintenance history for better tracking and decision-making.
3. Implement safety procedures for handling failures: Ensure that there are clear protocols to address safety risks when equipment fails, especially in environments where failure could pose serious hazards.
4. Keep spare parts stocked: Maintain an inventory of replacement parts for equipment prone to failure to minimize downtime when repairs are needed.
5. Create a response plan for equipment failure: Develop a quick, organized response plan to minimize the impact of failure, including who is responsible for repairs and how to restore operations efficiently.
6. Conduct root cause analysis: After each failure, perform a root cause analysis to identify why the failure occurred and whether it’s part of a larger issue.
7. Track costs and compare to preventive maintenance costs: Regularly monitor repair costs and equipment downtime to ensure RTF remains cost-effective compared to scheduling preventive maintenance.
8. Review and adapt the plan accordingly: Periodically evaluate the effectiveness of the RTF strategy and make adjustments based on performance data, costs and any operational changes.

Using a CMMS to See If an RTF Maintenance Plan Is Right for You

A computerized maintenance management system (CMMS) helps maintenance managers make informed decisions about whether an RTF maintenance strategy is suitable for their operations by providing data and insights on:

• Asset performance and failure history: A CMMS tracks equipment history, including past failures and repairs, helping managers identify equipment assets that can be allowed to fail without major consequences.
• Cost analysis: The system compares the costs of repairs after failure with the costs of preventive maintenance, allowing managers to see if RTF would be more cost-effective.
• Asset criticality assessment: CMMS software helps rank equipment based on how critical they are to operations, ensuring non-essential assets are considered for RTF while critical ones get preventive attention.
• Downtime tracking: By tracking equipment downtime and its impact on productivity, a CMMS shows whether unplanned failures from an RTF approach would disrupt operations or be manageable.
• Safety and compliance monitoring: The system ensures safety protocols are in place for equipment prone to failure, highlighting assets where RTF maintenance could pose safety risks or regulatory concerns.

What Sets Coast Apart

When it comes to the question of which CMMS works best, Coast stands out in a variety of ways. Highlights include:

• Intuitiveness and user-friendliness: Coast simplifies the decision-making process with an easy-to-use interface that requires minimal training, helping teams quickly access the data needed for RTF analysis.
• Mobile-first platform: Coast is designed for mobile use, allowing teams to track maintenance activities and respond to equipment failures in real-time, enhancing efficiency for managers on the go.
• Customizable workflows: Coast allows managers to tailor maintenance workflows based on specific needs, making it easier to implement a hybrid of RTF and preventive maintenance strategies.
• Real-time collaboration: Coast’s communication tools enable teams to coordinate quickly on failure responses, ensuring minimal downtime and smooth execution of RTF strategies.

Still not sure if Coast is right for you? Book a demo today.