What is Run-to-Failure (RTF) Maintenance? The Complete Guide

Run-to-Failure (RTF) is a maintenance strategy where assets are not monitored or maintained until they break down. The underlying logic is simple: for certain assets, the cost of equipment failure is lower than the cost of monitoring and performing preventive maintenance. Rather than spending time and resources on scheduled inspections, organizations using RTF accept that failure will occur and plan accordingly.

RTF is typically applied to non-critical assets where failure does not significantly impact operations, safety, or regulatory compliance. This makes it distinct from other maintenance strategies like Preventive Maintenance (PM) and Predictive Maintenance (PdM):

• Preventive Maintenance (PM): Scheduled maintenance performed to prevent failures before they occur. Wanna learn more about PM, here’s an article that explains What is Preventive Maintenance.
• Predictive Maintenance (PdM): Condition-based monitoring that anticipates failure using data and analytics. To learn more about PdM, consutl this article : What is Predictive Maintenance?
• Run-to-Failure (RTF): Assets are left to run until they fail, at which point they are repaired or replaced.

When Does Run-to-Failure Make Sense?

RTF is not a “no-maintenance” approach, it is a deliberate strategy used under specific conditions.

RTF is a viable option when:

• Failure has minimal consequences: The asset’s or piece of equipment failure does not cause safety risks, production downtime, or regulatory non-compliance.
• Repair or replacement is cost-effective: If the cost of planned maintenance and condition monitoring exceeds the cost of replacing the asset after failure, RTF is a better option for cost savings.
• Failure is difficult to predict: Some assets, such as electrical components, fail unpredictably, making preventive or predictive strategies ineffective.

Examples of RTF Use Cases:

• Non-critical pumps: If a backup system exists, failure of a secondary pump may not affect operations.
• Low-cost motors: If replacement is inexpensive and quick, monitoring may not be necessary.
• Light bulbs or small electronic components: These are often replaced only after failure.

Run-to-Failure (RTF) Maintenance: Advantages and Risks

As a maintenance strategy that allows equipment to operate until it breaks down, RTF presents both advantages and drawbacks. While RTF may reduce immediate maintenance effort and costs, it can introduce a range of operational risks.

Advantages of Run-to-Failure Maintenance

• Lower maintenance costs: No need for unnecessary servicing of assets that do not require maintenance.
• Eliminates unnecessary maintenance efforts: Labor and parts are not wasted on assets that function reliably until failure.
• Simplifies maintenance planning: No need for complex scheduling; failures dictate when maintenance occurs.

Disadvantages of Run-to-Failure Maintenance

• Unplanned downtime: Because failures are unexpected, they can disrupt operations, especially if multiple assets fail simultaneously. This can overwhelm maintenance teams, create bottlenecks in repair workflows, and extend operational downtime beyond initial estimates.
• Higher repair and replacement costs: Running assets to failure may leads to more severe damage, requiring expensive repairs or full replacements rather than minor preventive interventions.
• Potential safety risks: Some failures can pose safety hazards to workers, especially if the breakdown occurs suddenly and without warning.

The Importance of Using Run-to-Failure (RTF) on Low Criticality Assets Only

While Run-to-Failure (RTF) can be an effective maintenance strategy for non-critical assets, it must be applied carefully. When used on non-critical equipment, the risk of failures disrupting operations is minimal. However, applying RTF to critical assets can result in severe consequences, such as unplanned downtime, increased failure impact, safety hazards, and more severe damage. These risks can lead to significant operational disruptions, increased repair costs, and potential safety and compliance issues.

Conclusion

In conclusion, Run-to-Failure (RTF) maintenance can be a cost-effective and straightforward strategy when applied to non-critical assets where the consequences of failure are minimal.

By eliminating the need for regular monitoring and preventive maintenance, RTF reduces immediate maintenance efforts and costs. However, it is essential to carefully assess which assets are suitable for this approach, as applying RTF to critical equipment can lead to significant risks, including unplanned downtime, increased repair costs, and potential safety hazards.

Ultimately, RTF should be used selectively, ensuring that it aligns with the asset’s role within the organization’s operations and does not compromise safety, efficiency, or compliance.

Frequently Asked Questions (FAQ)

How to Choose the Right Maintenance Strategy?

Best practices for maintenance strategies involve using a mix of approaches based on criticality, risk, and risk tolerance. For the same asset, multiple strategies can be applied.

For example, a conveyor belt might have condition-based monitoring assigned to critical components like motors, while less critical parts, such as lighting, could follow a run-to-failure approach.

Is Run-to-Failure the same as Reactive Maintenance?

Yes, RTF is a type of reactive maintenance, but not all reactive maintenance is RTF. RTF is an intentional strategy, whereas general reactive maintenance is unplanned and often chaotic.

Can RTF be used for critical assets?

No, RTF is not recommended for critical assets since failure could lead to safety hazards, production losses, or regulatory non-compliance.

How do I decide if an asset is a good fit for RTF?

Ask yourself these questions:

• Is failure non-critical? (No safety or production risks?)
• Is repair/replacement cost-effective?
• Is failure unpredictable? (No clear maintenance triggers?)

If the answer to all these is “yes,” then RTF may be a suitable strategy.

Raphael Tremblay,
Spartakus Technologies
[email protected]