Run-To-Fail Maintenance: When Does It Make Sense in Industrial Maintenance?

Introduction

In industrial maintenance, choosing the right maintenance strategy can significantly impact operational efficiency, costs, and downtime. Many companies focus on preventive and predictive maintenance, but not all assets require frequent upkeep.

This is where Run-To-Fail (RTF) Maintenance comes in. Instead of scheduling unnecessary preventive maintenance, RTF allows assets to operate until they fail, at which point they are repaired or replaced.

While this approach may sound reactive, it can be a cost-effective strategy when applied correctly. But when does it make sense? And when should you avoid it?

This guide explores Run-To-Fail Maintenance, its benefits, risks, best practices, and real-world applications in manufacturing and industrial maintenance.

What is Run-To-Fail Maintenance?

Understanding the RTF Approach

Run-To-Fail (RTF) Maintenance is a reactive maintenance strategy where equipment is allowed to operate until it fails, at which point it is repaired or replaced.

Unlike preventive or predictive maintenance, RTF does not involve scheduled servicing or condition monitoring. Instead, it assumes that for certain assets, the cost of planned maintenance exceeds the cost of failure and repair.

Where is Run-To-Failure Used?

RTF is not suitable for critical machinery but is commonly applied to:

• Low-cost, easily replaceable equipment such as conveyor rollers, bearings, and light bulbs.
• Non-critical assets that won’t disrupt production when they fail.
• Redundant systems where a backup is available.

Common Examples of RTF in Manufacturing:

• Light Fixtures – Waiting for bulbs to burn out before replacing them.
• Pumps and Motors – Small, non-essential motors that can be swapped out quickly.
• Belts and Seals – Components with a short lifespan that are easier to replace than maintain.

When is Run-To-Failure a Smart Strategy?

RTF maintenance is a valid choice when:

• The asset is low-cost and non-critical to operations.
• Repairing after failure is cheaper than preventive maintenance.
• The asset doesn’t pose safety or regulatory risks if it fails.
• The facility has spare parts available for quick replacement.

Ideal Situations for Run-To-Fail Maintenance

Condition	When RTF is a Good Fit	When RTF Should Be Avoided
Asset Cost	Low-cost, disposable assets	Expensive, complex machinery
Impact of Failure	Minimal operational disruption	High downtime risk
Spare Parts Availability	Spare parts are stocked	No quick replacement available
Safety Risk	No safety or compliance issues	Failure could cause injuries or violations

Risks and Challenges of Run-To-Fail Maintenance

1. Increased Downtime Risks

Challenge: If RTF is applied to critical assets, unexpected failures can cause longer downtime and disrupt operations.

Solution: Apply RTF only to non-critical equipment and maintain spare parts for quick replacements.

2. Higher Emergency Repair Costs

Challenge: Unplanned failures can lead to expensive emergency repairs due to expedited shipping costs, unplanned labor hours, and production stoppages.

Solution: Track failure frequency and costs using CMMS software to determine if RTF is truly cost-effective.

3. Safety & Compliance Issues

Challenge: If applied to safety-critical systems, RTF can lead to accidents or regulatory violations.

Solution: Ensure critical and regulatory-required assets follow preventive or predictive maintenance instead.

4. Poor Inventory Management

Challenge: Without proper stock of spare parts, RTF can lead to extended downtime while waiting for replacements.

Solution: Maintain a stock of frequently failing components to enable fast repairs.

Run-To-Failure vs Other Maintenance Strategies

Maintenance Strategy	Approach	Best For	Limitations
Run-To-Fail (RTF)	Fix after failure	Non-critical, low-cost assets	High downtime risk if misused
Preventive Maintenance	Scheduled upkeep	High-use, high-value assets	Potential over-maintenance
Predictive Maintenance	Data-driven failure prediction	Complex, high-risk assets	Requires investment in sensors
Condition-Based Maintenance	Monitors real-time conditions	Assets with variable failure patterns	Requires monitoring technology

Best Practices for Implementing Run-To-Fail Maintenance

To maximize efficiency while using RTF, follow these best practices:

1. Choose the Right Assets

RTF works best for low-cost, replaceable equipment that doesn’t disrupt production when it fails.

2. Track Failure Data

Use CMMS software to log asset failures, track downtime, and analyze if RTF is saving costs.

3. Keep Spare Parts in Stock

Ensure that frequently failing components are readily available to prevent long delays.

4. Train Technicians for Fast Repairs

When failures occur, technicians should be prepared for rapid replacements to minimize downtime.

5. Combine RTF with Other Strategies

Most facilities use a hybrid maintenance model—applying RTF for non-critical assets and preventive/predictive maintenance for essential equipment.

Case Study: When Run-To-Fail Worked in a Manufacturing Plant

A packaging plant applied RTF maintenance to its conveyor rollers:

• Implementation: Instead of preventive maintenance, they kept spare rollers in stock and trained workers to replace them within minutes.
• Results: Reduced maintenance costs by 20 percent while avoiding unnecessary labor costs.

Takeaway: By applying RTF to the right assets, facilities can reduce waste while maintaining operational efficiency.

Future of Run-To-Failure Maintenance: Is It Sustainable?

With advancements in IoT, AI, and predictive analytics, maintenance is becoming more data-driven. While RTF remains relevant, companies are integrating it with:

• IoT Sensors: Tracking asset wear and alerting teams before critical failures.
• AI-Powered Predictive Maintenance: Identifying trends in failure patterns.
• Automated CMMS Systems: Optimizing maintenance schedules based on real-time asset conditions.

A hybrid maintenance approach—using RTF where it makes sense while leveraging technology for critical assets—is the future.

Conclusion

Run-To-Fail Maintenance is not a one-size-fits-all strategy, but when applied strategically, it can save costs and simplify maintenance for non-critical assets.

Key Takeaways:

• Use RTF for low-cost, easily replaceable assets.
• Avoid RTF for critical or expensive equipment.
• Maintain spare parts and fast repair procedures.
• Use CMMS software to track failures and costs.
• Consider a hybrid maintenance strategy to optimize efficiency.

Would Run-To-Failure work for your facility? Assess your assets and choose the best maintenance approach for long-term reliability.

FAQ: Common Questions About Run-To-Fail Maintenance