ManWinWin Maintenance Glossary

What is: Run-to-Failure Maintenance (RTF)

Run-to-Failure Maintenance (RTF)

Run-to-Failure Maintenance (RTF) is a maintenance strategy where equipment is allowed to run until it fails, at which point repairs or replacements are made. This strategy is often used for assets that are inexpensive to replace or have low operational impact if they fail. The approach assumes that performing scheduled maintenance or even predictive monitoring may be unnecessary, as the cost of proactive maintenance outweighs the potential benefits. While this method can work for less critical systems, it is typically avoided for high-value or mission-critical equipment, where failure can result in significant downtime, safety hazards, or financial losses.

RTF is most effective in specific scenarios, such as with non-critical, low-cost equipment, or in environments where failure is rare or unlikely to cause major disruptions. It is often contrasted with other strategies like Preventive Maintenance (PM), Predictive Maintenance (PdM), or Reliability-Centered Maintenance (RCM), which aim to reduce or prevent unplanned downtime through proactive monitoring and maintenance.

Benefits

Cost Savings: Since RTF involves minimal maintenance efforts until equipment failure, it can reduce ongoing maintenance costs, especially for assets that are cheap to replace or do not have high operational importance.
Simplified Operations: This approach reduces the complexity of maintenance scheduling, as there are fewer planned interventions or inspections. This can save time for the maintenance team and allow them to focus on more critical assets.
Suitable for Low-Cost Equipment: For assets with low replacement costs or that do not contribute significantly to overall production, RTF can be a viable option. It avoids spending resources on upkeep for items that are unlikely to impact operations.
Less Administrative Burden: Since maintenance is only triggered when the equipment fails, there is less need for detailed planning, monitoring, or paperwork related to scheduled maintenance.

Examples

Manufacturing: In a manufacturing facility, RTF could be applied to simple, non-essential conveyor belts or tools that are used intermittently. If they break down, they can be replaced or repaired on the spot without impacting overall production significantly.
Office Equipment: For non-critical office devices like printers or desk fans, RTF is often the best choice. These items can be used until failure, and replacement is quick and inexpensive.
Warehouse Equipment: Small forklifts or pallet jacks that are not used in critical operations may be maintained on a run-to-failure basis, as their breakdowns would not significantly affect warehouse operations.
HVAC Systems: For certain HVAC components, such as fans or air filters, RTF might be appropriate in buildings where the failure of a single unit does not immediately affect occupant comfort or safety.

Run-to-Failure Maintenance (RTF) is a practical strategy for assets where proactive maintenance isn’t justified by the costs of intervention or the impact of failure. However, for critical assets, alternative strategies like preventive or predictive maintenance are often necessary.
ManWinWin Software can support businesses in managing RTF as part of an overall maintenance strategy, ensuring that the right approach is applied to each asset based on its value and risk profile.