Run to Failure
Run to Failure (RTF) is a deliberate maintenance strategy where an asset is intentionally operated until it fails, at which point it is either repaired or replaced. Unlike reactive maintenance caused by neglect, RTF is a conscious decision based on risk analysis - applied when the consequences of failure are acceptable and the cost of prevention outweighs the cost of correction.
Key Points
- A deliberate strategy, not the same as neglecting maintenance
- Appropriate when failure consequences are low and predictable
- Most cost-effective for low-cost, non-critical, or redundant assets
- Requires spare parts planning and rapid response capability
- Should be documented as a conscious decision in maintenance plans
When Run to Failure Is Appropriate
- Low-cost assets: Items where the replacement cost is less than the cost of inspecting and maintaining them (e.g., light bulbs, filters, gaskets)
- Non-critical equipment: Assets whose failure does not impact safety, production, or service delivery
- Redundant systems: Assets backed by standby or parallel equipment that maintain operations during failure
- Random failure patterns: Components with no predictable wear pattern where preventive replacement would waste useful life
- Short-life consumables: Items designed to be used and replaced as part of normal operations
RTF vs Preventive Maintenance
The choice between RTF and preventive maintenance depends on the consequences and probability of failure. Preventive maintenance is justified when failure is costly, dangerous, or disruptive - the investment in prevention delivers a return through avoided losses. RTF is justified when failure is cheap, safe, and manageable - spending money to prevent it wastes resources. Most mature maintenance programs use both strategies, applying PM to critical assets and RTF to non-critical ones. The key is making this an intentional, documented decision rather than a default.
Risk Considerations
- Safety impact: Never use RTF for assets where failure could cause injury or environmental harm
- Collateral damage: Consider whether a failing component could damage other equipment or systems
- Service disruption: Evaluate whether unplanned downtime will affect customers or operations beyond the individual asset
- Repair lead time: Ensure replacement parts and labour are available quickly enough to meet operational needs
- Regulatory compliance: Some assets require documented preventive maintenance regardless of the risk analysis
Implementing RTF in CMMS
When implementing an RTF strategy in CMMS software, document the decision in the asset record with the rationale and risk assessment. Set up the asset without preventive maintenance schedules but ensure work request workflows are in place for rapid response when failure occurs. Maintain spare parts inventory for RTF assets that require quick turnaround. Track failure frequency and costs over time to validate the RTF decision - if failure costs exceed expectations, reconsider upgrading to a preventive strategy.
Implement the Right Maintenance Strategy with AssetLab
AssetLab provides the tools you need to put these concepts into practice with Canadian data residency and CAD pricing.