What is Run to Failure (RTF)?

Learn what Run to Failure maintenance is and how it cuts costs and boosts efficiency by using equipment fully until it fails.
The FieldEx Team
July 9, 2025
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Run to Failure (RTF) is a maintenance strategy where equipment is used until it fails before any repairs or replacements are made. This approach is one of several maintenance strategies and stands in contrast to preventive and predictive methods.

Run to Failure is often applied to non-critical assets where the impact of failure on overall operations is minimal. It is a deliberate strategy used to optimize maintenance resources and reduce unnecessary expenses.

Below, we dive into understanding what RTF is, when should it be implemented, what the advantages are from using it, what the challenges are from using it, how to implement it strategically, and how you can integrate the strategy into other maintenance approaches.

Let's get right to it.

Understanding Run to Failure

Run to Failure maintenance involves allowing equipment to operate until it no longer performs its intended function. The philosophy behind RTF is to maximize asset utilization by extracting the full value from equipment before initiating repairs or replacements.

This method is employed when the cost of preventive maintenance exceeds the expense incurred from running the equipment to failure.

Distinguishing RTF from Reactive Maintenance

Although both RTF and reactive maintenance address equipment failure, they are not identical. Reactive maintenance usually results from a lack of planning and involves unscheduled repairs in response to unexpected breakdowns.

In contrast, RTF is a planned approach where failures are anticipated and factored into the overall maintenance strategy. This planning allows organizations to manage spare parts inventory and allocate maintenance resources more effectively.

When to Implement Run to Failure

Suitable Scenarios

Run to Failure is best suited for non-critical assets where a failure does not lead to significant operational disruptions or safety hazards. Assets that are inexpensive to replace and do not require extensive preventive upkeep are ideal candidates for this maintenance approach.

This method is also beneficial when the cost of routine preventive maintenance cannot be justified by the economic value of the asset.

Examples of Appropriate Applications

Common examples of assets that can follow an RTF strategy include light bulbs, disposable filters, and non-critical motors. These items are inexpensive to replace, and their failure rarely impacts overall production or safety.

Platforms such as FieldEx offer further insights into applications where RTF can be a practical maintenance option.

Advantages of Run to Failure

Cost Savings

One of the primary benefits of Run to Failure maintenance is cost reduction. By eliminating the expenses associated with scheduled inspections and repairs, organizations can lower overall maintenance costs.

This approach minimizes the need for routine labor, planning, and scheduling.

Resource Optimization

RTF allows maintenance teams to focus their efforts on critical equipment that demands preventive or predictive attention.

By not expending resources on non-critical assets, companies can allocate maintenance personnel and budgets more effectively to support high-priority systems.

Maximized Asset Utilization

This strategy ensures that equipment is used to its fullest capacity before replacement. Rather than prematurely replacing assets, organizations benefit from a longer operational life, which can contribute to overall cost-effectiveness and resource conservation.

Challenges and Risks of Run to Failure

Unplanned Downtime

A significant challenge associated with RTF is the potential for unexpected equipment failures. Such failures can result in downtime that disrupts operations, particularly if the failure occurs in a component that, while non-critical, still impacts productivity.

Safety Concerns

In some instances, running equipment to failure can present safety hazards. If an asset fails in a way that could endanger personnel or compromise workplace safety, the RTF approach may need to be reconsidered.

Higher Long-Term Costs

While RTF can reduce short-term maintenance expenses, frequent replacements of equipment may lead to higher long-term costs.

It is important for organizations to weigh the benefits of delaying maintenance against the potential cumulative expense of repeated repairs or replacements.

Implementing an Effective Run to Failure Strategy

Asset Selection Criteria

The success of an RTF program begins with careful asset selection. Companies must identify which assets are suitable based on their criticality and replacement cost. Assets that have minimal impact on overall operations and safety are typically the best candidates for RTF.

Planning and Inventory Management

An effective RTF strategy requires robust planning and inventory management. Organizations should maintain a sufficient stock of spare parts and establish a reliable supply chain to address failures promptly. This readiness minimizes downtime when equipment finally fails.

Documentation and Monitoring

Keeping detailed records of equipment performance and failure histories is essential. This data helps inform decision-making, allowing maintenance teams to predict future failures and optimize replacement cycles.

Consistent monitoring of asset performance can also highlight trends that may indicate a need for a shift in maintenance strategy.

Integrating RTF with Other Maintenance Strategies

Hybrid Approaches

Many organizations find that a hybrid maintenance approach works best.

By combining Run to Failure with preventive or predictive maintenance, companies can tailor their strategy to the specific needs of different asset categories. This integration allows critical equipment to receive more frequent attention while less essential items follow the RTF approach.

Reliability-Centered Maintenance (RCM)

Reliability-Centered Maintenance provides a systematic framework for determining the most appropriate maintenance strategy for each asset.

By assessing the functions and potential failure modes of equipment, RCM helps organizations decide when RTF is suitable and when alternative methods are warranted.

Conclusion

Run to Failure maintenance is a valuable strategy for managing non-critical assets. By allowing equipment to operate until failure, organizations can reduce maintenance expenses, optimize resource allocation, and maximize asset utilization.

However, the approach comes with risks, such as unexpected downtime and potential safety hazards. Implementing an effective RTF strategy requires careful asset selection, proactive inventory management, and continuous monitoring.

When integrated with other maintenance strategies as preventive maintenance and RCM, Run to Failure can contribute to a balanced and efficient overall maintenance program.

By understanding the benefits and challenges of RTF and applying it judiciously, companies can enhance operational efficiency and reduce unnecessary costs while ensuring that critical systems receive the attention they require.

Smart Maintenance Starts with FieldEx | Whether you’re letting assets run to failure or blending RTF with scheduled care, FieldEx keeps everything connected in one smart platform. Want to see FieldEx in action? Book a free demo today, or reach out with any questions you may have. We’re here to help.

Frequently Asked Questions (FAQs) about Run to Failure Maintenance 

1. What is Run to Failure (RTF) Maintenance?

RTF is a maintenance strategy where equipment is used until it breaks down. Repairs or replacements are only made after failure occurs. It's a deliberate, cost-focused approach; not the same as neglect.

2. Is Run to Failure the same as reactive maintenance?

Not quite. While both deal with fixing broken equipment, reactive maintenance is unplanned, while RTF is intentional and strategic. With RTF, failures are anticipated and prepared for.

3. When is Run to Failure a good strategy?

RTF works best for non-critical, low-cost assets (such as light bulbs, disposable filters, or small pumps) where failure doesn’t disrupt operations or pose safety risks.

4. What are the advantages of Run to Failure maintenance?

  • Lower upfront costs (no scheduled upkeep)
  • Full asset utilization before replacement
  • Better resource focus on high-priority equipment

5. What are the risks of using RTF?

  • Unexpected downtime if failure impacts workflow
  • Possible safety hazards if asset failure poses risks
  • Higher long-term costs from frequent replacements

6. How do I choose which assets are suitable for RTF?

Look for assets that are:

  • Inexpensive and easy to replace
  • Not mission-critical
  • Safe to fail without harming people or operations

7. Does RTF mean I don’t need to track equipment performance?

Not at all. Tracking failures and performance data is essential in RTF. It helps optimize replacement timing and informs your overall maintenance strategy.

8. Can I combine Run to Failure with other maintenance strategies?

Yes! Many companies use hybrid approaches, blending RTF for non-critical assets and preventive or predictive maintenance for essential systems.

9. How does RTF fit into Reliability-Centered Maintenance (RCM)?

RCM helps evaluate each asset’s role and risk. It guides you in deciding when RTF is appropriate and when a more proactive approach is necessary.

10. How can FieldEx support a Run to Failure strategy?

FieldEx lets you track asset lifecycles, log failure histories, manage inventory for quick replacements, and combine RTF with preventive workflows – all in one connected platform.

11. Is FieldEx affordable for small teams or startups?

Yes! FieldEx offers flexible pricing plans, including a free tier for small teams to help you get started without breaking the budget. You only pay for what you need, and scale when you're ready. Check out our pricing page to learn more!

12. Is FieldEx easy to use for non-technical teams?

More than easy! FieldEx is designed for real-world users, not just tech pros.

It’s clean, intuitive and mobile-friendly, so your team can log jobs, track tasks and access asset info from the field with zero headaches.

13. Can FieldEx integrate with my existing systems?

Yup, FieldEx connects easily with tools you’re already using like CRMs, calendars and inventory systems. You won’t have to start from scratch or juggle multiple platforms.

14. How do I get started with FieldEx?

Simply schedule a free demo, and see how FieldEx helps you reduce downtime, automate maintenance and stay in control. Or reach out with any questions you may have. We’re here to help.

Related reads:

  1. FieldEx CMMS: Ultimate Guide
  2. What is TPM (Total Productive Maintenance) - Full Guide 2025
  3. How to Optimize Condition-Based Maintenance for Peak Efficiency
  4. Step-by-Step Guide to Selecting the Right Maintenance Strategy
  5. The P-F Curve in Maintenance: Predict Failures, Prevent Downtime
  6. Proactive vs Reactive Maintenance: Key Differences, When to Use
  7. How to Fix Maintenance Issues with CMMS and Cut Downtime
  8. What is Preventive Maintenance? (The Complete Guide)
  9. What is CMMS Software? Definition, Benefits, How it Works
  10. What to Consider Before Buying a CMMS Software

About the Author

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The FieldEx Team

FieldEx is a B2B field service management software designed to streamline operations, scheduling, and tracking for industries like equipment rental, facilities management, and EV charging, helping businesses improve efficiency and service delivery.

Complex operations simplified with one software.

No paperwork. No spreadsheets. No blindspots. Just one solution that simplifies your field service operations.
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