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 srategically, and how you can integrate the strategy into other maintenance approaches.
But before that, let's read about: Maintenance, Repair and Operations (MRO).
Now that's done, let's dive right in.
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.
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.
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.
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.
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.
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.
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.
Let's take a break and read something else: How to Identify Bad Maintenance Data (and how to FIX it!).
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.
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.
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.
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.
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.
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.
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 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.
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.
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