In maintenance, the right strategy is crucial. Run-to-Failure maintenance (RTF) is a debated option. Some find it cost-effective, others risky. This post explains RTF, covering its pros, cons, and ideal scenarios, including field-tested tips.
What is Run-to-Failure Maintenance?
Run-to-Failure Maintenance (RTF), or breakdown maintenance, means using equipment until it fails. Then, you fix or replace it. It’s a reactive approach—addressing problems only after they appear. This differs from preventive maintenance (regular servicing to prevent issues) and predictive maintenance (using data to predict failures). Light bulbs are a prime example, making it a valid maintenance strategy for specific scenarios. An RTF maintenance program focuses on addressing issues after they occur rather than scheduling routine upkeep.
Pros of Run-to-Failure Maintenance
RTF’s main advantage is initial cost savings. No money is spent on regular maintenance, which frees up funds, especially for smaller businesses. It requires fewer expenses and has no regular schedule. This simplicity can reduce the overall maintenance cost.
RTF makes sense for non-critical, low-value items with a short life. Replacing every dimming light bulb is impractical. Instead of maintaining all equipment meticulously, use run-to-failure for non-critical, easy-to-replace components.
Cons of Run-to-Failure Maintenance
The biggest risk is unexpected equipment failure. This unplanned downtime impacts productivity and profits. Emergency repairs often exceed planned maintenance costs.
Emergency parts and expedited technicians add to the expense. Neglected equipment can develop larger issues. An RTF maintenance strategy can create more problems, escalating costs.
Critical equipment or safety systems failing pose significant safety risks. Unplanned downtime, repairs, and operational inefficiencies become major drawbacks.
When Does Run-to-Failure Maintenance Make Sense?
Despite its downsides, an 2018 survey showed 80% of facilities personnel considered RTF for low-risk situations. Effective run-to-failure hinges on asset categorization. RTF is often called a “fit and forget” strategy due to the minimal effort required until failure occurs.
RTF suits small, replaceable items like light bulbs, not vital systems. Envision crucial manufacturing equipment failing mid-production—an expensive lesson. For crucial operations, a balanced approach and proper parts inventory are needed. This will ensure effective maintenance programs, while minimizing unnecessary costs associated with preventative or predictive maintenance of parts subject to a high failure rate.
How to Implement a Run-to-Failure Strategy Effectively
If RTF suits specific equipment, these methods improve efficiency and reduce risks. A 2018 survey found equipment failures cause 42% of manufacturing downtime. The maintenance team should evaluate factors, such as operational inefficiencies caused by downtimes to implement the RTF approach effectively.
Categorize Your Assets
List and categorize all assets. Consider replacement ease, lifespan, and impact of breakdowns on key processes. This determines RTF suitability. This classification will determine the most cost-effective RTF maintenance strategy.
Computerized Maintenance Management Systems
Spreadsheets become inadequate for tracking RTF, even in mid-sized operations. A CMMS (computerized maintenance management system) manages RTF, preventive, and predictive workflows within your operations. Evaluate current floor plans or mobile CMMS features for efficient asset tracking. For equipment selection guidance, consider CMMS workshops. The RTF strategy, or run-to-failure maintenance, requires good asset management systems. An asset management system helps plan maintenance by streamlining documentation such as work orders, preventive maintenance checklists, parts inventories, failure patterns, and floor plans.Regular Inspections
Even with RTF, regular checks are important. These inspections allow the team to identify systems close to failure before it disrupts work. This lets maintenance address potential failures, minimizing production impact.
Comparing Run-to-Failure with Other Maintenance Strategies
RTF is one of many maintenance methods. Use a mix of plans based on your different workflows. Weigh where run-to-failure is appropriate. Factor in equipment cost, considering various approaches for each machine’s lifespan.
Run-to-Failure Maintenance Case Studies
This office park example demonstrates effective RTF. Instead of scheduled lamp replacements, they waited for corridor lighting to fail, reducing costs and freeing up staff. This is an effective maintenance strategy for random failures, particularly when repair costs are lower than preventive measures. A run-to-failure strategy can also serve as an effective response plan for unplanned failures. This helps to improve maintenance strategies.
While primarily associated with simple technologies (lighting, shock absorbers), a May 2024 study highlighted its use by NASA’s Mars Exploration Rover program. They applied it to the rover’s main memory, where rewriting could trigger failure. For hard-to-repair systems, RTF becomes necessary, demanding thorough data collection, especially where cascading failures threaten crucial processes.
One industrial kitchen wrongly used RTF for an oven. Breakdowns created chaos, requiring rushed repairs and disrupting service. Preventive maintenance would have avoided this. Using the wrong maintenance strategy, even on inexpensive items like light bulbs, can cost money, and pose safety risks in an industrial setting.
Tools to Support Your Run-to-Failure Maintenance Strategy
Smaller facilities often track run-to-failure processes with basic tools. Larger environments with complex maintenance strategies benefit from dedicated software. Consider CMMS or SaaS solutions like MicroMain CMMS. Review educational content from online resources such as the reliability connect website and others that can teach you more about making run-to-failure work with your maintenance team time.
Such systems improve team communication and efficiency. Webinars showcasing case studies illustrate how tracking, planning, and monitoring tools enable success for small-scale RTF or mixed-strategy facilities.Conclusion
Run-to-Failure Maintenance (RTF) can be a practical approach for non-critical, inexpensive items that carry minimal risk of cascading failures. However, it is essential to recognize that RTF is not a one-size-fits-all solution. It’s vital for facility managers to carefully evaluate the specific needs of each asset and integrate it within a larger maintenance plan. By incorporating a Computerized Maintenance Management System (CMMS), facility managers can enhance their decision-making, ensuring that RTF is applied strategically where it makes the most sense.
A CMMS is an invaluable tool for managing both preventative maintenance and run-to-failure maintenance programs. It allows for seamless tracking of maintenance schedules, equipment conditions, and helps identify when to shift between maintenance strategies. Using a mixed approach, incorporating both RTF and preventative maintenance, provides facility managers with the flexibility to manage operations effectively and optimize the lifespan of equipment. This balanced strategy is especially crucial for specialized systems, such as the ones used in high-tech environments like the Mars rover, where maintenance planning is critical.
However, it’s important to acknowledge the risks associated with RTF. For example, in a warehouse study, even seemingly simple equipment like shelving generated substantial hidden costs due to unplanned incidents. These unexpected breakdowns can result in downtime, inventory damage, and safety hazards. Therefore, when evaluating whether to adopt a run-to-failure maintenance program, it is essential to weigh the unseen costs and potential disruptions against the benefits of a more proactive approach.
In industries where safety and operational efficiency are paramount, reactive maintenance can increase accident risks. While RTF can provide cost savings in certain scenarios, the potential for accidents and disruptions should not be underestimated. A well-crafted maintenance plan should account for the need to mitigate these risks, ensuring a careful balance between cost efficiency and accident prevention.
Strategic implementation of RTF, when combined with preventative maintenance, can be a valuable tool in a facility manager’s toolkit. By continuously tracking performance and condition through enterprise asset management systems or management software, facilities can optimize their approach to maintenance. These systems allow for detailed root cause failure analysis, giving facility managers and maintenance personnel the ability to track maintenance run-to-failure spending and adjust plans as needed. By keeping well-documented and accessible maintenance procedures, organizations ensure that equipment failures are handled efficiently while preventing unanticipated downtime.
Ultimately, while run-to-failure maintenance offers cost advantages in specific cases, its application must be done with careful planning and strategic evaluation. It’s crucial to avoid using RTF for critical operations or where safety concerns exist. With the right facility management tools and insights, facility managers can make informed decisions that balance maintenance efficiency, cost control, and safety.
