Run-to-Failure Maintenance
Run-to-failure (RTF) is a deliberate maintenance strategy in which an asset is operated until it fails, at which point corrective maintenance is performed or the asset is replaced. It is a legitimate approach for non-critical, low-cost, or easily replaceable items where the cost of preventive maintenance exceeds the cost of failure. RTF should not be confused with neglect; it is an intentional decision based on risk and cost analysis.
Why it matters
Applying preventive maintenance to every asset regardless of criticality wastes resources. Run-to-failure is the most cost-effective strategy for items like light globes, consumable parts, or redundant components where failure has no safety or operational impact. The risk arises when RTF is applied by default rather than by design, leading to unexpected downtime on critical assets.
How MapTrack helps
MapTrack helps teams classify assets by criticality so they can deliberately assign a run-to-failure strategy where appropriate, while ensuring high-criticality assets receive proactive maintenance.
Frequently asked questions
When is run-to-failure an appropriate strategy?
RTF suits assets that are inexpensive to replace, have no safety implications on failure, do not cause significant operational disruption, and where preventive servicing costs more than replacement. Examples include consumable hand tools, standard light fittings, and non-critical accessories with readily available spares.
How do you decide which assets should run to failure?
Organisations typically use a criticality assessment that considers the consequence of failure (safety, production, cost) and the probability of failure. Assets scoring low on both dimensions are strong candidates for RTF. This analysis should be documented and reviewed periodically as operating conditions change.
Related terms
Corrective Maintenance
Corrective maintenance refers to repair or restoration work carried out after a fault, defect, or failure has been identified in an asset. It may be triggered by an operator report, a failed inspection, or an unexpected breakdown. Corrective tasks range from minor adjustments to major overhauls, depending on the severity of the issue.
Preventive Maintenance
Preventive maintenance (PM) is a proactive maintenance strategy in which assets are serviced at predetermined time or usage intervals to reduce the likelihood of failure. Tasks may include inspections, lubrication, filter changes, calibrations, and component replacements. PM schedules are typically based on manufacturer recommendations, regulatory requirements, or historical failure data.
Downtime
Downtime is any period during which an asset is unavailable for its intended function. It can be planned (scheduled maintenance, shutdowns, inspections) or unplanned (breakdowns, failures, waiting for parts). Downtime is typically measured in hours and expressed as a percentage of total available time, providing a key indicator of asset availability.
Asset Lifecycle Management
Asset lifecycle management (ALM) is the practice of managing a physical asset through every stage of its life, from planning and acquisition through operation, maintenance, and eventual disposal or replacement. It integrates financial, operational, and technical data to optimise decisions at each stage. The goal is to maximise the value an asset delivers over its entire useful life while minimising total cost of ownership.
Total Cost of Ownership (TCO)
Total Cost of Ownership (TCO) is a financial metric that captures all costs associated with owning and operating an asset over its entire lifecycle, including acquisition price, financing costs, maintenance and repair, fuel or energy, insurance, registration, operator costs, downtime costs, and disposal or residual value. TCO provides a comprehensive view of the true cost of an asset beyond its purchase price.
See how MapTrack handles run-to-failure maintenance