Run to Failure (RTF): When It Makes Business Sense

Run to Failure (RTF) is a maintenance strategy that allows equipment to operate until it breaks. While the mantra “if it ain’t broke, don’t fix it” can save money, it often overlooks the real cost of failure—lost production, safety risks, and cascading equipment damage.

In certain circumstances, RTF is the optimal approach, but it must be a calculated decision. Below are the critical factors you should evaluate before letting a machine run to failure.

1. Safety – Does a failure pose a risk to personnel? Never compromise safety; if an incident could harm someone, RTF is unacceptable.
2. Collateral Damage – A small motor may fail without consequence, but if its breakdown halts a production line and results in raw‑material waste, the hidden cost rises sharply. Additionally, a single component failure can trigger a chain reaction.
3. Condition‑Monitoring Costs – Monitoring systems and labor may outweigh the benefit of early detection, especially for low‑impact assets like roof fans.
4. Repair Costs – Historical data show that emergency repairs can be up to ten times more expensive than scheduled maintenance. Evaluate whether the asset’s failure cost justifies RTF.
5. Replacement Logistics – Is a spare part in inventory? How long will a replacement take, and what production downtime will result? These variables can tip the balance toward or away from RTF.

Other considerations—such as regulatory compliance, warranty terms, and the criticality of the asset—may also influence the decision. Always weigh the full cost of failure against the benefits of proactive maintenance.

For the original discussion, visit SKF’s website.

At J/E, we are an authorized distributor of SKF bearings, seals, and lubricants. Contact us or email info@je-bearing.com for product inquiries.