Run-To-Failure vs Breakdown Maintenance: What’s the Difference?

Maintenance strategies play a key role in keeping equipment running smoothly. Two common approaches are run-to-failure and breakdown maintenance. While they may seem similar, these methods have important differences.

This article will also compare run-to-failure and breakdown maintenance with other maintenance strategies, such as corrective maintenance.

Run-to-failure maintenance lets equipment operate until it stops working, while breakdown maintenance responds to unexpected failures as they happen. Run-to-failure is planned for non-critical assets that are cheap to replace.

Breakdown maintenance applies to both critical and non-critical equipment.

Understanding these strategies helps companies choose the best way to maintain their equipment. The right approach can save money and prevent unplanned downtime. Picking between run-to-failure and breakdown maintenance depends on each piece of equipment’s specific needs.

Understanding Maintenance Strategies

Maintenance strategies are key to keeping any piece of equipment running smoothly. Different approaches suit various situations and assets. Let’s explore two common strategies and compare their uses.

Defining Run-to-Failure Maintenance

Run-to-failure maintenance is a strategy in which machines operate until there is an equipment break. This approach works best for non-critical assets with low repair costs.

For example, in a cardboard box production factory, a non-critical stapling machine can be used under the run-to-failure approach. This method allows for continuous use without regular maintenance, addressing issues only after the machine fails, which is cost-effective and time-saving.

Companies use this method when:

• Replacement parts are cheap and easy to get
• Downtime won’t cause major issues
• Regular checks cost more than letting it fail

Run-to-failure needs minimal planning. Managers wait for equipment to stop working before fixing it.

This strategy can save money on some items. But it’s risky for necessary machinery. Unexpected breakdowns may lead to longer downtimes and higher costs.

Defining Breakdown Maintenance

Breakdown maintenance is a reactive approach. It kicks in when equipment suddenly fails and needs urgent repair, with maintenance performed to address the unexpected malfunction.

Key points about breakdown maintenance:

• It’s often unplanned and disruptive
• Technicians respond quickly to fix issues
• It applies to both critical and non-critical assets

This method is also called emergency or reactive maintenance. It aims to get broken equipment back up and running fast.

Breakdown maintenance can be costly. It may lead to:

• Longer downtimes
• Higher repair expenses
• Lost production time
• Unplanned failures

Yet, it remains common in many industries for certain types of equipment.

Source: WorkTrek

Comparing Maintenance Approaches

Run-to-failure and breakdown maintenance are both forms of corrective maintenance. They differ in key ways from preventive and predictive strategies.

Both run-to-failure and breakdown maintenance involve dealing with faulty equipment, but run-to-failure is a planned approach, while breakdown maintenance is reactive.

Differences between the two:

• Run-to-failure is planned; breakdown maintenance is not
• Run-to-failure suits low-priority items; breakdown applies to all equipment

Both strategies contrast with proactive methods like:

• Preventive maintenance: Regular, scheduled upkeep
• Predictive maintenance: Using data to forecast failures

Choosing the right approach depends on:

• Equipment criticality
• Failure consequences
• Repair costs
• Available resources
  Source: WorkTrek

Smart maintenance management often combines multiple strategies. This helps balance costs with equipment reliability and performance.

The Role of Maintenance in Operations

Maintenance choices shape how businesses run. They affect costs, productivity, and equipment life. In some scenarios, allowing equipment to break down is considered acceptable, mainly when safety risks are minimal. Smart maintenance helps companies succeed.

Operational Impact of Maintenance Choices

Run-to-failure maintenance can work for some equipment. It’s used when replacing parts is cheaper than fixing them, and it saves money on routine checks.

But it has risks. Sudden breakdowns can halt work. This hurts productivity and profits.

Breakdown maintenance fixes things only when they stop working. It can lead to more downtime, and repairs may take longer and cost more.

Planned maintenance prevents many problems. It keeps machines running smoothly. This boosts efficiency and cuts long-term costs.

Businesses must balance these options. The right mix depends on equipment type and importance.

Downtime and Its Effects on Productivity

Equipment failure causes unplanned downtime. This stops work and wastes time. Workers sit idle while machines are fixed.

Even short delays add up. They can mean missed deadlines and unhappy customers.

Breakdown maintenance often leads to more downtime. Repairs take time to start, and parts may not be on hand.

Planned maintenance reduces surprises. It finds problems early. This means shorter, scheduled breaks instead of long, unexpected ones.

Less downtime means more output. Workers can focus on their jobs instead of waiting for repairs, boosting overall productivity and helping meet business goals.

Cost Considerations in Maintenance

Maintenance costs play a big role in asset management. Companies need to weigh repair expenses against equipment value. Smart planning can help reduce costs over time. It is also crucial to compare breakdown maintenance to other maintenance strategies, considering factors such as equipment criticality and cost implications.

Analyzing Maintenance Costs

Run-to-failure maintenance can seem cheaper at first, as it requires no ongoing upkeep. But sudden breakdowns may cost more in the long run.

Breakdown maintenance often leads to higher repair bills. Emergency fixes are pricey. They can also cause costly downtime.

To cut costs, companies should track repair history. This helps spot problem areas. It also shows which fixes work best.

A cost-benefit analysis compares different approaches. It looks at:

• Parts costs
• Labor fees
• Downtime expenses
• Equipment lifespan

This data helps pick the best maintenance plan for each asset.

Budgeting for Asset Maintenance

Good maintenance planning is key to controlling costs. It helps avoid surprise expenses.

Managers should set aside funds for regular upkeep. This includes money for:

• Routine inspections
• Minor repairs
• Parts replacement

For critical equipment, extra budget may be needed. This covers potential breakdowns.

Companies can use past data to predict future costs. This helps create more accurate budgets.

Some firms use special software to track expenses. It can spot trends and suggest ways to save money.

Smart budgeting also includes staff training. Well-trained workers can spot issues early, preventing big problems later.

Safety and Risk Management

Safety is a key factor when choosing between run-to-failure and breakdown maintenance. Both strategies have different impacts on workplace safety and risk management.

Run-to-failure maintenance can pose higher safety risks. Equipment may fail unexpectedly, potentially causing accidents or injuries. This approach requires strong safety protocols to protect workers.

Breakdown maintenance also carries risks. Emergency repairs can be rushed, increasing the chance of mistakes. Workers may need to intervene in dangerous situations to fix critical equipment.

Source: ABB

What is the difference?

Risk management differs between the two approaches:

• Run-to-failure: Focuses on containing risks of sudden failures

• Breakdown maintenance: Emphasizes quick, safe responses to breakdowns

Both strategies need clear safety procedures. This includes:

• Personal protective equipment requirements
• Emergency shutdown protocols
• Proper training for maintenance staff

Safety Audits

Regular safety audits help identify and address potential hazards. This is crucial for both maintenance approaches to minimize risks to workers and equipment.

Ultimately, the choice between run-to-failure and breakdown maintenance must prioritize safety. Companies must assess the risks associated with each strategy for their specific equipment and workplace.

Maintenance Execution and Tracking

Proper execution and tracking are key to successful maintenance programs. They help organizations manage repairs and keep equipment running smoothly.

Work Order Management and Execution

Work orders are essential for managing maintenance tasks. They outline what needs to be done, who should do it, and when. A good work order system helps prioritize tasks and allocate resources efficiently.

Many companies use CMMS software to manage work orders. This software makes creating, assigning, and tracking maintenance jobs easy and helps schedule preventive maintenance tasks.

CMMS tools often include mobile apps. These let technicians access work orders in the field. They can update job status and log completion in real time

Source: Keystone Industries

Importance of Maintenance Documentation

Good documentation is crucial for effective maintenance. It creates a record of all work done on equipment. This helps spot trends and plan future maintenance.

Maintenance reports should include details like:

• Date and time of work
• Equipment serviced
• Problems found
• Actions taken
• Parts used
• Time spent on the job

Well-kept records help with troubleshooting. They show what’s been tried before when similar issues occur. This can speed up repairs and reduce downtime.

Documentation also aids in compliance. It provides proof of regular maintenance for safety inspections or audits.

Technological Integration in Maintenance

Modern maintenance strategies use advanced technologies to improve efficiency and reduce costs. These digital tools help predict failures, manage assets, and optimize operations.

Implementing CMMS Solutions

Computerized Maintenance Management Systems (CMMS) are key to effective asset management. CMMS software tracks equipment history, schedules maintenance, and manages inventory.

CMMS solutions offer several benefits:

• Automated work order generation
• Real-time asset status updates
• Improved inventory control
• Enhanced reporting capabilities
• Key Performance Indicators (KPIs)
• Compliance & Control
• Health and Safety Guidelines

CMMS helps organizations make informed decisions about their equipment by centralizing maintenance data. It allows teams to shift from reactive to proactive maintenance strategies.

CMMS also supports continuous improvement efforts. Teams can analyze past maintenance activities to identify trends and optimize future work.

Data Analysis and Predictive Maintenance

Data analysis transforms maintenance practices. By examining equipment performance data, teams can predict failures before they occur.

Key aspects of data-driven maintenance include:

• Collecting real-time equipment data
• Using artificial intelligence to identify patterns
• Developing predictive models for asset health

Predictive maintenance reduces downtime and extends equipment life. It allows teams to schedule repairs at optimal times, minimizing disruptions to operations.

This approach also helps with inventory management. Organizations can stock the right items at the right time by predicting part failures.

Illustration: WorkTrek / Data: Global Education Board

The Role of IoT in Maintenance Strategies

The Internet of Things (IoT) connects equipment to the digital world. Sensors on machines collect and transmit data in real time.

IoT devices in maintenance:

• Monitor equipment performance constantly
• Alert teams to potential issues quickly
• Provide data for predictive analysis

Source: Q Services

Integrating IoT

IoT integration enhances both run-to-failure and preventive maintenance strategies. For run-to-failure, IoT sensors detect imminent failures, allowing for timely replacements.

In preventive maintenance, IoT data helps refine maintenance schedules. This ensures tasks are performed only when needed, saving time and resources.

Source: Softweb Solutions

Maintenance Strategy Optimization

Optimizing maintenance strategies is key for businesses to improve efficiency and cut costs. The goal is to find the right balance between different approaches.

A good maintenance strategy combines multiple methods. It may use run-to-failure for some equipment and preventive care for others.

Choosing the best strategy depends on several factors:

• Equipment criticality
• Failure patterns
• Maintenance costs
• Downtime impact

Preventive maintenance programs involving regular inspections and servicing can help extend equipment life and reduce unexpected breakdowns.

Data analysis plays a big role in optimization. Tracking repair history and failure rates helps identify trends. This information guides decision-making on when to repair or replace assets.

Continuous improvement is essential for maintenance strategy optimization. Regular reviews allow companies to adjust their approach as needs change. They can phase out ineffective practices and adopt new technologies.

Training staff is another important aspect. Well-trained technicians can spot issues early and perform maintenance more effectively.

Ultimately, the best maintenance strategy balances cost, reliability, and performance. It evolves to meet changing business needs and technological advances.

Advantages and Disadvantages

Both run-to-failure and breakdown maintenance have pros and cons. Each approach impacts asset conditions and repair costs differently.

Benefits of Run-to-Failure Maintenance

Run-to-failure maintenance can be cost-effective for certain assets. It requires minimal planning and upfront costs. This method works well for non-critical equipment with low replacement costs.

Companies save money on routine inspections and repairs. They can fully use an asset’s lifespan. This strategy is simple to implement and manage.

Run-to-failure fits assets where:

• Failure doesn’t cause safety issues
• Downtime has little impact
• Replacement is cheaper than maintenance

Drawbacks of Breakdown Maintenance

Breakdown maintenance has significant downsides. It often leads to higher repair costs and longer downtime, and unexpected failures disrupt operations and production schedules.

This approach can shorten equipment lifespan. It may cause secondary damage to connected systems. Emergency repairs are usually more expensive than planned maintenance.

Disadvantages include:

• Unpredictable failures and costs
• Increased safety risks
• Lower equipment reliability
• Potential for more severe breakdowns

Breakdown maintenance makes it hard to budget for repairs. It can lead to rushed fixes and subpar work quality. This method is risky for critical assets or those with high replacement costs.

Communication and Training

Communication plays a key role in both run-to-failure and breakdown maintenance strategies. Clear channels help teams respond quickly when issues arise.

For run-to-failure, staff need to know which assets follow this approach. They should understand when to report problems and how to request replacements.

Breakdown maintenance relies on fast communication. Teams must quickly relay equipment failures to maintenance staff, allowing for rapid response and repair.

Training is vital for both methods. Employees should learn to spot signs of wear and impending failure. This helps even with run-to-failure, allowing time to order replacement parts.

Illustration: WorkTrek / Data: Pumble

Necessary skills

Maintenance teams require specific skills for each approach:

• Run-to-failure: Focus on efficient replacement procedures
• Breakdown maintenance: Emphasis on diagnostics and repair techniques

Regular refresher courses keep staff up-to-date on best practices. This ensures they can handle various maintenance scenarios effectively.

Communication

Proper communication and training lead to the following:

• Faster problem resolution

• Reduced downtime

• Improved safety

• Better resource management

By investing in these areas, companies can maximize the effectiveness of their chosen maintenance strategy.

Frequently Asked Questions

Run-to-failure and breakdown maintenance are complex topics with many nuances. These questions explore key aspects, strategies, and applications in industrial settings.

What are the examples of run-to-failure maintenance in industry?

Run-to-failure maintenance is used for non-critical equipment. Light bulbs in office buildings are a common example. They’re left on until they burn out, then replaced.

Another example is disposable air filters in HVAC systems. These are used until they become clogged, then swapped out for new ones.

What are the potential advantages and disadvantages of run-to-failure maintenance?

Run-to-failure maintenance can save money on unnecessary preventive maintenance. It’s simple to implement and requires minimal planning.

A big disadvantage is the risk of unexpected breakdowns. If critical equipment fails suddenly, this can lead to production delays, higher repair costs, and safety hazards.

How does run-to-failure maintenance compare to condition-based maintenance?

Run-to-failure maintenance allows equipment to operate until it breaks down. Condition-based maintenance uses sensors and data to predict when failures might occur.

Condition-based maintenance can prevent unexpected breakdowns. It’s more complex and expensive to set up than run-to-failure, but it can save money long-term for critical assets.

What are the four primary types of maintenance strategies?

The four main maintenance strategies are:

1. Reactive maintenance
2. Preventive maintenance
3. Predictive maintenance
4. Reliability-centered maintenance

Each strategy has its benefits and drawbacks, depending on the equipment and industry.

Could you explain the concept of run-to-failure maintenance?

Run-to-failure maintenance involves using equipment until it stops working. Then, it’s either repaired or replaced.

This approach is best for non-critical assets with low repair costs. It’s also used when failure patterns are unpredictable or when equipment is near the end of its life cycle.

How is breakdown maintenance defined and when is it typically employed?

Breakdown maintenance is fixing equipment after it has already failed. It’s often unplanned and requires immediate action.

This type of maintenance is used for both critical and non-critical equipment. It’s common in industries where unexpected failures can occur despite preventive measures.