Created: 2023.07.22
Introduction Run-to-failure and breakdown maintenance strategies are often perceived as similar, but they have key differences in terms of application and management. This whitepaper aims to clarify these distinctions and provide insights on how businesses can adopt these strategies more intentionally.
Defining Run-to-Failure and Breakdown Maintenance 2.1 Run-to-Failure Maintenance
This strategy involves using an asset until it fails, after which it is discarded and replaced with a new one. It is typically applied to assets with a limited life expectancy and no cost-effective methods to predict failure in advance.
2.2 Breakdown Maintenance
In contrast, breakdown maintenance entails using an asset, repairing it when it breaks down, and repeating the use-repair cycle until the asset is no longer suitable for use. This strategy is typically applied to assets with unpredictable failure patterns and those which can be economically repaired.
Case Study: Sprinkler Systems
A sprinkler system illustrates the differences between run-to-failure and breakdown maintenance. While the system as a whole follows a breakdown maintenance strategy, individual sprinkler heads adhere to a run-to-failure approach.
Stock Management and Replacement
Both maintenance strategies require similar stock management processes. Businesses need to decide whether to keep spare items for run-to-failure assets or order new ones when required. The same consideration applies to breakdown maintenance, but for the parts that commonly fail or wear out.
Exceptions and Adjustments
In some cases, run-to-failure maintenance assets might be fewer than initially assumed. For example, if hard water causes the most common failures in a sprinkler system, businesses may opt to replace the affected parts and treat them with de-calcification solutions before reusing them.
The Importance of Understanding Maintenance Strategies
While it may seem feasible to overlook the differences between run-to-failure and breakdown maintenance, being intentional about maintenance strategies enables businesses to optimize asset management and reduce costs. Understanding these distinctions helps organizations make informed decisions about their maintenance practices.
Endnotes
[1] In climates with annual freeze cycles, businesses may need to perform scheduled maintenance in addition to run-to-failure and breakdown maintenance strategies.
[2] Recent changes in government regulations, such as solder requirements for electronic equipment, have influenced product lifespans. This factor should be considered when deciding on stock management and replacement strategies for electronic assets.