We have a number of embedded systems requiring r/w access to the filesystem which resides on flash storage with block device emulation. Our oldest platform runs on compact flash and these systems have been in use for over 3 years without a single fsck being run during bootup and so far we have no failures attributed to the filesystem or CF.
On our newest platform we used USB-flash for the initial production and are now migrating to Disk-on-Module for r/w storage. A while back we had some issues with the filesystem on a lot of the devices running on USB-storage so I enabled e2fsck in order to see if that would help. As it turned out we had received a shipment of bad flash memories so once those were replaced the problem went away. I have since disabled e2fsck since we had no indication that it made the system any more reliable and historically we have been fine without it.
Now that we have started putting in Disk-on-Module units I've started seeing filesystem errors again. Suddenly the system is unable to read/write certain files and if I try to access the file from the emergency console I just get "Input/output error". I enabled e2fsck again and all the files were corrected.
O'Reilly's "Building Embedded Linux Systems" recommends running e2fsck on ext2 filesystems but does not mention it in relation to ext3 so I'm a bit confused to whether I should enable it or not.
What are your takes on running fsck on an embedded system? We are considering putting binaries on a r/o partition and only the files which has to be modified on a r/w partition on the same flash device so that fsck can never accidentally delete important system binaries, does anyone have any experience with that kind of setup (good/bad)?