Failure classification is one of the most powerful features in Maximo Application Suite, but it is also one of the most inconsistently implemented. Most organizations capture failure data. Few structure it correctly, and fewer use that data to drive decisions when it comes to asset management.
‍

Maximo provides a structured framework to do all three. When configured and used properly, failure classification becomes the foundation for reliability analysis, maintenance optimization, and long-term asset strategy.

What Failure Classification Actually Means in Maximo

In Maximo Application Suite, failure classification is a structured way to capture and categorize failures using predefined codes. These codes are organized into a hierarchy of failure class, problem, cause, and remedy, allowing organizations to standardize how failures are recorded and analyzed.
‍

This structure answers three core questions:

• What failed
• Why it failed
• What was done to fix it
  ‍

Each level of the hierarchy plays a role:

• Failure Class defines the category of asset or failure type
• Problem captures the observed issue
• Cause identifies the underlying reason
• Remedy documents the corrective action
  ‍

For example:

• Failure Class: Pump
• Problem: Leakage
• Cause: Damaged seal
• Remedy: Replace seal
  ‍

This hierarchy is configured in the Failure Codes application and reused across assets, locations, and work orders to ensure consistency.

Where Failure Classification Lives in Maximo

Failure classification is primarily captured in the Work Order Tracking application, within the Failure Reporting tab.
‍

When work is completed:

• The failure class is typically inherited from the asset or location
• The technician selects a problem code
• Cause and remedy codes can be added to provide additional detail
  ‍

This is a critical step in the process. If failure data is not captured here in a structured way, it cannot be reliably analyzed later. Consistent use of the Failure Reporting tab is what transforms maintenance activity into usable data.

How the Failure Hierarchy Works

Failure codes in Maximo are structured as a hierarchy with defined relationships between each level.

• A failure class sits at the top
• Problems are associated with that class
• Causes are linked to specific problems
• Remedies are tied to causes
  ‍

This hierarchy controls how users interact with failure data. When a problem is selected, Maximo filters the available causes and remedies based on that selection. This ensures that users are choosing from relevant, predefined options rather than entering inconsistent data. This structured approach is what makes failure classification usable for reporting and analysis.

The Link Between Failure Classes and Assets

Failure classes are defined at the organization level and can be applied to assets and locations.
‍

When assigned correctly:

• The failure class is automatically carried into work orders
• Users are guided to the appropriate subset of failure codes
• Data remains consistent across sites and teams
  ‍

If failure classes are not assigned to assets:

• Users see a full list of codes
• The hierarchy loses its filtering behavior
• Data becomes inconsistent and difficult to analyze
  ‍

This is one of the most common gaps in Maximo implementations.

Designing Failure Codes That Work in Practice

Failure classification is often overengineered. The goal is not to create the most detailed hierarchy possible. The goal is to create one that people will actually use.
‍

Effective failure hierarchies are:

• Relevant to the asset or system
• Simple enough for quick selection
• Consistent across teams
• Built to evolve over time
  ‍

A practical approach is to start with failure classes and problem codes, then expand into cause and remedy as patterns emerge. If the hierarchy is too complex, adoption drops. If adoption drops, the data loses value.

How to Analyze Failure Classification Data

Capturing failure data is only useful if it is analyzed. Maximo enables reporting across failure classifications at the work order, asset, and site level. This allows organizations to move beyond individual events and identify broader trends.
‍

Some of the most valuable ways to use this data include:

Identifying recurring problems

Grouping work orders by problem code highlights which issues occur most frequently and where to focus improvement efforts.

Understanding root causes

Cause codes help distinguish between equipment failures, operational issues, and external factors.

Evaluating maintenance effectiveness

Remedy codes show whether corrective actions are solving the problem or simply repeating the same fixes.

Supporting reliability analysis

Failure data provides the foundation for metrics such as failure rates and mean time between failures, supporting broader reliability strategies.

Practical Use Case: Repeated Pump Failures

Consider a facility experiencing frequent pump failures. Without structured failure classification, work orders may include inconsistent descriptions that are difficult to compare.
‍

With proper classification:

• Problem codes identify recurring leakage
• Cause codes point to seal degradation
• Remedy codes show repeated replacement actions
  ‍

This reveals a clear pattern. Instead of continuing reactive repairs, the organization can investigate operating conditions, review component selection, or adjust maintenance strategies. This is where failure classification moves from documentation to decision-making.

Common Pitfalls

Failure classification is often implemented, but not fully utilized. Common issues include:

Missing failure classes on assets

Without this, the hierarchy cannot guide users effectively.

Overly complex code structures

Too many options reduce usability and consistency.

Inconsistent data entry

Lack of training or unclear definitions leads to unreliable data.

No governance

Failure codes need to be reviewed and maintained over time.

Limited analysis

Data is captured but not used to drive improvements.

‍

Addressing these issues is what separates basic implementation from real value.

Where Failure Classification Fits in MAS

Failure classification is a foundational component of Maximo Application Suite. It supports and enhances:

• Asset performance management
• Reliability strategies
• Condition-based maintenance
• Reporting and analytics
  ‍

Structured failure data improves visibility into asset performance and strengthens the effectiveness of advanced capabilities across MAS. While Maximo provides the framework, failure classification creates a consistent, structured dataset that allows organizations to understand failures, identify patterns, and improve maintenance strategies over time. When done right, failure classification becomes one of the most important building blocks of a data-driven asset management approach.

‍