Understanding the Most Frequently Occurring CMMS Failure Codes
A failure code in your organization’s CMMS means it’s time to take action. An indicator of a problem, whether minor or major, is something that, by design, you should take care of immediately.
But the only thing worse for a facilities manager than receiving a failure code is NOT receiving one when they should. An undiagnosed facilities issue can turn into a major problem, costing thousands of dollars in repair fees, and potentially thousands more in lost revenue due to downtime.
But a failure code isn’t something to dread; it’s just a part of your CMMS working properly. And hopefully whatever the cost is associated with repairing the issue is small compared to what could happen.
What is a CMMS failure code?
A CMMS (Computerized Maintenance Management System) failure code is a predefined identifier used to categorize and track equipment or system failures within maintenance management software. These asset based failure codes provide a standardized and systematic way to record and analyze failures in various assets or processes. Failure codes enable maintenance teams to quickly identify and communicate the nature of a failure, facilitating efficient troubleshooting, accurate reporting, and data-driven decision-making for maintenance planning and resource allocation. The use of CMMS failure codes enhances maintenance efficiency, minimizes downtime, and supports continuous improvement efforts.
How are CMMS failure codes used?
CMMS failure codes are crucial in increasing efficiency in maintenance operations, anticipating future equipment issues, and generating detailed work orders. CMMS failure codes streamline work order management and asset maintenance processes. When a failure occurs, maintenance personnel can quickly generate work orders that contain the relevant failure code. These detailed work orders ensure that technicians have the necessary information to address the specific equipment failure effectively. Furthermore, the association of failure codes with assets enables organizations to track and analyze failure history for individual equipment pieces. This information supports proactive maintenance planning, spare parts inventory management, and resource allocation.
Increase efficiency in maintenance operations
CMMS failure codes enable the categorization and classification of equipment failures. By assigning specific failure codes to different types of equipment malfunctions, maintenance personnel can quickly identify and document the nature of the failure. This standardized identification and documentation streamline troubleshooting and repair processes, as technicians can easily access relevant information associated with specific failure codes. The use of common failure codes facilitates the efficient allocation of maintenance resources, allowing teams to prioritize and address critical issues promptly. As a result, maintenance operations become more streamlined and efficient.
Anticipate future equipment issues
CMMS failure codes can help anticipate future equipment issues. By analyzing the historical data associated with failure codes, maintenance teams can identify recurring failure trends and patterns. This trend analysis helps in predictive maintenance, where potential equipment failures can be anticipated based on past occurrences. By using failure codes as indicators, maintenance personnel or reliability engineers can proactively plan maintenance activities to prevent future failures. This approach aligns with reliability-centered maintenance (RCM) strategies, which focus on identifying critical equipment prone to specific failure codes and implementing proactive maintenance measures.
Generate detailed work orders
CMMS failure codes are instrumental in generating detailed work orders for maintenance tasks. When a failure is recorded and associated with a specific failure code, the CMMS can automatically generate work orders with the relevant failure codes assigned. These work orders contain specific instructions related to troubleshooting and repairs associated with the identified failure. The detailed work orders ensure that maintenance technicians have all the necessary information and guidance to address the specific equipment failure. Moreover, the documentation of failure codes linked to equipment and the tracking of repair history enable comprehensive maintenance records, facilitating future reference and analysis.
Why use CMMS failure codes?
Standardize your failure documentation
CMMS failure codes provide a structured and standardized approach to documenting equipment failures. By assigning specific codes to each type of asset failure, organizations can ensure consistent and uniform documentation across all their assets. This standardization simplifies communication, enhances clarity, and reduces ambiguity in failure descriptions. It enables maintenance personnel to quickly understand and assess the nature of failures, facilitating efficient troubleshooting and repair processes.
Develop maintenance reporting
CMMS failure codes play a crucial role in developing comprehensive maintenance reports on asset failures. By consistently using failure codes to track and record equipment failures, organizations can generate insightful reports that highlight failure trends, frequency, and associated costs. These reports provide valuable information for management to identify critical areas that require attention, allocate resources effectively, and make informed decisions regarding maintenance strategies, such as preventive or predictive maintenance.
Compliance with regulatory standards
Many industries are subject to regulatory standards and requirements related to equipment maintenance and safety. CMMS failure codes help organizations comply with these standards by providing a systematic and organized approach to failure documentation. For example, the oil and gas industry are required to collect certain data due to the ISO 14224 standard in order to be compliant. Failure codes enable clear identification of issues, aiding in audits, inspections, and compliance reporting. Organizations can demonstrate their adherence to regulatory standards by effectively using CMMS failure codes to document and manage equipment failures.
Implementing a failure analysis-centric maintenance approach
CMMS failure codes support organizations in adopting a failure analysis-centric maintenance approach. By systematically categorizing and tracking asset failures, organizations can perform in-depth failure data analysis. They can identify root causes, patterns, and trends associated with specific failure codes. This analysis helps identify opportunities for improvement, implement corrective actions, and prevent recurring failures. By leveraging failure codes, organizations can transition from reactive maintenance to a proactive maintenance strategy, improving equipment reliability and minimizing downtime.
Important CMMS failure code categories
These failure codes within a CMMS show maintenance issues as they occur, allowing you to target them early, preventing them from becoming larger, more costly issues.
Broken
The broken code indicates a complete or partial component or system failure. It signifies that the equipment is no longer functioning as intended, requiring repair or replacement to restore functionality. Broken failure codes are crucial for identifying critical equipment failures and initiating appropriate maintenance actions.
Calibration
Calibration failure codes reveal a deviation from the desired measurement or performance standards due to inaccurate calibration. This category is essential for ensuring the accuracy and reliability of equipment that requires precise calibration, such as instruments, sensors, or gauges. Identifying and addressing calibration failures promptly helps maintain the integrity of measurement processes and enhances the overall quality of products or services.
Foreign matter
Foreign objects or substances in the equipment or system causing issues or disruptions trigger the foreign matter error code. This code includes contamination, blockages interfering with the normal equipment operation. By tracking foreign matter failures, organizations can implement preventive measures, such as improved filtration systems or enhanced maintenance procedures, to minimize the risk of future disruptions.
Loose
The loose failure code is applied when components or connections within the piece of equipment becomes loose or detached, leading to operational inefficiencies or potential hazards. Detecting and addressing loose failures promptly is crucial to prevent further damage, ensure safety, and maintain optimal performance. Tightening or re-securing loose components helps eliminate potential risks and improves the reliability of the equipment.
Leak
Leak failure codes indicate the presence of fluid or gas leakage from equipment or systems. Leaks can lead to performance degradation, equipment damage, safety hazards, or environmental concerns. By promptly identifying and repairing leaks, organizations can prevent equipment failures, minimize downtime, reduce energy wastage, and comply with regulatory requirements related to safety and environmental protection.
Clogged
Clogged failure codes are utilized when equipment or systems are obstructed or impeded by the accumulation of debris, sediment, or other substances. Clogging restricts fluid flow, decreases efficiency, and potentially causes severe damage. Tracking and addressing clogged failures enable organizations to implement preventive maintenance practices like regular cleaning, filtration system maintenance, or fluid flushes to ensure uninterrupted operation and extend equipment lifespan.
Overheating
Overheating failure codes are applied when equipment or components exceed safe operating temperatures. Overheating can lead to component failure, reduced performance, or fire hazards. Tracking overheating failures helps organizations identify potential causes such as insufficient cooling, faulty ventilation, or excessive workload, enabling them to implement appropriate corrective measures to prevent equipment damage and maintain safe operating conditions.
Corrosion
Corrosion failure codes are used to indicate the deterioration or degradation of equipment or components due to chemical reactions, moisture, or environmental factors. Corrosion can compromise structural integrity, impair functionality, and lead to premature equipment failure. Monitoring and addressing corrosion failures are crucial for implementing appropriate maintenance practices like corrosion prevention coatings, regular inspections, or material selection to prolong equipment life and ensure reliable operation.
Simplify failure reporting with Brightly
Brightly’s CMMS can help your maintenance team stay on top of all potential and developing failure codes, helping to keep your facilities running smoothly and efficiently. Their asset management solutions give you a single source of truth from which to manage all of your systems, improving productivity and cost-effective maintenance practices. Speak with a Brightly expert and learn how their CMMS can help your organization.
