Failures are inevitable in any maintenance strategy. The challenge isn’t just fixing them—it’s understanding why they happen, how they impact operations, and what can be done to prevent them in the future.

Failure codes play a crucial role in capturing, analyzing, and addressing issues before they lead to costly breakdowns. This guide explores failure types, their importance, and how businesses can use failure data to improve reliability and minimize downtime.

What Are Failure Codes and Why Do They Matter?

Failure codes are standardized alphanumeric identifiers that help technicians understand the root cause of an issue. They provide insights into patterns, help track recurring failures, and make it easier to implement proactive maintenance strategies.

Failure codes help organizations determine:

• What went wrong
• Why it happened
• How to fix it

The Three Types of Failures

Not all failures are the same. Some happen suddenly, while others develop over time. Understanding these differences is key to effective maintenance planning.

1. Functional Failure

Occurs when an asset stops performing its intended function.

Example: A conveyor belt motor that stops running.

2. Hidden Failure

A failure that isn’t immediately noticeable but poses risks.

Example: A backup generator with a dead battery that is only discovered when it is needed.

3. Potential Failure

Early signs of an impending failure before it completely breaks down.

Example: Unusual vibration in a motor indicating misalignment.

How Failure Codes Improve Maintenance Efficiency

Using failure codes effectively helps businesses:

• Identify recurring issues and implement long-term fixes
• Improve work orders with clear failure descriptions
• Analyze root causes to prevent repeat breakdowns
• Optimize asset life by addressing minor issues early

Common Failure Codes and What They Mean

Most organizations use failure codes to categorize and track common issues. Below are some of the most frequently used failure codes:

• Overheating – Equipment running beyond safe temperature limits
• Leak Alerts – Fluid or gas leaks that indicate system failure
• Failure to Start – Electrical or mechanical issues preventing operation
• Equipment Jams – Mechanical blockages disrupting normal function
• User Errors – Incorrect handling or improper setup leading to malfunctions

Using Failure Codes for Preventive and Predictive Maintenance

Failure codes are a roadmap to better maintenance strategies. Here’s how they can be used effectively:

1. Identify Patterns: Track failures to spot recurring trends and take proactive steps.
2. Improve Work Orders: Provide technicians with data-driven failure information.
3. Enhance Root Cause Analysis: Use Failure Modes and Effects Analysis (FMEA) to identify and prevent future issues.
4. Automate Preventive Actions: Integrate failure codes into a CMMS to trigger maintenance alerts.

Best Practices for Managing Failure Codes

To get the most out of failure tracking, follow these best practices:

• Keep It Simple: Use a standardized failure code structure that is easy to understand.
• Train Your Team: Ensure technicians know how to use failure codes properly.
• Close the Loop: Link failure codes with completed repairs to improve future maintenance planning.
• Leverage Technology: Use CMMS/EAM systems to store, track, and analyze failure data.

Final Thoughts: Turning Failures into Opportunities

No business can eliminate failures completely, but tracking, analyzing, and learning from them can significantly reduce downtime and improve efficiency. Failure codes provide a clear picture of what is working, what isn’t, and what needs to change.

When combined with predictive maintenance tools, failure codes help businesses transition from reactive fixes to proactive solutions. This ensures optimal asset performance and minimal disruptions.