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[PatrikLundell]

I've pitted something like 50 undead and goblins into magma. Earlier I had one case earlier where the victim got lose without any difference in the procedure used. Now the last two attempts resulted in a goblin on the rampage. With the last one I checked and double checked that the victim was indeed caged in the pitting zone (and not among those waiting for execution in the stripping hold, which I suspect was the case with the previous one), as well as that the Jobs list showed it was due for pitting. I've checked and double checked the hatch, and it still is Forbidden and pet impassable.

[Astrid]

When taking an enemy out of the cage in order to pit him or transport him there's always a very slim chance of him breaking loose trying to escape. Or wouldnt you do that as prisoneer?

That's why keeping the pitting room secured is generally a good idea.

[Brewster]

Yup, pitting isn't as effective anymore. They can escape or climb out now. Thieves have a better chance since they are sneaky little buggers.

[PatrikLundell]

Well, the "suddenly" means in this fortress. All of the victims were pitted here, and every one of them I try to pit now escapes instead. The cages are built by the pit, so there is no transporting as such. The "before" and "after" are within the same fortress and the same DF version.
When I didn't lock the hatch the undead did indeed climb out.
And, I would do my very best not to be caught by a murdering lunatic such as myself in the first place:)

The stripped goblins aren't too bad (only bruises so far), but I don't really like doing this with stripped undead.

Well, it looks like I have to add a wall, station the militia in the pittery, and shock some haulers who have to haul the resultant corpse to the sentient refuse incinerator next door.

[Astrid]

Out of curiousity, if you havent, check the descriptions of the Dwarfes where pitting fails, check if they are weaklings. Would be interesting if it indeed is related to that. But i am guessing here.

[utunnels]

Yeah, there's a chance.
I usually station a squad near the pit just in case.

Also, some creatures are able to cling to the edge of the pit (likely climber skill in effect).

[PatrikLundell]

A bit difficult to check who the pitter was, as the indication I get of a failed pitting is of the type that work is interrupted by Goblin Maceman, so I'd have to look carefully to catch the pitter job allocation before the work is performed, but weakness is an interesting thought.

The undead dwarf I tried to pit as GCS silk farm bait couldn't be pitted because it wouldn't show up in the pitting list. I then reengineered it and had the cage lifted with a lever and a hatch beside this (controlled by the same lever). The undead stood on the open hatch and refused to fall, despite repeated opening and closing of the hatch, and I guess this is case of clinging to the side. A successfully pitted goblin now serves as silk farm target (after reverting the construction to allow pitting).

[Bumber]

Smoothed natural walls can't be climbed. That's your best bet to avoid climbing escapees.

[PatrikLundell]

I'm fairly sure they're not climbing, but escaping before being pitted, since I'm pitting into magma (which also makes it a bit late for smooting). The case where I pitted without locking the hatch had a burning undead on the rampage.
Since the last post I've successfully pitted 9 goblins without any incidents. One of the pitters was "very weak" with a strength of 700 something.

Edit: The next batch of 8 all failed. The pitters had various characteristics. My pittery is now covered in blood and body parts...

Edit 2: And all the pitting since then has worked without incident. It seems either none fail or all fail when designating a batch of 8.