Hi Keith,
Thoughts on your questions: 1) In house Maximo does provide for a better solution than Crystal. Starting with 7.6.0.8 Ad-Hoc capabilities to create inspection forms and a limited response types were available. Going up to V7.6.1.1 there are out-of-box multiple inspection report and ability to 'group' inspection results and report them together using routes and work orders.
2) Not sure when external report integration was dropped by Maximo. BIRT and Cognos are now the top promotions.
3) There are OOB Inspection reports available through Work Center. The Inspection Form combines Job Plans, Preventive Maintenance, Work Order Tracking, Assets, and Locations applications in Maximo. In Maximo 7.6.1, Inspection Forms can be recommended for Assets and Locations by clicking 'Associate Inspection Form'.
Why 'fear BIRT'?