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apmOptimizer® — maintenance and spare parts software

Maintenance planning and optimisation for fleets and complex assets: RAMS and MSG-3 analysis to cut downtime, extend asset life and control spares cost.

Choosing apmOptimizer®

  • Who should evaluate apmOptimizer?: Maintenance, reliability and logistics teams choosing maintenance intervals, repair levels and spare-stock policies for complex assets or fleets. Use it to compare the cost and availability consequences of alternative plans. The software is deployed on premises.
  • What should you prepare?: The asset or product structure, failure and repair data, mission profile, maintenance tasks, costs and spare-part lead times. Define the availability or service-level targets and the resource constraints the plan must meet.
  • What can you review?: Life cycle cost breakdowns, maintenance tasks and intervals, repair-policy comparisons, spare-stock levels and availability or downtime metrics. Use scenario comparisons to explain the trade-offs behind a proposed plan.

Key Modules

  • LCC: Life Cycle Cost analysis with CAPEX / OPEX breakdowns and scenario comparisons.
  • Scheduled Maintenance Optimization: Optimize PM intervals, inspection frequencies and overhaul cycles.
  • RCM & MSG-3 management: Structure tasks from FME(C)A into actionable maintenance programs compliant with industry practices.
  • LORA: Level Of Repair Analysis to select repair / replace / overhaul strategies and echelon policies.
  • PdM & RBI: Balance condition-based maintenance and inspection plans; ROI assessment for sensors and IIoT.
  • Field Data Analysis: Extract failure distributions from field failure logs.
  • Spare Parts & Inventory Optimization: Stock levels, reorder points, multi-echelon policies, lead-time and obsolescence handling.
  • Performance Analysis: Evaluate availability, downtime, throughput and service level KPIs under mission profiles.

Key Features

  • Life Cycle Cost (LCC): Optimization with CAPEX / OPEX breakdowns and scenario comparisons.
  • Level Of Repair: Repair / replace / overhaul decisions with echelon policies and resource constraints.
  • Scenario Manager: Including site-dependent requirements and mission profiles.
  • Availability: Availability modeling with MTTR / MTBF-driven KPIs.
  • Field Data Analysis: Fit distributions (Weibull, Exponential, Log-Normal) and update plans accordingly.
  • Predictive Maintenance: Decision-making tool for comparing ROI on investments in PdM systems.
  • Spare Parts Optimization: Stock levels, reorder points, service levels and multi-echelon policies.
  • Scheduled Maintenance Optimization: PM intervals, inspections and overhaul cycles.
  • RCM / MSG-3 Program Builder: Structure tasks from FME(C)A into actionable maintenance plans.

Advanced Modeling Capabilities

  • Failure modes: Evident, gradual and hidden; mixed distributions (Exponential, Weibull, Log-Normal, Normal).
  • Constraints & objectives: Minimize LCC subject to availability / service-level targets and budget / resource limits.
  • Redundancy and sparing: Hot / cold standby rules, repair queues and resources.
  • Analysis capabilities: Analytical solvers for sensitivity, uncertainty and what-if exploration.
  • Logistics: Warehouses and echelons, supplier lead times, minimum order quantities, shelf-life and obsolescence.

Core Benefits

  • Cut costs: Reduce maintenance, downtime and spare stock while sustaining high SLA / availability.
  • Smart inventory: Avoid stock-outs and overstock with optimized reorder points and spares.
  • Faster, better decisions: Rapid analytic runs to converge on feasible, budget-aligned plans.
  • Strategic clarity: Quantify trade-offs (CAPEX vs. OPEX, PM vs. PdM) with clear ROI indicators.
  • Design-time integration: Plan logistics and maintenance during design for a smoother rollout.
  • Operational resilience: Fewer bottlenecks, improved readiness and customer satisfaction.

How It Works

  • Data intake: Import the product tree, parts and failure data from CARE® (FME(C)A / RBD) or Excel / CSV; define mission profiles and environments.
  • Model policies: Set repair/replace strategies, inspection tasks, PdM triggers, logistics echelons, lead times and cost parameters.
  • Optimize: Run LCC, spares and schedule optimizers; iterate PdM/RBI and LORA decisions to meet availability and budget targets.
  • Validate & sensitivity: Use analytics to test robustness to demand, failure rate and lead-time uncertainty.
  • Report & deploy: Publish maintenance plans, stock lists and KPIs; export to Excel, Word and HTML and share with operations and procurement.

Integration with BQR's toolchain

  • Synthelyzer®: Extracts schematic/BOM and context from ECAD at design time.
  • fiXtress®: Supplies realistic component stresses and MTBF to inform failure rates and lifing assumptions.
  • CARE® Suite: Provides FME(C)A, RBD and failure data; closes the loop with safety and maintainability analyses.
  • Together, these tools provide a digital-twin maintenance and reliability workflow from schematic to system maintainability, safety and reliability.

Outputs & KPIs

  • LCC breakdown — CAPEX, spares, labour, downtime, logistics.
  • Availability, readiness and expected downtime per asset / fleet; MTTR and MTBF-driven KPIs.
  • Optimized maintenance program — task list, intervals, resource plan.
  • Spare parts policies — stock levels, reorder points, service levels, multi-echelon allocations.
  • ROI for sensors / IIoT and inspection equipment; recommended PdM / RBI configuration.
  • Exportable reports in Excel, Word and HTML; dashboards and Pareto views for cost and risk drivers.

Typical Use Cases

  • Fleets and rolling stock, aviation ground support and defense systems.
  • Oil & gas, utilities and process industries — rotating equipment, pipelines, substations.
  • High-throughput manufacturing lines, robotics and automation cells.
  • Data centers and telecom infrastructure — availability-critical services.

Questions for your apmOptimizer® evaluation

  • Can apmOptimizer support planning before field data is available?: The documented workflow accepts product and failure data from CARE or Excel/CSV as well as field failure logs. For a new asset, make the input assumptions explicit and compare scenarios; field data can inform later analysis.
  • How do LORA, maintenance and spare-parts planning fit together?: Level Of Repair Analysis compares repair, replace and overhaul strategies. Maintenance planning sets tasks and intervals; spare-parts analysis considers stock, service levels and lead times. Evaluate these decisions together against cost and availability targets.
  • How should we assess potential savings?: Compare an existing plan with alternatives using the same asset scope, cost inputs, availability target and time horizon. Review which changes drive the result and how failure-rate or lead-time assumptions affect it. Savings depend on the asset and the starting plan.