Understand production performance
Estimate production, availability, expected failures and the operational behaviour of the complete system.
Reliability Digital Twin Software
Production-centric reliability simulation for complex industrial systems
AeROS® connects equipment reliability, maintenance strategy, system configuration, operating constraints and production flow—so engineers can understand consequences and compare alternatives before implementation.
AeROS® — Asset Reliability and Operations Simulation
Desktop application for Windows 10 or higher.
The AeROS Model
Connect the engineering system
Reliability data
Maintenance policies
Production flow
Resources and constraints
Production, loss, failures and resource demand
The Engineering Problem
Availability is only the beginning
Two systems can report similar availability yet deliver very different production outcomes. Bottlenecks, storage, redundancy, operating rate, maintenance resources and the location of each failure all influence the final consequence.
AeROS represents these relationships in a Reliability Digital Twin. Simulation then shows how equipment behaviour propagates through the production system, making the assumptions and trade-offs behind engineering decisions visible.
Engineering Decisions
Understand what changes—and why
AeROS is designed to help engineers investigate specific decisions, not merely calculate another availability value.
Quantify failure consequences
Use Critical Loss and Local Loss to distinguish equipment downtime from its actual contribution to system production loss.
Compare engineering alternatives
Test configurations, operating strategies, reliability improvements and maintenance policies before implementation.
Plan maintenance resources
Evaluate how crew, spare availability and restock policies influence maintenance and production outcomes.
Modelling Capabilities
Connect reliability, production and operations
AeROS® goes beyond traditional Reliability Block Diagram (RBD) modeling by combining reliability analysis, production system simulation, and operational constraints within a single Reliability Digital Twin environment. It helps engineers quantify how equipment reliability, maintenance strategies, operational uncertainty, and system constraints affect production performance.
Advanced Reliability Modeling
- Supports both repairable equipment-level models and non-repairable component-level life models.
- Features Life-Stress Models based on cumulative damage theory to quantify the impact of production rate on equipment reliability.
- Supports load-sharing configurations where equipment reliability depends on production allocation.
- Supports Time-To-First-Failure analysis for mission, campaign, and early-life reliability studies.
- Enables user-defined CDFs for custom random event modeling.
Production-Centric Simulation
- Models production systems using flow conservation principles to represent realistic production behavior.
- Models flowrate variations using Flowrate Profile constructs.
- Provides a Storage construct for buffering with configurable Full, Empty, High, and Low threshold events.
- Provides a Startup construct to simulate restart delays caused by hidden failure modes.
- Includes a Redundant Resource Manager for complex standby and shared-resource scenarios.
Operational Constraints & Resource Planning
- Incorporates crew and spare-part constraints for realistic maintenance and production scenarios.
- Provides specialized plots for System Availability, System Flowrate, and Spare Availability.
- Features Spare Restock Optimization batch calculations to support spare-parts planning.
Performance Analysis & Improvement Planning
- Quantifies the impact of equipment failures using Critical Loss and Local Loss metrics.
- Includes a Reliability Improvement Allocation tool to identify high-value improvement opportunities.
- Features a Tristate Plot to visualize each item’s operating state—running, standby, or down—alongside its production rate profile, helping users validate and debug complex reliability digital twins.
- Helps identify performance gaps and quantify risks for targeted improvements.
From Data to Model
Built-in Reliability Data Analysis
AeROS includes built-in Life Data and Recurring Event analysis tools allowing reliability parameters to be estimated directly within the AeROS environment.
Users can analyze failure time data, suspension data, and recurring event data without exporting the dataset to external reliability software. The analysis results can then be immediately used in the simulation model.
This integrated capability provides several advantages:
- Seamless workflow from data preparation to simulation
- Consistent reliability assumptions between analysis and RAM modeling
- Faster model development without switching between multiple software tools
historical failure data → reliability modeling → production and availability simulation.
Applied Engineering
Examples and case studies
Explore how reliability simulation can be applied to production systems, maintenance resources, storage, load sharing and other engineering questions.
Availability as a Reliability Metric in RAM StudiesQuantifying Equipment Contributions to Production Loss Within a Production NetworkRAM Analysis of an Offshore PlatformInventory Management - Spare Restock Triggering PolicyEstimating Field Return Distribution Based on Reliability Test Results and Surveyed Usage ProfilesProduction Impact of Supply Quantity Variations: A Queueing Theory Approach Using AeROSOptimizing Buffer Tank Size in Chemical Processes Under Equipment Reliability ConstraintsModeling and Simulating a Renewable Energy System for Performance AnalysisA RAM analysis for Consecutive-K-out-of-N data communication systemRAM Modeling containing Items with Hidden Failure ModeThe Hidden Cost of Load Sharing in Production Systems
Customer Evidence
Developed through industrial application
AeROS continues to evolve through engineering work with organisations operating complex, production-critical assets.
AeROS is remarkably user-friendly with features that significantly enhance workflow efficiency. The cost of ownership is substantially lower than comparable RAM software solutions in the market.
Principal Engineer
Petronas Carigali Sdn Bhd
The advanced features in AeROS enable realistic production process modeling unmatched by other reliability simulation tools. This capability provides exceptional confidence in production system risk assessments.
Project Manager
Leading Refinery Plant in Indonesia
Start with the engineering decision
Tell us about the asset, operating context, available information and decision you need to support. We can help determine whether AeROS is the appropriate approach.