Two engineers in hard hats and hi-vis inspecting rooftop cooling plant at a data centre
Data centres

Turning a complex maintenance plan into a schedule the operator could trust

How QTS replaced an expert-built spreadsheet process with a constraint-based maintenance plan for a 45MW hyperscale data centre, then compressed twelve months of work into nine and a half when the build programme changed.

12 months into 9.5After the build programme changed

45MWsite scheduled end to end
12 → 9.5months, after the handover programme changed
3build phases coordinated into one maintenance plan
12equipment classes scheduled through one controlled calendar

The challenge

QTS needed to build the planned preventive maintenance schedule for a new 45MW hyperscale data centre containing thousands of assets across twelve equipment classes and three separate construction handover phases. Every maintenance date depended on a network of operational constraints: redundant systems couldn't be taken offline together, cooling equipment had seasonal restrictions, and some assets shared physical spaces or needed maintenance in a defined sequence.

The existing plan, built manually by experienced, time-poor in-house individuals, was inconsistent and flawed. The problem was the thousands of interconnected decisions adding pressure and mismatches in scheduling: there was no simple way to demonstrate every rule had been respected. The plan depended on the sustained concentration of one experienced individual who also had a new site to bring into operation.

What we changed

Optia converted QTS's maintenance requirements into a constraint-based scheduling model. The model understands which systems provide redundancy for one another, accounts for relationships between generators, UPS equipment and transfer systems, and encodes seasonal restrictions and shared service spaces directly, so it cannot produce a valid schedule unless the constraints are satisfied.

Once critical rules are satisfied, the model optimises how work is distributed so maintenance doesn't cluster into unmanageable peaks. Daily service volumes are capped and work is sequenced across the building to cut unnecessary movement of engineers and specialist equipment. The final deliverables included the maintenance schedule, a monthly planning view and a validation file, with Excel deliberately retained as the primary output to match how site engineers and leadership needed to work.

When the site handover programme moved, the maintenance workload originally planned across twelve months had to fit into approximately nine and a half. Optia reconfigured the model around the revised dates and returned a new plan within five days, preserving the agreed redundancy, sequencing and operational constraints.

The results

QTS received a fully deconflicted annual maintenance calendar covering the 45MW site, giving a controlled basis for committing dates to engineers and vendors. When the construction programme changed, the same approach compressed twelve months into nine and a half and produced the revised schedule within five days. The European implementation has since become a reference point for the wider organisation, with interest from the US team in applying the same model.

In their words

“I couldn't have done this confidently whilst doing all the other work that I've needed to do. You have been able to take that off my plate and you provided a PPM planner, which is exactly what I asked for. So it is everything.”

Operational Readiness Director, QTS

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