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Abstract: Equipment plays an important role in open pit mining industry and its cost competence at efficient operation and
maintenance techniques centered on reliability can lead to significant cost reduction. The application of optimal maintenance process
was investigated for minimizing the equipment breakdowns and downtimes in Sungun Copper Mine. It results in the improved
efficiency and productivity of the equipment and lowered expenses as well as the increased profit margin. The field operating data of
10 trucks are used to estimate the failure and maintenance profile for each component, and modeling and simulation are
accomplished by using reliability block diagram method. Trend analysis was then conducted to select proper probabilistic model for
maintenance profile. Then reliability of the system was evaluated and importance of each component was computed by weighted
importance measure method. This analysis led to identify the items with critical impact on availability of overall equipment in order
to prioritize improvement decisions. Later, the availability of trucks was evaluated using Monte Carlo simulation and it is revealed
that the uptime of the trucks is around 11000 h at 12000 operation hours. Finally, uncertainty analysis was performed to account for
the uncertainty sources in data and models.
Key words: operating costs; maintenance; mining dump truck; reliability; availability; uncertainty
and reliability functions. The Markov chain method is limited on the maintenance operation analysis of mine
also used to evaluate the performance and availability of trucks only.
some repairable systems [29]. This is a direction for
system analysis which is not used in this work. 4.1 Data collection
Collection of failure data was the first phase in this
4 Case study project. The failure data come from different sources like
field data, generic data, test and inspection data. Due to
Sungun Copper Deposit is the second largest copper availability of the collected field data, the modeling and
mine in Iran. Geological reserve of the deposit is analysis are mostly performed by utilization of this field
estimated up to 828 million tons with average copper data. The database is composed of operation time, age of
grade of 0.62%. The mine operation is managed in the the trucks, maintenance data recorded for the trucks
mine site by employing a fleet of 52 and 20 Komatsu 32 components. The maintenance and operational data were
and 100 ton trucks, respectively, 11 Caterpillar 988 collected in time interval of 20102011. The equivalent
loader, 1 Liebherr 17 cubic meter shovels, 8 Komatsu operation times for a month and a year are approximately
PC800 excavators and 9 drilling rigs. This work is considered as 500 and 6000 h, respectively.
J. Cent. South Univ. (2014) 21: 23722382 2375
A main obstacle in data collection process was the reliability block diagram was developed for the system
deficiency of adequate data for the appropriate statistical based on its structure. Due to the design configuration of
analyses. There are methods to deal with this situation the truck system, the operations of considered sub-
including expert judgment [30], Bayesian updating systems were required for mission success of the dump
method [31], and combination of homogenous data truck. Therefore, the weakest link model was found a
method (similar parts of the equipment). Accordingly, it proper model for this purpose.
is assumed that the maintenance data are homogenous in
this work. Therefore, the combination of homogenous 4.3 Trend analysis
data technique is applied to deal with the scarcity of data. Non-parametric methods are alternatives for analysis
This method is appropriate for the fleet of equipment or of the failure and repair data trend. This analysis provides
the systems with dominant identical components and a curve of the mean cumulative function for mean number
similar condition [32]. The assumptions are made in a of failure at specified time against service lifetime to
way that the design, hardware, function, operation illustrate the trend of failure data during total period [34].
conditions, procedures, system structure, location and
If the failure data plot results a straight line, it is
environment are all similar [18]. Moreover, the age of
concluded that there is no trend. Based on this analysis,
dump trucks was a major factor for justification of the
each unit is composed of a staircase function that
identical conditions of trucks. Since each system has an
demonstrates the cumulative number of failures for a
intrinsic different failure random behavior at its service
particular event. Finally, regression of the generated
lifetime, in this work, 10 dump trucks are chosen with
points describes the trend procedure. Also, assembly of
the age of approximately 15000 operation hours. This
units generates a set of staircase curve of each unit in the
age is in the region of useful lifetime of trucks. In the
population, so that the mean cumulative number of
useful lifetime, the failure mostly occurs under a
failures is estimated. The serial correlation test is used
systematic process whereas the failure behavior for a
for studying the independence of the failure data. Serial
new system is based on the infant failure and in older
systems, the failure occurs in wear out region. correlation plot is based on i-th lifetime failure against
(i1)-th one. If only one cluster of points is generated
4.2 Modeling of system then no trend is observed. The trend exists if two or more
The system of dump truck is decomposed to its clusters, or a straight line is generated [18]. Probability
sub-systems and components in order to analyze the plot is used for estimating the statistical distribution
system reliability. Figure 2 demonstrates the hierarchical parameters when the failure data follow IID condition
decomposing of dump truck system into the main sub- whereas the GRP method is used whenever the failure
systems and also further decomposition of each data demonstrate a trend. The testing trend and serial
sub-system into its components. The failure mode and correlation for braking sub-system shows that the IID
effect analysis approach were conducted to assess the condition is obtained as shown Fig. 3 and Fig. 4,
significant failure modes for each component [33]. The respectively.
component i is critical to system failure and is calculated Fig. 6 Measuring reliabiltity importance for all of transmision
by components at 500 operation hours
the calculations and results. It includes approximations, maintenance policies). Random variable sampling is
assumptions, sampling errors, selecting probability designed for variables with considering the dependency
distribution functions, models for estimation of statistical among them if significantly available. This process is
parameters and simulation process. Methods for repeated for sufficient sample size to estimate
estimation of input uncertainty include maximum availability values. A typical sampling for k elements in n
likelihood estimation, Bayesian, maximum entropy. iterations for estimating of availability function is given
Propagation of uncertainty also affects the results. by
Several methods exist for uncertainty propagation
x11 , x12 , , x1k A(t )1
including Monte Carlo simulation, response surface
method, method of moments and bootstrap sampling [29]. x12 , x22 , , xk2 A(t ) 2
(10)
Monte Carlo simulation is used here for propagation of
uncertainties. This method is designed based on x n , x n , , x n A(t ) n
1 2 k
probabilistic models and statistical sampling. Monte
Carlo method procedure is composed of sampling from where xkn is k-th parameter in n-th iteration, and A(t) is
CDF of each xi parameter that is involved in availability the availability value.
estimation (reliability distribution functions and Confidence intervals method is utilized for
J. Cent. South Univ. (2014) 21: 23722382 2381
presenting uncertainty of the estimated results. In this centered maintenance is evaluated for the Komatsu
method, a boundary with acceptable confidence level is mining trucks at the Sungun Copper Mine. The analysis
associated with the estimated response variable. The process is comprised for both repairable and non-
confidence bounds are calculated by Fisher Matrix repairable items. The reliability analysis is implemented
approach on censored data [36]. According to this for each sub-system at various mission time. The
method, the mean and variance of the availability probabilistic failure process modeling is performed for
function is determined. Maximum likelihood estimation repairable and non-repairable items using the GRP and
is used for point estimation of statistical parameters. RP methods, respectively. The importance measure
Determination of variance and covariance of the MLE analysis indicates that the wheels are the most critical
parameters matrix is obtained by the inverse of Fisher component. Later, the analysis based on the availability
Matrix: indicates that the mean availability of the dump truck is
var( x1 ) cov( x1 , x2 ) cov( x1 , xi ) 91.8% at 12000 operation hours. The uncertainty
cov( x , x ) var( x2 ) cov( x2 , xi ) analysis is done to find the confidence interval of the
1 2
F 1 (11)
estimated equipment reliability and availability. Research
findings are provided to the maintenance management
cov( x1 , xi ) cov( x2 , xi ) var( xi )
team for planning better decisions about the maintenance
1
2 2 2 operation, condition monitoring of the critical items,
2
x1 x2 x1 xi inventory of the spare parts and their re-order level
x1
2 2 2 which leads to reduction in the equipment downtime.
F 1
x x x22
x2 xi (12) This leads to an improvement of the equipment
1 2
productivity and reduction of the operating costs. The
2 2 2 future researches are planned about maintenance
optimization and preventive maintenance intervals.
x1 xi x2 xi xi2
where xi is the statistical parameters, F1 is inverse of the Acknowledgment
Fisher Matrix, is the log-likelihood function. Authors wish to appreciate the support of the
The upper and lower intervals for mean availability Maintenance Department of Mobin Co. and Sungun
values at 12000 operation hours by using Monte Carlo Copper mine.
simulation uncertainty propagation method with
considering 500 iterations and confidence interval 95% Nomenclature and abbreviations
are given in Fig. 8. CMD Complete data
CND Censored data
CDF Cumulative distribution function
DFI Decreasing failure intensity
EXP Exponential
GRP Generalized renewal process
IFI Increasing failure intensity
IID Identical and independent distribution
K-S Test Kolmogorov-Smirnov test
LK Likelihood value
ML Log-mean
NL Log-normal
SL Log-standard deviation
Fig. 8 Boundary intervals for mean availability function at M Mean
12000 operation hours MLE Maximum likelihood estimation
NHPP Non-homogenous Poisson process
5 Conclusions N-2P Normal-2 parameters
PLP Power law process
The RAM analyses are essential in the maintenance
of the heavy machinery as productivity of the equipment PDF Probability density function
strongly depends on it. In this work, the reliability- RAM Reliability, availability and maintainability
2382 J. Cent. South Univ. (2014) 21: 23722382
RF Restoration factor and maintainability analysis [D]. Sweden: Lule University of
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S Standard deviation
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Correlation coefficient of load-haul-dump vehicles in an underground hard rock mine [J].
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