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Article
Publication date: 1 October 2019

Balaraju Jakkula, Govinda Raj M. and Murthy Ch.S.N.

Load haul dumper (LHD) is one of the main ore transporting machineries used in underground mining industry. Reliability of LHD is very significant to achieve the expected targets…

495

Abstract

Purpose

Load haul dumper (LHD) is one of the main ore transporting machineries used in underground mining industry. Reliability of LHD is very significant to achieve the expected targets of production. The performance of the equipment should be maintained at its highest level to fulfill the targets. This can be accomplished only by reducing the sudden breakdowns of component/subsystems in a complex system. The identification of defective component/subsystems can be possible by performing the downtime analysis. Hence, it is very important to develop the proper maintenance strategies for replacement or repair actions of the defective ones. Suitable maintenance management actions improve the performance of the equipment. This paper aims to discuss this issue.

Design/methodology/approach

Reliability analysis (renewal approach) has been used to analyze the performance of LHD machine. Allocations of best-fit distribution of data sets were made by the utilization of Kolmogorov–Smirnov (K–S) test. Parametric estimation of theoretical probability distributions was made by utilizing the maximum likelihood estimate (MLE) method.

Findings

Independent and identical distribution (IID) assumption of data sets was validated through trend and serial correlation tests. On the basis of test results, the data sets are in accordance with IID assumption. Therefore, renewal process approach has been utilized for further investigation. Allocations of best-fit distribution of data sets were made by the utilization of Kolmogorov–Smirnov (K–S) test. Parametric estimation of theoretical probability distributions was made by utilizing the MLE method. Reliability of each individual subsystem has been computed according to the best-fit distribution. In respect of obtained reliability results, the reliability-based preventive maintenance (PM) time schedules were calculated for the expected 90 percent reliability level.

Research limitations/implications

As the reliability analysis is one of the complex techniques, it requires strategic decision making knowledge for the selection of methodology to be used. As the present case study was from a public sector company, operating under financial constraints the conclusions/findings may not be universally applicable.

Originality/value

The present study throws light on this equipment that need a tailored maintenance schedule, partly due to the peculiar mining conditions, under which they operate. This study mainly focuses on estimating the performance of four numbers of well-mechanized LHD systems with reliability, availability and maintainability (RAM) modeling. Based on the drawn results, reasons for performance drop of each machine were identified. Suitable recommendations were suggested for the enhancement of performance of capital intensive production equipment. As the maintenance management is only the means for performance improvement of the machinery, PM time intervals were estimated with respect to the expected rate of reliability level.

Details

Journal of Quality in Maintenance Engineering, vol. 26 no. 2
Type: Research Article
ISSN: 1355-2511

Keywords

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Article
Publication date: 22 July 2020

Balaraju Jakkula, Govinda Raj Mandela and Murthy Ch S N

In the present worldwide situation, the survival of a business is a major crucial aspect. The business cannot be succeeded unless it produces the anticipated production levels…

919

Abstract

Purpose

In the present worldwide situation, the survival of a business is a major crucial aspect. The business cannot be succeeded unless it produces the anticipated production levels. Achievement of this can be possible only by maintaining the equipment into an adequate level. Load-Haul-Dumpers (LHDs), as the main workhorse and massive transporting machines, are highly utilized in underground mining operations. Despite the usage of LHDs, these are prone to the uneven and unexpected occurrence of potential failures. These are causes to minimize the production and productivity of capital intensive equipment. To get a good profitability index, it is very necessary to have the required levels of equipment reliability and availability. Estimation of reliabilities and availabilities play a critical role in the performance evaluation of equipment.

Design/methodology/approach

By keeping the significance of the present research work in view in this research paper one of the well appropriate techniques such as fault tree analysis (FTA) was utilized to assess the reliability of the LHD system based on the function flow diagram. Best fit distribution of data sets were made by the utilization of Kolmogorov–Smirnov (K-S) test. Parametric estimation of theoretical probability distributions was done by utilizing the maximum likelihood estimation (MLE). Failure rate of each LHD system has computed based on the best fit results from “Isograph Reliability Workbench 13.0”. Reliability configuration of each LHD system has modeled using reliability block diagram (RBD), as well as the FTA.

Findings

Independent and identical distribution (IID) assumption of data sets was validated through statistic U-test (Chi Squared test). On the basis of test results, the data sets are in accordance with IID assumption. Therefore renewal process approach has been utilized for further investigation. Allocations of best fit distribution of data sets were made by the utilization ofK-S test. Parametric estimation of theoretical probability distributions was made by utilizing maximum likelihood estimation (MLE) method. Reliability of each individual subsystem has been computed according to the best fit distribution. The deductive method called RBD was utilized to investigate the given system reliability by analyzing with graphical representations of logic system and observed highest percentage of reliability as 69.44% (LH29). FTA has been utilized to investigate the availability percentage of a system and observed highest percentage value as 79.51% (LH29). This technique also helps to identify the most critical parts/cut sets by using Fussell-Vesely (F-V) importance measure.

Research limitations/implications

As the reliability analysis is one of the complex techniques, it requires strategic decision-making knowledge for the selection of methodology to be used. As the present case study was from a public sector company, operating under financial constraints the conclusions/findings may not be universally applicable.

Originality/value

The present study throws light on this equipment that need a tailored maintenance schedules, partly due to the peculiar mining conditions, under which they operate. This analysis provides the information on several aspects such as present working condition of the machines, occurrence of various potential failure modes, influence of failure modes on its performance and reliable life aspects etc. Also, these investigations asses the forecasting of necessary managerial practices or control measures like possible design modifications and replacement actions of components to ensure the required levels of availability and utilization of the equipment. Both qualitative and quantitative analysis of FTA has been performed to determine the minimal/most influencing cut sets of the system and to estimate overall system availability within the work environment. Based on the computed results reasons for performance drop of each machine was identified and suitable recommendations were suggested to improve the performance of capital intensive systems.

Details

International Journal of Quality & Reliability Management, vol. 38 no. 3
Type: Research Article
ISSN: 0265-671X

Keywords

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