Development of a Methodology for Optimizing Repair Intervals of Open-Pit Mining Equipment Units

Abstract

This article proposes a methodology for optimizing the maintenance intervals of mining equipment components, using the example of steering cylinders in CAT 16M and 16M3 motor graders operated by KazMinerals Bozshakol mining enterprise. The study is based on the analysis of actual production statistics from 2018 to 2025, including both scheduled and unscheduled repairs. Causes of failures and component operational resources were quantitatively assessed using MTBF (Mean Time Between Failures) and MTBS (Mean Time Between Services) indicators. The calculations identified two optimal maintenance intervals — 7000 and 12000 engine hours. These intervals are tailored to actual operating conditions and are aimed at preventing unexpected failures while making maintenance strategies more flexible and effective. The method allows for adaptive scheduling of maintenance activities, based on real-world operational data, and ensures more efficient utilization of equipment resources. Moreover, the proposed approach improves the reliability of production processes, reduces unnecessary expenses, and optimizes the overall maintenance workflow.