Development of a Methodology for Optimizing Repair Interval Timing for Mining Equipment Units
Kadyrov A. Kukesheva A. Daribzhan M. Aidraliyev A.
December 2025Multidisciplinary Digital Publishing Institute (MDPI)
Eng
2025#6Issue 12
This study presents a methodology for optimizing repair intervals of mining equipment by integrating economic efficiency and reliability criteria. A review of existing maintenance strategies revealed their limitations, and a mathematical model was developed that incorporates both projected financial expenditures and the probability of equipment failures, enabling more accurate prediction of the optimal repair timing. This study introduces a novel integration of the Weibull reliability distribution with a cost-convolution optimization model, explicitly capturing the trade-off between economic efficiency and failure risk. Unlike traditional fixed-schedule approaches, the proposed model provides analytically optimized repair intervals derived from observed degradation trends. Statistical analysis demonstrates that unplanned repairs are, on average, 56% more costly than scheduled ones, highlighting the need to revise current preventive maintenance practices. The cost comparison is based on 34 restoration records collected from publicly available supplier price lists and field maintenance logs, converted into a unified currency. Based on operational data and reliability parameter estimation, the optimal repair interval was determined to be 5129 machine hours, which minimizes both the probability of failure and total maintenance-related financial losses, while reducing unplanned downtime. Unlike traditional fixed-schedule approaches, the proposed model allows adaptive adjustment of maintenance intervals according to the actual degradation characteristics of the equipment. The practical significance of the research lies in its ability to help mining enterprises reduce expenditures on corrective repairs, extend the service life of machinery, and improve overall operational efficiency. The findings contribute to advancing maintenance optimization in the mining industry, supporting more sustainable and cost-effective equipment management.
economic efficiency , equipment availability , maintenance cost analysis , mining equipment , preventive maintenance , reliability modeling , repair interval optimization , unplanned downtime , Weibull distribution
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Department of Transport Engineering and Logistics Systems, Faculty of Transport, Logistics and Engineering Economics, Non-Profit Joint-Stock Company “Abylkas Saginov Karaganda Technical University”, 56 Mira Boulevard, Karaganda, 100027, Kazakhstan
KazMinerals Bozshakol, Ekibastuz, 141200, Kazakhstan
Department of Transport Engineering and Logistics Systems
KazMinerals Bozshakol
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