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Analyzing Reliability and Maintainability of Crawler Dozer BD155 Transmission Failure Using Markov Method and Total Productive Maintenance: A Novel Case Study for Improvement Productivity

Author

Listed:
  • Kartick Bhushan

    (Department of Mechanical Engineering, Indian Institute of Technology (Indian School of Mines), Dhanbad 826004, India)

  • Somnath Chattopadhyaya

    (Department of Mechanical Engineering, Indian Institute of Technology (Indian School of Mines), Dhanbad 826004, India)

  • Shubham Sharma

    (Mechanical Engineering Department, University Center for Research & Development, Chandigarh University, Mohali 140413, India
    School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China)

  • Kamal Sharma

    (Institute of Engineering and Technology, GLA University, Mathura 281406, India)

  • Changhe Li

    (School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China)

  • Yanbin Zhang

    (School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China)

  • Elsayed Mohamed Tag Eldin

    (Faculty of Engineering and Technology, Future University in Egypt, New Cairo 11835, Egypt)

Abstract

Surface mining is the world’s most costly industry due to its enormous expenses. Reduced production is forcing mining companies to automate their equipment, predominantly heavy earth mining machinery (HEMMs), for example, dump trucks, shovels, and dozers. The backbone of pit mining is the crawler dozer, commonly known as a dozer. Crawler dozers are tracked earth-moving machines with metal blades positioned in front for pushing materials such as rocks, soil, etc. In order to survive the harsh competition, dozers must be durable and adequately maintained. Crawler dozers work under challenging conditions to avoid production delays that result in losses such as breakdowns, transmission failures, and other issues in mining operations. Transmission failures, among other issues with dozers, are one of the hardest to resolve. This study evaluates the reliability, availability, and maintainability (RAM) of a BD155 crawler dozer transmission using failure and repair data and the Markov method. A realistic case study on (BD155) transmission failure and associated subsystems has been performed. Potential approaches and alternatives are also identified to increase dependability and performance. This article also discusses best maintenance practices for minimizing transmission failures and boosting productivity. The availability of the BD155 increases to 71% from 62% using proper planning and maintenance.

Suggested Citation

  • Kartick Bhushan & Somnath Chattopadhyaya & Shubham Sharma & Kamal Sharma & Changhe Li & Yanbin Zhang & Elsayed Mohamed Tag Eldin, 2022. "Analyzing Reliability and Maintainability of Crawler Dozer BD155 Transmission Failure Using Markov Method and Total Productive Maintenance: A Novel Case Study for Improvement Productivity," Sustainability, MDPI, vol. 14(21), pages 1-17, November.
    • Handle: RePEc:gam:jsusta:v:14:y:2022:i:21:p:14534-:d:963918
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    References listed on IDEAS

    as
    1. Prerita Odeyar & Derek B. Apel & Robert Hall & Brett Zon & Krzysztof Skrzypkowski, 2022. "A Review of Reliability and Fault Analysis Methods for Heavy Equipment and Their Components Used in Mining," Energies, MDPI, vol. 15(17), pages 1-27, August.
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    3. Barabady, Javad & Kumar, Uday, 2008. "Reliability analysis of mining equipment: A case study of a crushing plant at Jajarm Bauxite Mine in Iran," Reliability Engineering and System Safety, Elsevier, vol. 93(4), pages 647-653.
    4. Geeta Yadav & Dheeraj Joshi & Leena Gopinath & Mahendra Kumar Soni, 2022. "Reliability and Availability Optimization of Smart Microgrid Using Specific Configuration of Renewable Resources and Considering Subcomponent Faults," Energies, MDPI, vol. 15(16), pages 1-16, August.
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