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

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.