Mining Goes Digital – Mueller et al. (Eds)
© 2019 Taylor & Francis Group, London, ISBN 978-0-367-33604-2
534
An integrated simulation model for opportunistic maintenance
O. Golbasi
Middle East Technical University, Ankara, Turkey
M. Olmez Turan
Colorado School of Mines, Golden, USA
C. Karpuz
Middle East Technical University, Ankara, Turkey
ABSTRACT: Maintenance policies embody various work packages with different intention
of implementation. When and how to perform these work packages for which equipment is
always a problem that needs to be solved specific to the machine itself. Since a surface mining
operation is carried out generally in demanding working conditions and multiple equipment
hold an operational dependency to accomplish a production cycle, it may be tough to
constitute the scope and content of the related maintenance policy. Although the literature
on maintenance modelling commonly concentrates on corrective repairing and preventive
replacement, opportunistic maintenance that investigates whether an opportunity exists for
the proactive maintenance of a running component in case of failure of another dependent
component is not discussed as required. Indeed, opportunistic maintenance is practically
observed at mine sites. In this basis, the current study aims to develop an integrated simulation
model that considers mathematical interaction of corrective, preventive and opportunistic
maintenance, and their effects on stochastic uptime and downtime behavior of systems.
A numerical example applied for multiple shovels is also provided to highlight the outcomes
of the developed model.
1 INTRODUCTION
Maintenance policy modelling may be defined as obtaining and comparing feasible solutions
in the policy content with an objective function that intends to maximize equipment availability or minimize direct, indirect or combinational cost factors. In such a model, the model
constraints may cover various factors such as, inventory limits, budget, reliability threshold,
and production target. At this point, the model scope highly depends on the type of equipment to be maintained, and the maintenance activities that need to be practical and beneficial
against the deterioration in equipment components.
The relevant literature generally classifies maintenance implementations in two main
groups as corrective and preventive. Corrective maintenance has a run to failure strategy,
and be applied after failure occurrence. It may be divided into two subcategories as immediate and deferred corrective maintenance. They are valid for the cases where the negative consequences of a component failure should be removed immediately or maintenance may be
delayed since the damaged component is not operationally critical, respectively. On the other
hand, preventive maintenance requires a scheduled and/or technological interference for the
upcoming failures to prevent both component and production damages beforehand. Maintenance implementation with predetermined time intervals, condition-based maintenance,
and opportunistic maintenance are considered as the branches of preventive maintenance.
In this basis, preventive repairing or replacement of specific components in predetermined
time intervals may be financially feasible in some circumstances. On the other hand, some
© 2019 Taylor & Francis Group, London, ISBN 978-0-367-33604-2
534
An integrated simulation model for opportunistic maintenance
O. Golbasi
Middle East Technical University, Ankara, Turkey
M. Olmez Turan
Colorado School of Mines, Golden, USA
C. Karpuz
Middle East Technical University, Ankara, Turkey
ABSTRACT: Maintenance policies embody various work packages with different intention
of implementation. When and how to perform these work packages for which equipment is
always a problem that needs to be solved specific to the machine itself. Since a surface mining
operation is carried out generally in demanding working conditions and multiple equipment
hold an operational dependency to accomplish a production cycle, it may be tough to
constitute the scope and content of the related maintenance policy. Although the literature
on maintenance modelling commonly concentrates on corrective repairing and preventive
replacement, opportunistic maintenance that investigates whether an opportunity exists for
the proactive maintenance of a running component in case of failure of another dependent
component is not discussed as required. Indeed, opportunistic maintenance is practically
observed at mine sites. In this basis, the current study aims to develop an integrated simulation
model that considers mathematical interaction of corrective, preventive and opportunistic
maintenance, and their effects on stochastic uptime and downtime behavior of systems.
A numerical example applied for multiple shovels is also provided to highlight the outcomes
of the developed model.
1 INTRODUCTION
Maintenance policy modelling may be defined as obtaining and comparing feasible solutions
in the policy content with an objective function that intends to maximize equipment availability or minimize direct, indirect or combinational cost factors. In such a model, the model
constraints may cover various factors such as, inventory limits, budget, reliability threshold,
and production target. At this point, the model scope highly depends on the type of equipment to be maintained, and the maintenance activities that need to be practical and beneficial
against the deterioration in equipment components.
The relevant literature generally classifies maintenance implementations in two main
groups as corrective and preventive. Corrective maintenance has a run to failure strategy,
and be applied after failure occurrence. It may be divided into two subcategories as immediate and deferred corrective maintenance. They are valid for the cases where the negative consequences of a component failure should be removed immediately or maintenance may be
delayed since the damaged component is not operationally critical, respectively. On the other
hand, preventive maintenance requires a scheduled and/or technological interference for the
upcoming failures to prevent both component and production damages beforehand. Maintenance implementation with predetermined time intervals, condition-based maintenance,
and opportunistic maintenance are considered as the branches of preventive maintenance.
In this basis, preventive repairing or replacement of specific components in predetermined
time intervals may be financially feasible in some circumstances. On the other hand, some