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Abstract

The design and implementation of a preventive maintenance plan in the Ecuadorian mining industry requires systematic methodologies to reduce failures in crushing and grinding machines, improving operational availability and productivity. The main problem identified is the reliance on corrective maintenance with no historical records of failures, which causes unexpected shutdowns. This study applies the FMEA (Failure Mode and Effects Analysis) methodology to evaluate the criticality of equipment using the Risk Priority Number (NPR), complemented with the Weibull distribution to model useful life times (Flores et al., 2020). Key equipment such as the ball mill and jaw crusher at a mining beneficiation plant were analyzed. The results indicate that 25% of the subcomponents have NPR > 300 (unacceptable risk), mainly concentrated in structural elements subjected to severe operating conditions. The implementation of the proposed preventive plan is estimated to reduce unplanned shutdowns by 40–50%, increasing availability from 73% to 90%. Weibull integration provides a robust statistical framework for the transition from reactive maintenance to predictive schemes, optimizing intervention intervals and extending the life of critical assets

Fields of Study & Subjects

Reliability and Maintenance Optimization Power System Reliability and Maintenance Management and Optimization Techniques

Publication details

Journal / source
STUDIES IN MULTIDISCIPLINARY REVIEW
Volume
7
Issue
1
Pages
xxx–xxx
Publication date
3 March 2026
Language
EN