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SIMULATION-BASEDOPTIMIZATIONOFMAINTENANCECREWCONFIGURATIONIN
MININGSITES
MADENSAHALARINDABAKIM-ONARIMEKİBİYAPILANDIRMASININSİMÜLASYONTABANLI
OPTİMİZASYONU
S.F.Sahiner
,*
,O.Golbasi
1
1
MiddleEastTechnicalUniversity,MiningEngineeringDepartment
(*CorrespondingAuthor:fsahiner@metu.edu.tr)
ÖZ
Madencilik sektörü, insan kaynağı, kanıtlanmış rezerv ve ekipman filosu gibi kısıtlı kaynakların
verimliveetkileşimliolarakkullanılmasınıgerektirenbirüretimsektörüdür.Madencilikşirketleri,maksimum
üretkenlikveverimliliğisağlamakamacıyla,bukaynaklararasındahassasbirdengekurmalıdırlar.Birmaden
işletmesininenkritikbölümlerindenbirisi,ekipmanfilosununoperasyonelkalımlılığıvegüvenilirliğinidevam
ettirmeyeyönelikbakımveonarımfaaliyetlerinigerçekleştirenveplanlayanbakımveonarımbölümüdür.Bu
bölümler,farklıteknik yeterlilik ve branşlardainsankaynağınaihtiyaç duymaktadırlar.Bir bakımve onarım
bölümüiçingereklifarklıniteliklerdekipersonelsayısı,ilgilimadencilik operasyonundaçalışanekipmanlar,
bunların maruz kaldıklarıarıza modları,bu arızaların ortaya çıkış frekansları ve sonrasında gerçekleştirilen
onarım sürelerigibifaktörlerdenetkilenmektedir.Arızafrekansları,bakımveonarımsürelerive arızamodu
için görevlendirilen çalışan sayısı gibi belirsizlikler farklı seviyelerdemevcut olup, belirsizliğin arttığı
durumlarda çalışan noksanlığına bağlı olarak bakım ve onarım yapılamama durumları da sıklıkla
gözlenmektedir. Bir sahada, gereğinden fazla personelin çalıştırılması bakım ve onarım faaliyetlerinin
zamanında yapılmasına olanak sağlarken, yüksek fiziki giderlere de neden olmaktadır. Bu durum, bakım-
onarımpersoneliazlığıveçokluğudurumlarındaoluşabileceküretimkayıplarıvefizikimasraflararasındabir
değiş-tokuşnoktasıyanioptimizeedilmesi gerekli birproblemiyaratmaktadır. Mevcut araştırma çalışması,
işleyen bir maden alanında farklı ekipman ve arıza modu davranışlarını dikkate alan ve buna göre farklı
branşlarda gerekli bakım ve onarım personel sayılarını optimize etmeye çalışan bir simülasyonmodelinin
oluşturulmasını amaçlamaktadır. Böylelikle; model, maksimum verimlilik ve performansı sağlamakiçin
gereklipersonellerifarklıekipmanarızamodlarınatahsisetmeyihedeflemektedir.
Anahtar Sözcükler: Sürekli-OlaySimülasyonu, Optimizasyon,Bakım ve Onarım,Madencilik,Makineve
Ekipman,İşgücü
IMCET2023/ANTALYA/TÜRKİYE/November28-December1
541
Cite as: Sahiner, S. F. and Golbasi, O. (2023). Simulation-Based Optimization of Maintenance Crew Configuration in Mining Sites.
Proceedings of the 28th International Mining Congress and Exhibition of Türkiye (pp. 541-549). Antalya: UCTEA Chamber of Mining Engineers.
ABSTRACT
The minin g sector is a produc tion industry that re quires the effic ient and interacti ve use of limited
resourcessuchashumanresources,provenreserves,andequipmentfleets.Miningcompaniesmustestablisha
delicatebalanceamong theseresourceswiththeaimofachievingmaximumproductivityandefficiency.One
ofthemostcriticaldepartmentsofaminingoperationisthemaintenanceandrepairdepartmentresponsiblefor
performingandplanningmaintenanceandrepairactivitiestoensuretheoperationalreliabilityandreliability
oftheequipmentfleet.Thesedepartmentsrequirehumanresourceswithdifferenttechnicalcompetenciesand
specialties. The number of personnel with different qualifications required for a maintenance and repair
departmentisinfluencedbyfactors suchasthe equipmentused inthe relevant miningoperation,thefailure
modes t hey are exposed t o, the frequencie s at which these failures occur, a nd the subsequ ent repair times.
Uncertaintiessuchasfailurefrequencies,repairtimes,andthenumberofemployeesassignedtofailuremodes
often exist at differentlevels, andinsituations whereuncertaintyincreases,casesofmaintenanceandrepair
notbeingcarriedoutduetoashortageofpersonnelarefrequentlyobserved.Employinganexcessivenumber
ofpersonnelinthefieldallowsmaintenanceandrepairactivitiestobecarriedoutontimebutalsoleadstohigh
physicalexpenses.Thissituationcreatesatrade-offpointbetweenproductionlossesandphysicalexpensesthat
needtobeoptimizedwhenitcomestotheshortageorexcessofmaintenanceandrepairpersonnel.Thecurrent
research aims to create a simulation model that takes into account different equipment and failure mode
behaviorsinaworking miningarea and attemptsto optimizetherequiredmaintenanceandrepairpersonnel
numbers in different specialties accordingly. Thus, the model aims to allocate the necessary personnel to
differentequipmentfailuremodestoachievemaximumefficiencyandperformance.
Keywords: ContinuousEventSimulation,Optimization,MaintenanceCrew,Mining,Workforce
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INTRODUCTION
With mass production and gl obalization improvem ents, machines hav e become crucial in various
manufacturingsectors.Consequently,astrongcorrelationbetweenproductionoperationsandmaintenancehas
become e ssential for the overall success of com panies. Equipment m alfunctions can dire ctly or indirectly
disruptproduction,resultinginsignificantfinanciallosses.Therefore,ithasbecomeimperativeforproduction
companies to establish a competent and well-organized maintenance department with a skilled workforce
possessingdiversecompetenciestoensureuninterruptedproduction.Intheminingsector,whichheavilyrelies
onmachinery, miningcompanies mustalso establish efficient maintenance departmentsin their operational
areas.Mining equipmentvariesincomplexityandis used insurface mines,underground mines,andmineral
processingfacilities, facing multiple failuremodes thatdemanddifferent maintenanceactions. Maintenance
workshops comprise units and employees with diverse qualifications in mining areas. Additionally, the
maintena nce policies in mining are diver se and complex, with main tenance work repres enting a substantial
shareoftheoperatingcost.Therelationshipbetweenmaintenanceandoperatingcostsintheminingindustry
has been extensively discussed in various studies and literature. The findings reveal several important
observatio ns; for instance , equipment m aintenance cos t in mining con stitutes a signifi cant portion, ran ging
from20% to 35%,ofthetotal operating cost(Unger and Conway,1994).Inspecific regionslike Chileand
Indonesia, m aintenance cos ts for surface min es surpass 60% of the operating cost (Won g et al., 2000). In
addition,maintenancecostsdominateasubstantialportionoftheequipmentoperatingcostacrossthemining
industry,ranging from40%to50% (KumarandForsman,1992). Moreover, a Finnishcompany sharedthat
maintenance costsin theirmines account forapproximately 30% of theproduction cost (Harjunpaa,1992).
Lastly, un planned mainten ance activities ha ve been shown to lead to a 10% production lo ss in Australian
undergroundcoalmines(Clark, 1990).Theseobservationsunderscorethesignificantimpactofmaintenance
costs on the overall operational expenses in the mining sector and highlight the importance of effective
maintenancestrategiestoensureefficientanduninterruptedproduction.
Theliteraturehighlightsthatmaintenanceisunavoidableinmachinery-basedproductionindustriesand
can significantly impact operating costs, leading to both direct expenses and indirect consequences like
productionloss.Therefore,whendevisingmaintenancepolicies,itiscrucialtodevelopabalancebetweenthe
physical cost of maintenancework and the value of production loss per unit. The composition of the
maintena nce crew, referring to the number of ind ividuals with different qua lifications, is a critical factor in
makingmaintenance-relateddecisions.Findingtherightbalanceinthemaintenancecrewisessentialasboth
over-employmentandunder-employmentcanaffectthecostdynamics,includingdirectandindirectexpenses.
Thisstudyaims to developa continuoussimulationalgorithmtodetermine the optimalmaintenance
crew in t erms of quantity and qualification. The objective is to minimize the overall cost, con sidering the
stochasticnatureofequipmentfailuresexperiencedataminingsite.
Problem St atement
Maintenance plays a crucialrole in production areas,as itenhancesand sustains the reliability and
functionality of systems. However, maintenance activities can lead to production loss if the maintenance
departmentlacksthenecessaryworkforce.Additionally,maintenanceactionscanbeexpensiveandlimitedby
available resources. Hence, balancing system breakdown costs and maintenance expenses is essential.
Neglecting maintenance can re sult in excessiv e failures, leadi ng to downtime a nd system dete rioration. To
ensure sustained production and improved operational profitability, it is crucial to establish an optimal
maintenance policy that minimizes both direct and indirect cost items related to employee expenses. In
machine-intensive sectors suchasmining,where production relieson multiple well-coordinatedheavy-duty
machines , maintenance cost sc an be substantial and sig nificantly contri bute to the total operatin g cost. The
maintenance cost included in the operating cost budget can differ significantly across industries. For the
manufacturingindustry,ittypicallyrangesfrom3%to15%,whileformetallurgicalprocesses,itfallsbetween
15%and20%.However,inthehighlymechanizedminingindustry,theaccountedmaintenancecostcanbeas
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highas50%(Ben-Dayaetal.,2016).Furthermore,innumerousindustries,thechallengeofallocatinglimited
resourcestoaspecificsetoftasksisacommonoccurrence.Atthispoint,optimizinglaborresourceallocation
andconfigurationisessentialtoenhancesystems'servicelevelswhileminimizingdirectandindirectcosts.In
the case of a highly machine-intensive industry like mining, determining the optimal human resource
configurationformaintenanceactivitiesbecomesverycrucial.
Objective & Scope of the Study
Thecurrentstudyaimstodevelopasimulationalgorithmcapableofoptimizingthemaintenancecrew
configurationinanoperationinvolvingmultipletypesofequipmentwithrandomfailuremodes.Theprimary
goalistominimizethecumulativecostassociatedwiththe maintenancecrew,encompassingbothdirectand
indirectcostitems.Directcrew-inducedcostsincludevariouselementssuchassalary,insurance,foodservice,
shuttle servic e, rent help, and fa mily help. Indire ct costs, on the other hand, encompas s production losses
resulting from scheduled maintenance downtime and potential unavailability of the maintenance crew. In
addition to themainobjective,the study aimstoachieve severalsub-objectives. First,anindustrialresearch
componentisconductedtoinvestigatethefactorsdeterminingmaintenancecrewconfiguration,specificallyin
theminingindustry.Understandingthesefactorsiscrucialforoptimizingthecrewstructureeffectively.
Besides, the studyseekstoestablishthedependenciesbetweenproduction lossandthemaintenance
workforce.Byunderstandinghowthesetwofactorsarerelated,theresearcherscanbetterdesignamaintenance
crew config uration that minimi zes production los ses. To facilitate the ob jectives, the resea rch endeavors to
develop a m aintenance cre w simulation algor ithm within a cont inuous event sim ulation environme nt. This
algorithm will enable the evaluation and optimization of the crew configuration under various scenarios.
Moreover, the study involves implementing the developed model using an operational dataset after pre-
processingdata groups.This practicalimplementationusing real-world datawillenhancethe reliability and
relevance of t he results. Lastly , the researchers fo cus on verifying a nd validating the developed simu lation
algorithm toensure itsaccuracyandeffectiveness in optimizing themaintenance crew configuration.In the
applicationpart, thestudy utilizesthe historical maintenance dataset of a five-excavatorfleet operating in a
surfacecoalmine.Thefailuresarecategorizedintotwocommontypes:mechanicalandelectrical.
LITERATURE REVIEW
Maintenancecanbedefinedastheauxiliaryactivitiestoensurethatasystem,whichmayhavevarying
complexity and functions, remains in a satisfactory state by conducting regular checks, replaceme nts and
repairs on its components. As aresult, amaintenance policyinvolves a combination of actionswith distinct
objectivestoenableacomponenttofunctioneffectivelythroughoutthesystem'sentireservicelife.Theprimary
purpose of ma intenance action si s to enhance the func tionality and depend ability of systems .N evertheless,
improving reliability can be expensive in certain situations and is constrained by technical and financial
limitations. Consequently, there exists a delicate balance between the economic impact of maintenance
activities andthepotentialdeteriorationofthesystem.Toensure optimalresults,amaintenancepolicymust
bedesignedtomaintainthesystem'sreliabilityabovethedesiredlevel,takingintoaccountitsroleandvalue
inproduction.However,itisessentialtoavoidimplementingexcessivelyhigh-ratedpreventiveworkpackages,
as they may lead to additional investment costs and increased system unavailability due to preventive
downtimes.
Foraminingcompany,threecriticalassetsarecrucial:humanresources,orereservesforexploitation,
and an equipment fleet. Among these, human resources employed in operational areas hold particular
significance.Thenumberandqualificationsofpersonnelmustbedeterminedbasedonthedivisionalcapacity
requireme nts in mining areas. N otably, the mainte nance facility is obse rved to be the most lab or-intensive
aspect, asit requiresa considerablenumber ofindividuals withdiverse qualifications to ensure theoptimal
performan ce of the equipment fleet. Several studies have focused on mining equipm ent maintenance and
managementdecision-makingprocessesfortheminingsector.
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Barberá etal.(2014) utilized theGAMMmethod toanalyze two slurry pumps in amining plantin
Chile,suggestingimprovementsforpumpmaintenance.AliandReza(2014)developedanewapproachusing
statistical modelstodetermineloading equipment'soverhaulandmaintenancecostinsurfacemining. Morad
etal.(2014)investigatedmaintenancepoliciesforoperatingtrucksinSungunCopperMinetominimizefailure
downtimes.Kovacevicetal.(2016)describedatwo-stepmethodtoanalyzefactorsinfluencinghumanerrors
duringminingmachines'maintenanceactivity.Nikulinetal.(2016)presentedacomputer-aidedapplicationto
evaluatetheoperationalandmaintenancestrategyforcomplexprocesseswithequipment.GölbaşıandDemirel
(2017)developedasimulationalgorithmtooptimizeinspectionintervalsandminimizemaintenancecostsfor
miningmachines.Jonssonetal.(2018)discussedanalyzingdigitalizedcondition-basedmaintenancedatainan
iron ore mine. Angeles and Kumral (2020) proposed a maintenance management approach to improve
equipmentavailability and reliability inaminingtruck fleet. These studies contribute valuable insights and
practical tools for effectively maintaining mining systems regarding cost minimization and availability
maximization.
In addition, various simulation studies in the mining industry have been conducted to evaluate
uncertaintiesattheoperationallevel,optimizeprocesses,andaddressvariousaspectsofminingoperations.For
instance, Hashemi and Sattarvand (2014) developed a model using discrete-event simulation to analyze
interaction s between loadi ng and hauling syst ems in mines, r esulting in improved dispatching sy stems and
reducedtruckqueueingtime.UpadhyayandNasab(2018)presentedasimulationandoptimizationframework
toenhanceshort-termproductionplanninganddecision-makinginminingoperations,consideringuncertainties
and dependencies between various factors. Golbasi and Demirel (2017) introduced an inspection interval
optimize r using a stochast ic, continuous , and dynamic simulation str ucture to determ ine the best co st-wise
decisionsinequipmentmaintenancepolicies.
Other studies explored optimiza tion in truck dispatching and allocation to shovels (Moradi et al.,
2019), truck allocation considering uncertainties in dispatching operations (Moradi et al., 2019), and the
effectof humanfactorsonminingequipmentreliability(Ozdemirand Kumral,2018).Additionally,Ozdemir
and Kumral (2019) proposed a two-stage dispatching system to maximize the utilization of truck-shovel
systems, le ading toi ncreased material quantity .Gol basia ndTu ran(2 020) introduced a maintenance po licy
optimizer todetermine optimal maintenance work packages based on equipment uptime and downtime
character istics. Bernardi et al. (2 020) compared mat erials handling sy stems in a mine to optim ize handling
systemsand minimizeoperatingcostsusingdiscreteeventsimulation.GolbasiandKina(2022)developeda
fuelconsumptionsimulatortoevaluatefuelusageinhaultrucksoperatingunderstochasticconditions.
These studieshaveprovidedvaluable insightsandpracticaltools for effectively maintaining mining
systemsregardingcostminimizationandavailabilitymaximization,improvingminingoperations,optimizing
maintenance policies, and enhancingdecision-making processes. However,optimization of human resource
configurationinminingactivitieshasnotbeenobservedintheliterature.
MODEL DEVELOPMENT
The algorithm's objectiveis todetermine the optimal maintenance crew configuration for a mining
area,ensuringthemostcost-effectiveoperationbystrikingabalancebetweenphysicalexpensesandproduction
losses re sulting from over or under-employm ent of skilled wor kers. The mainten ance crew incurs v arious
physicalcostitems,includingwages,employmentinsurance,foodservice,transportation,andaccommodation.
Over-employment in different maintenance branches can lead to a significant increase in direct costs.
Conversely,under-employmentinamaintenancebranchcancausenotableproductionlossesasrelatedfailure
types may n ot receive timely at tention, impac ting machinery avai lability. It is cruc ial to avoid overla pping
maintenanceactivitiesforsimilarfailuremodesthatrequiresimilartechnicalcompetency,asfailuretoevaluate
failure mode characterization and crew member occupancy rates jointlycan disrupt machinery availability.
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Giventhatminingareasutilizenumerousequipmentwithvaryingnumbersandoperationalrequirements,
any misjudgment in maintenance behavior can lead to catastrophic situations, reduce equipment
utilization, and result in additional unavailability periods that harm short-term production plans. The
algorithmlogicisillustratedinFigure1briefly.
Figure1.SimulationModelAlgorithm
The model was tested on a fleet of five excavators, each with distinct failure occurrence and
maintenance characteristics. Failures were categorized into mechanical and electrical types, which
determinedthe crewgroups.Through200simulations,theinteractionswithin the systemwereevaluated
by varyin g the total numb er of mechanical an d electrical crew members in each run. Each simulat ion
coveredanobservationperiodof4,383hours.Theresultsindicatedthattheoptimizedcrewconfiguration,
consisting of 4 members inthe electrical and 4 members in the mechanical divisions, minimized the
cumulativedirectandindirectcosts.Thefleet'sgeneralevaluation,includingfiveexcavators,canalsobe
seenandFigure2.
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Figure2.TotalDowntime(B)andTotalCost(A)for5ExcavatorsforEachCrewPolicy
CONCLUSIONS
In a machine-based production company, the maintenance department consists of various
divisionswithdifferentcrewconfigurations,dependingonthecompany'sproductionprofile,complexity,
andtypesofmachinesinvolvedinproductionphases.Inminingareas,operationscanbeeithersurfaceor
underground, depending on the mining method, and specific heavy-duty machinery with varying
production rates is requiredbased on the mining type and production capacity. A mining company
typically possesses a large fleet of machines, including loading, hauling, drilling, and auxiliary
equipment.Eachmachinemayexperiencedifferentfailuremodeswithvaryingoccurrencefrequency and
consequences,resultingindifferentdowntimeprofiles.
Given that the m aintenance cre w is a limited resource with specific num bers of people in each
division,it is crucial to determine the optimal configuration of the maintenance crew, considering the
trade-of fbet weenthe total financial co nsequences of diff erent crew config urations. To addr ess this, the
studydevelopsa multi-scenario continuous-eventsimulationmodeltoidentifytheoptimalcapacityand
qualification of the maintenance crew for a functional mining operation. The developed model is
implemented for the maintenancecrew requirement of a fleet covering five excavators experiencing
randomfailureswithvaryingmaintenancerequirementsanddurations.Theoverallcostis minimizedfor
acrewconfigurationwith4and4peopleintheelectricalandmechanicaldepartments.
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