Performance-Based Replacement Time Analysis of Open Pit Excavators: A West African Case Study

Open-pit excavators are subject to degradation due to harsh working conditions. Determining their optimal replacement time remains a challenge for decision-makers. The majority of current models utilize mathematical predictions to minimize the total cost of ownership. A decision-making model based on the analyses of both historical and real-time performance and technical condition is required for timely and efficient replacements. This study employs the overall mining equipment effectiveness method, which monitors technical indicators such as productivity, utilization rate, mechanical availability rate, and technical availability rate. Operational data collected over 24 months from three open-pit excavators (with operating hours over 33,000 hours) were used to perform the case study. The findings showed that the overall mining equipment effectiveness approach is an effective tool that offers valuable information for well-informed equipment replacement decisions. Based on the results, there was no need for an immediate replacement in this case study. However, a review of the current maintenance practices was recommended to the mine.