Methodology for extending service life: application to large-scale excavation assets

Authors
DOI:
https://doi.org/10.47456/bjpe.v12i2.51915
Keywords:
increased useful life, asset management, Reliability
Abstract

This paper presents the application of Life Data Analysis (LDA) as a tool for reliability assessment and optimization of replacement cycles of mechanical components in large‑scale electric excavators used in mining operations. The proposed methodology is based on the collection and treatment of historical operational data, statistical modeling using probabilistic distributions, and the analysis of the impact of extending asset service life on reliability and operational costs. The study was applied to the main mechanical systems (hoisting, digging, swing, and propulsion) of Caterpillar 7495HD and 7495HR large‑scale excavator models, using data from the period between 2020 and 2025. The results indicate that, for most of the components analyzed, it is possible to extend replacement cycles while maintaining reliability levels within previously established limits. The application of the methodology to a hoist gearbox demonstrated a 20% increase in service life, with a significant reduction in the number of preventive replacements. Financial projections indicate substantial potential gains resulting from reduced costs related to components, installation kits, and losses associated with equipment downtime, thereby demonstrating the technical and economic feasibility of the proposed approach.

Author Biographies
  1. Marie Clayre Freitas Ferreira, Federal University of Technology of Paraná

    Nascido em 17/08/1999, em Santo Antônio do Tauá (PA). Possui formação em Engenharia de Elétrica (UFPA), Mestrado em Engenharia Elétrica (UNICAMP) e Pós- Graduação em Engenharia de Confiabilidade (UTFPR). É colaborador da Vale Base Metals – Salobo/PA, desde Fevereiro de 2025. Exerce a função de Engenheiro de Confiabilidade. https://orcid.org/0000-0002-7919-7306

  2. Esmael de Miranda Magno, Centro Universitário Leonardo da Vinci

    Nascido em 16/05/1982, em Almeirim (PA). Possui formação em Engenharia de Mecânica (UNIALSELVI) e Pós- Graduação em Engenharia e Gerenciamento de Manutenção (PROMINAS). É colaborador da Vale Base Metals – Salobo/PA, desde Agosto de 2018. Exerce a função de Engenheiro Sênior de Estratégia de Manutenção de Ativos. https://orcid.org/0009-0000-7624-1175

  3. Bruna Cristina da Silva, Federal University of São Paulo

    BRUNA CRISTINA DA SILVA

    Engenheira de Materiais (Unifesp), Pós graduação em Engenharia de Confiabilidade, MBA Gestão de Projetos (USP), Certificação Especialista em Análise de Falhas, Master Black Belt Lean Six Sigma. https://orcid.org/0009-0005-1819-6253

References

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Cruz, W. P. (2013). Análise estatística usando a distribuição de Weibull de ensaios de fadiga axial em juntas soldadas pelo processo GMAW e GMAW-CW mineração (Trabalho de Conclusão de Curso). Universidade Federal do Pará, Marabá, PA, Brasil.

Fogliatto, F. S. & Ribeiro, J. L. D. (2009). Confiabilidade e manutenção industrial. 1ª ed. Rio de Janeiro: GEN LTC.

Luz, J. V. P. & Viana, H. R. C. (2025). Desenvolvimento de uma ferramenta em python para análise de dados de tempo de falha com aplicações em engenharia de manutenção. Revista Aracê. https://doi.org/10.56238/arev7n7-175

Minitab. (2025). Parâmetros. Recuperado de https://support.minitab.com/pt-br/minitab/help-and-how-to/probability-distributions-random-data-and-resampling-analyses/supporting-topics/parameters/shape/

Ozawa, M. T. (2017). Aplicação de parâmetros da distribuição de Weibull na análise do potencial energético de um microgerador eólico em cidades do estado do Paraná (Trabalho de Conclusão de Curso). Universidade Tecnológica Federal do Paraná, Ponta Grossa, PR, Brasil.

Silva, M. P. B. (2024). Estudo sobre a viabilidade da implementação do carregamento bilateral em escavadeiras de grande porte na mineração (Trabalho de Conclusão de Curso). Universidade Federal de Catalão, Catalão, GO, Brasil.

Cover Image
The image presents an aerial view of an open-pit mining operation, showing large hydraulic excavators operating across extensive excavation fronts and material stockpiles, together with transport infrastructure associated with the production process. The visual composition emphasizes the scale of heavy excavation assets and highlights challenges related to reliability, maintenance, and life-cycle management of industrial equipment. The scene symbolizes the application of methodologies aimed at extending asset service life through life data analysis, maintenance engineering, and performance-based decision-making, with the goals of increasing availability, reducing costs, and optimizing productivity. At the top, the article title “Methodology for Extending Service Life: Application to Large-Scale Excavation Assets” is displayed, followed by the authors Ferreira, Magno & Silva (2026). At the bottom, the identification of the Brazilian Journal of Production Engineering and the journal’s ISSN are shown.
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Additional Files
Published
2026-06-13
Issue
Vol. 12 No. 2 (2026): Regular Issue (April - June)
Section
OPERATIONS & PRODUCTION PROCESS
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Copyright (c) 2026 Ferreira, M. C. F., Magno, E. de M., & Silva, B. C. da.

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How to Cite

Ferreira, M. C. F., Magno, E. de M., & Silva, B. C. da. (2026). Methodology for extending service life: application to large-scale excavation assets. Brazilian Journal of Production Engineering, 12(2), 176-184. https://doi.org/10.47456/bjpe.v12i2.51915