Application of an integrated multi-criteria failure risk assessment framework on an industrial vibrating screen

Vibrating screens are critical separation units in mineral processing circuits, yet their failure analysis in industrial practice remains predominantly reactive and limited to component-level diagnostics. This study presents the industrial application and validation of an integrated multi-criteria failure risk assessment framework applied to a vibrating screen operating under real andesite processing conditions. The proposed framework combines qualitative cause analysis (Ishikawa diagram), extended multi-criteria Failure Mode and Effects Analysis (FMEA) with weighted risk assessment and combined indicators, and quantitative Fault Tree Analysis (FTA). The results show that although bearing wear had the highest occurrence frequency, the vibration mechanism was identified as the most system-critical failure, with a calculated annual failure probability of 20.8%. Sensitivity analysis identified bearing-related failures as the dominant risk contributor ( I FV = 0.567), with insufficient lubrication identified as the primary basic event ( I FV = 0.289). Based on these findings, a risk-oriented maintenance plan was developed to support the transition to predictive maintenance and reduce maintenance-related costs by 37.5%, with a 14-month payback period and an annual return on investment (ROI) of 85.7%. The proposed framework provides a transferable methodology for improving reliability and optimising maintenance of vibrating and rotating machinery across the mineral processing industry.