Enhancing production assurance in longwall coal mining through reliability assessment of the shearer

Mechanized longwall mining is one of the most productive methods for underground coal extraction, where continuous operation of the shearer machine is essential for maintaining stable production levels. Failures in the shearer or its subsystems can lead to unplanned downtime, reduced availability, and significant production losses. Therefore, evaluating the operational reliability of shearer machines and quantifying their impact on production performance are critical for effective mine management. In this study, the production capacity of a mechanized longwall coal mine is assessed through reliability analysis of the shearer machine, with particular attention to its critical subsystems. Reliability functions were developed for the water supply and electrical subsystems, which were identified as the main contributors to operational interruptions. The results show that the reliability of the electrical and water subsystems approaches zero after approximately 1500 h and 2500 h of operation, respectively. Using the derived reliability models, the associated production risk was quantified and estimated at 0.38 tons per hour. The proposed approach provides a practical and transferable framework for linking subsystem reliability to production risk in mechanized mining operations. The findings can support maintenance planning, downtime reduction strategies, and improved production reliability in underground coal mines.