—The reduction of shovel breakdown time in coal mining is crucial for maintaining operational efficiency and minimizing production losses. This study aims to address shovel breakdown issues by applying the DMAIC (Define, Measure, Analyze, Improve, Control) approach, a structured Six Sigma methodology designed to optimize processes and eliminate inefficiencies. Through the DMAIC framework, key factors contributing to shovel breakdowns were identified and analyzed. The Define phase involved understanding operational challenges and setting goals for reducing downtime. In the Measure phase, historical breakdown data were collected and performance baselines established. Root causes of shovel failures were identified during the Analyze phase using tools like Pareto charts, failure mode analysis, and cause-and-effect diagrams. Solutions were then developed and implemented in the Improve phase, focusing on preventive maintenance schedules, training programs, and equipment upgrades. Finally, the Control phase ensured sustained improvements through continuous monitoring and the implementation of standard operating procedures (SOPs). Results indicated a significant reduction in breakdown time, leading to improved operational efficiency and cost savings. This research demonstrates the effectiveness of the DMAIC approach in enhancing equipment reliability and can serve as a model for other industries facing similar challenges.
Mahto et al. (Thu,) studied this question.