Optimization of Operational Risk in Ecuadorian Mining Using FMEA and Weibull Distribution to Reduce Critical Equipment Failures

José David Barros  Enriquez; Carlos David  Amaya-Jaramillo; Danny Alexander Rivas  Sierra; Edgar Atilio Suárez  Bardelline; Milton Iván Villafuerte  López; Ángel Moisés Avemañay  Morocho

doi:10.51903/jtie.v5i2.489

Authors

José David Barros Enriquez Faculty of Industry and Production Sciences, State Technical University of Quevedo, Quevedo, Ecuador EC120550 https://orcid.org/0000-0003-2165-4065
Carlos David Amaya-Jaramillo Electronic and Automatization Career, Investigation Group INIAC, Manuel Félix López Agricultural Polytechnic Higher School of Manabí (ESPAM MFL), Calceta 130350, Ecuador https://orcid.org/0000-0003-2339-8800
Danny Alexander Rivas Sierra Faculty of Industry and Production Sciences, State Technical University of Quevedo, Quevedo, Ecuador EC120550 https://orcid.org/0000-0003-1262-5115
Edgar Atilio Suárez Bardelline Faculty of Engineering Sciences, State Technical University of Quevedo, Quevedo 120550, Ecuador https://orcid.org/0009-0005-2302-8465
Milton Iván Villafuerte López Faculty of Industry and Production Sciences, State Technical University of Quevedo, Quevedo, Ecuador EC120550 https://orcid.org/0000-0003-2848-6877
Ángel Moisés Avemañay Morocho Faculty of Industry and Production Sciences, State Technical University of Quevedo, Quevedo, Ecuador EC120550 https://orcid.org/0000-0003-3233-9730

DOI:

https://doi.org/10.51903/jtie.v5i2.489

Keywords:

FMEA, Weibull, mining, operational risk, preventive maintenance, equipment reliability

Abstract

Designing and implementing a preventive maintenance plan in the Ecuadorian mining industry requires systematic methodologies to reduce failures in crushing and grinding machines, improving operational availability and productivity. The main problem identified is reliance on corrective maintenance, with no historical failure records, which causes unexpected shutdowns. This study applies the FMEA (Failure Mode and Effects Analysis) methodology to evaluate the criticality of equipment using the Risk Priority Number (NPR), complemented with the Weibull distribution to model useful lifetimes. Key equipment such as the ball mill and jaw crusher at a mining beneficiation plant were analyzed. The results indicate that 25% of the subcomponents have NPR > 300 (unacceptable risk), mainly concentrated in structural elements subjected to severe operating conditions. A scenario analysis based on the fitted Weibull models and on reductions reported in the literature projects that implementation of the proposed preventive plan would reduce unplanned shutdowns by 40–50%, raising operational availability from the current 73% to approximately 90%; these figures are model-based projections and not post-implementation measurements. Weibull integration provides a robust statistical framework for the transition from reactive maintenance to predictive schemes, optimizing intervention intervals and extending the life of critical assets.

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