Reliability Analysis and Life Cycle Cost Optimization of Hydraulic Excavator

Authors

  • Sandeep Kumar Mishra Subir Chowdhury School of Quality and Reliability, Indian Institute of Technology Kharagpur, India – 721302
  • Neeraj Kumar Goyal Subir Chowdhury School of Quality and Reliability, Indian Institute of Technology Kharagpur, India – 721302 https://orcid.org/0000-0003-4251-6876
  • Arup Mukherjee TATA Hitachi Construction Machinery Co. Pvt. Ltd, Kharagpur, India -721301

DOI:

https://doi.org/10.13052/jrss0974-8024.1626

Keywords:

Availability, excavator, life cycle cost, reliability, repairable system

Abstract

This study focuses on conducting a reliability analysis of an excavator from its field failure data and improve its reliability cost effectively. The aim of the research is to perform reliability estimation of systems and identify the critical subsystem with significant contributions to system unreliability. The reliability analysis was performed using repairable system data analysis approaches. Life cycle cost (LCC) was estimated for critical subsystems, and it was optimized to select cost effective reliability improvement strategy. The results of the study provide valuable insights into the performance and cost-effectiveness of the excavator and its subsystems, which can assist manufacturers and operators in optimizing their equipment’s reliability, availability while considering the cost implications over the life cycle of the equipment. The results show that the undercarriage has critical contributions to system unreliability. This study attempts deep down reliability analysis of critical undercarriage components for optimal selection of improvement method among feasible alternatives. LCC analysis and its optimization performed on the critical sub-system is expected to help OEM save approx. 15% of LCC. The empirical data used in the paper is based on field data gathered during the operational life of the hydraulic excavator over approx. six years in its Indian operations.

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Author Biographies

Sandeep Kumar Mishra, Subir Chowdhury School of Quality and Reliability, Indian Institute of Technology Kharagpur, India – 721302

Sandeep Kumar Mishra is a mechanical engineering graduate who has spent over a decade working in India and abroad in the field of quality. He is a N2 Certified Japanese speaker, lead QMS auditor and Six Sigma Black belt analyst. He is currently pursuing MTech. in quality & reliability engineering from Subir Chowdhury School of Quality and Reliability, IIT Kharagpur. His research interest includes fleet reliability analysis of complex systems, life cycle cost optimization, life data analysis, quality control of slow-moving models, etc.

Neeraj Kumar Goyal, Subir Chowdhury School of Quality and Reliability, Indian Institute of Technology Kharagpur, India – 721302

Neeraj Kumar Goyal is currently an Associate Professor in Subir Chowdhury School of Quality and Reliability, Indian Institute of Technology Kharagpur, India. He received his PhD degree from IIT Kharagpur in Reliability Engineering in 2006. His areas of research and teaching are network reliability, software reliability, electronic system reliability, reliability testing, probabilistic risk/safety assessment, and reliability design. He has completed various research and consultancy projects for various organizations, e.g., DRDO, NPCIL, Vodafone, ECIL, etc. He has contributed several research papers to international journals and conference proceedings.

Arup Mukherjee, TATA Hitachi Construction Machinery Co. Pvt. Ltd, Kharagpur, India -721301

Arup Mukherjee received his B.E. (hons), M.E. (Gold Medallist) and PhD degree in metallurgy engineering from Jadavpur University, Kolkata, India, in 1988, 1993 & 2023 respectively. He has over 30 years of industrial experience, currently serving as Vice President of Tata Hitachi Construction Machinery wherein he is heading & guiding Quality, Design, R&D, Planning and Production engineering departments. His current research interests include metallurgy engineering, new product development, reliability engineering, Failure diagnosis, manufacturing, IOT and Industry 4, etc.

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Published

2024-03-17

How to Cite

Mishra, S. K., Goyal, N. K., & Mukherjee, A. (2024). Reliability Analysis and Life Cycle Cost Optimization of Hydraulic Excavator. Journal of Reliability and Statistical Studies, 16(02), 297–328. https://doi.org/10.13052/jrss0974-8024.1626

Issue

2023: Vol 16 Iss 2

Section

Articles