A Digital Circular MRO Model for Mining: Qualitative Evidence and Framework Design

Introduction, Background, and Objectives

Mining operations continue to depend on linear Maintenance, Repair, and Operations (MRO) structures, limiting the ability to regenerate value from high-capital equipment and intensifying material consumption and carbon emissions. This study investigates how MRO systems can transition toward a digitally enabled circular model that extends component life and reduces material intensity across the equipment lifecycle.

Methods

A qualitative research design was applied using purposive sampling and semi-structured interviews with 22 specialists in reliability engineering, remanufacturing, supply chain, logistics, and sustainability across major mining firms and Original Equipment Manufacturers (OEMs). Interview data were coded and analysed using thematic analysis to identify operational, digital, and contractual constraints that shape the feasibility of circularity in current MRO systems.

Results

The analysis revealed four categories of barriers: (1) fragmented asset-health visibility, (2) inconsistent remanufacturing standards, (3) misaligned OEM–operator incentives, and (4) limited digital traceability for component provenance. Using these empirical insights, the study synthesizes engineering reliability principles, circular-economy logic, digital architecture, and supply-chain coordination theory to propose a Four-Loop Circular MRO Structure. The model formalises four value-regeneration pathways—Reuse, certified material Recovery, load-sensitive Reduction, and OEM-governed Return—each supported by explicit digital enablers: IoT-based condition telemetry, AI-driven remanufacturing candidate identification, Digital Twins for predictive simulation, and blockchain-secured material passports for authenticated component flows.

Contributions

The study provides:

1. A qualitatively validated conceptual model that operationalises circular MRO in heavy-equipment environments.
2. A digital-systems blueprint that integrates reverse logistics, reliability engineering, and OEM–operator coordination.
3. Empirical insights into the real-world organisational and contractual dynamics that influence circularity adoption in mining supply chains.

Conclusion and Future Work

Future research will quantitatively test the model through simulation and digital twin experiments to evaluate its potential impact on emissions reduction, component reliability, and supply chain performance.