Shahrood University of Technology Journal of Mining and Environment 2251-8592 Articles in Press 2025 09 09 Development of a Match Factor for Optimizing Haulage Fleet Efficiency in Open-Pit Mining Operations 3606 10.22044/jme.2025.16360.3188 EN Mehrnaz Mohtasham University of MohaghDepartment of Mining Engineering, Faculty of Engineering and Technology, University of Mohaghegh Ardabili, Ardabil, Iranegh Ardabili Journal Article 2025 06 04 In open-pit mining, haulage equipment accounts for a significant portion of total operating costs. Optimizing fleet performance is therefore crucial for reducing costs and improving productivity. Within this system, loading equipment plays a key role, as truck efficiency depends heavily on loader performance. The match factor, a metric that evaluates compatibility between loaders and trucks, is commonly used to enhance fleet efficiency. However, many existing approaches fail to account for practical mining conditions such as equipment downtime, accurate truck cycle times, and material fragmentation resulting from blasting. These omissions can lead to inaccurate fleet performance evaluations and higher operational costs. This study proposes an improved match factor method that incorporates these critical variables. It includes equipment downtime, truck cycle time estimates based on travel routes, and material fragmentation. The model applies to both homogeneous and heterogeneous fleet configurations and integrates the operational efficiency coefficient of each machine to reflect real conditions more accurately. The model was tested using data from the Sungun copper mine. The match factor values were calculated both with and without accounting for equipment downtime, and loader capacities were adjusted according to the size distribution of blasted material. Results showed that in heterogeneous fleet operations, the match factor increased from 0.74 to 0.85 when operational efficiency was included. Subsystem analyses also revealed match factor values below 1, indicating a need for additional trucks. Overall, the enhanced model enables more efficient equipment use, reduces loader idle time, and contributes to substantial operating-cost savings.