A new and improved hydrocyclone wear maintenance control system for managing wear maintenance among a plurality of hydrocyclone separators and method for its use are provided. The system includes one or more usage measurement devices and one or more electronic wear sensors disposed in communication with one or more hydrocyclone separators, along with a computer algorithm operable for recognizing a predetermined hydrocyclone maintenance plan based on an end-user assessment and input to achieve a preferred or optimal schedule, estimated wear, analyzing slurry flow time data and wear condition data for calculating an estimated wear profile, automatically directing said hydrocyclone control system to activate and deactivate one or more hydrocyclone separators as necessary to follow the predetermined hydrocyclone maintenance plan, calculating a subsequent estimated wear profile based on further analysis, and allowing adjustments to be made to the predetermined hydrocyclone maintenance plan based on the subsequently estimated wear profile. The system and method provide for improved wear maintenance scheduling.