Abstract
Abstract Overall equipment effectiveness (OEE) is a well-accepted measure of performance in industry. In this thesis, the components of OEE were calculated over a period of 28 months using failure and repair data gathered from food and beverages packaging line. The failure and repair data of the packaging line were statistically analyzed to understand the nature of the failure patterns, and to estimate the reliability and maintainability characteristics of the packaging line in precise quantitative terms, moreover, the best fit distribution for TBF and TTR based on failure data were computed, these distributions were included in the simulation model to describe the reliability behavior of the packaging line. Among the techniques to tackle maintenance and reliability issues, simulation can undoubtedly play an important role as it provides what-if analysis and hence help to evaluate quantitative benefits. This thesis also describes the modelling of machine breakdown behavior in industrial machines, a packaging line machines in the Aseptic Liquid Food (ALF) factory. The model also examines three important scheduled tasks (parameters) influence on packaging machines to study the correlation between these parameters and the occurrence of breakdown. Results show that the component Availability of the OEE metric should be improved to optimise the productivity and the efficiency of the line. the model results of failure time metrics (i.e. MTBF and MTTR) were validated using Output Analyzer template within Arena simulation software; and the results were near actual figures of collected data. The results of second experiment model showed a decrease in breakdown occurrences compared to first experiment, however, the scheduled tasks usage rate didn't correlate to breakdown occurrences, indicating the need to study and analyze different possible reasons of breakdown occurrence. Keywords: TPM, WCM, OEE, Simulation and modelling