Transitioning to a counter-based maintenance strategy at the packaging filling lines of Heineken

This thesis investigates the transition to a counter-based maintenance strategy for Heineken's packaging filling lines, addressing inefficiencies in the current time-based maintenance system. The proposed model aims to optimize maintenance scheduling by leveraging operational data, specifically machine usage data, to plan maintenance activities more accurately. It automates the assessment of equipment usage, identifies optimal maintenance intervals, and minimizes over- and under-maintenance with a mathematical model. This incorporates predictive analytics to forecast production levels, ensuring maintenance activities are scheduled based on actual machine wear and usage. The research at the Zoeterwoude brewery demonstrates the model's effectiveness in reducing over- and under-maintenance and costs. The results reveal significant potential for improving maintenance efficiency and underscore the practical value of the counter-based strategy for maintenance management in large-scale manufacturing operations.