This paper presents a dynamic simulation model of complex production lines. The model has been used to improve reliability of production line and also for planning and scheduling of maintenance and production. The model presented here is based on stochastic simulation in time domain. Random failures, finite buffers, feedback loops, variable production speeds and scheduled preventive maintenance are taken into account. Collected production data from process automation system has been extensively used in modeling. The approach presented is valuable for the industrial practitioners in the maintenance business and may also be adapted to other areas where operational experience exists. A prototype model has also been merged into production management system. Model can be continuously updated by new data and implications can be observed. Improvements in knowledge of production effectiveness and reliability have been achieved.

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