Faculty of Engineering - Department of Industrial

The project objective is to enhance the productivity in different aspects of (Sky Cola) -a
soft drinks factory- and reduce the amount of wasted water used to wash the plastic
bottles, to minimize the associated cost, because water is used only once and thrown
away directly into the sewage system, causing the high cost. Another problem that
affect the productivity is the changeover time, which has a high impact on the
production line availability. One more problem is observed in the packaging stage. The
performance of the packaging machine is lower, not only than its ideal performance
state, but also, lower than the rest machines of the production line, resulting in a
bottleneck.
The proposed solution to reduce the changeover time is to implement the Single Minute
Exchange of Die methodology (SMED). Another packaging machine will be added to
resolve the bottleneck problem; this modification will be simulated through the
ARENA simulation software to get the closest results to the real ones. Finally, to
recycle the washing water and use it one more time, a filtration unit will be added to the
washing stage, taking into consideration the water chemical and bacteriological validity
for human usage.
It is believed that implementing the SMED methodology will reduce the changeover
time by about 60%. In addition, the estimated implementing of adding an additional
packaging machine will increase the production rate from 101 to 123 bottles per
minute. Moreover, it is expected that reusing the rinsing water after a filtration cycle
will save 42.85% of the water and will increase the profit by 46.68% annually.