Abstract
Currently, manufacturers seek to provide customized and sustainable products, requiring flexible manufacturing systems and advanced production management to cope with customization complexity and improve environmental performance. The reconfigurable manufacturing system (RMS) is expected to provide cost-effective customization in high responsiveness. However, reconfiguration optimization to produce sustainable mass-customized products in RMS is a complex problem requiring multi-criteria decision making. It is related to three problems, process planning, scheduling, and layout optimization, which should be integrated to optimize the RMS performance. This paper aims at integrating the above three problems and developing an effective approach to solving them concurrently. It formulates a multi-objective mathematical model simultaneously optimizing process planning, job-shop scheduling, and open-field layout problem to improve RMS sustainability. The penalty for product tardiness, the total manufacturing cost, the hazardous waste, and the greenhouse gases emissions are minimized. Economic and environmental indicators are defined to modify the Pareto efficiency when searching the Pareto-optimal solutions. Exact Pareto-optimal solutions are obtained by brute-force search and compared with those of the non-environmental indicator model. NSGA-III is adopted to obtain the approximate Pareto-optimal solutions in high effectiveness and efficiency. A small numerical example is applied to validate the mathematical model and resolution methods.
Highlights
Customers today require unique personalized products as well as sustainable ones.Companies on the other hand want to improve their environmental impact while surviving in today’s environment characterized by highly variable and uncertain demand.Low-carbon product family design is an excellent idea to deal with the diverse needs of customers and the pressure from government policy for environmental protection [1].Sustainable manufacturing is useful in minimizing material and energy wastage as well as improving machine utilization and process productivity coupled with higher customer satisfaction [2]
The reconfigurable manufacturing system (RMS) is recognized as one of the most advantageous next-generation manufacturing systems allowing flexibility in producing a variety of parts and in changing the system itself, which could facilitate the everquicker introduction of new products caused by the current customer-driven market and the increased awareness of environmental issues [3]
Including the environmental sustainability for this integrated production management problem in RMS, which is limited in previous research; modifying the Pareto efficiency by combining the characteristics of this problem to get a reasonable number of Pareto-optimal solutions for decision makers; and surveying the appropriate parameters to design a decent heuristic approach in order to solve this problem effectively and efficiently
Summary
Customers today require unique personalized products as well as sustainable ones. Companies on the other hand want to improve their environmental impact while surviving in today’s environment characterized by highly variable and uncertain demand. Effective methods to generate the best layout arrangements are significant to improve business profit and customer satisfaction as well as to promote environmental protection and the achievement of MC with RMS in practice. The work aims to formulate the integrated process planning, scheduling, and layout problem as well as to propose a suitable method to produce multiple mass-customized products in RMS with minimum tardiness penalty, total cost, and amount of pollutants. Including the environmental sustainability for this integrated production management problem in RMS, which is limited in previous research; modifying the Pareto efficiency by combining the characteristics of this problem to get a reasonable number of Pareto-optimal solutions for decision makers; and surveying the appropriate parameters to design a decent heuristic approach in order to solve this problem effectively and efficiently.
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