Modularity-based quality assessment of a disruptive reconfigurable manufacturing system-A hybrid meta-heuristic approach

• Published in: International journal of advanced manufacturing technology Vol. 115; no. 5-6; pp. 1421 - 1444
• Main Authors: Khan, Abdul Salam, Homri, Lazhar, Dantan, Jean Yves, Siadat, Ali
• Format: Journal Article
• Language: English
• Published: London Springer London 01.07.2021; Springer Nature B.V; Springer Verlag
• Subjects: CAE) and Design; Computer-Aided Engineering (CAD; Cost analysis; Decision making; Engineering; Engineering Sciences; Exact solutions; Genetic algorithms; Heuristic methods; Hybrid systems; Industrial and Production Engineering; Linear programming; Mechanical Engineering; Mechanics; Media Management; Mixed integer; Modular design; Modularity; Multiple objective analysis; Nonlinear programming; Original Article; Particle swarm optimization; Process planning; Quality assessment; Reconfiguration; Solution space; Sorting algorithms; Reconfigurable manufacturing system; Reconfigurable process plan; Multi-objective optimization; Quality assessment; Variation; Cost; Hybrid heuristics
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-021-07229-6

This study considers quality aspects in the process planning of a reconfigurable manufacturing system. The goal is to analyze how the variation in quality impacts the process planning, i.e., cost-based design and modular features. Besides this, the analysis helps in identifying the number of conforming and failed products delivered by a process plan. First, a multi-objective mixed integer non-linear programming model is proposed that contains the novel objectives of cost, quality decay, and modular efforts. Secondly, the model is implemented on an industrial case study by using an exact solution approach and a novel hybrid version of two popular meta-heuristics, namely non-sorting genetic algorithm and multi-objective particle swarm optimization. The hybrid heuristic helps strengthening the application of approaches by creating a balance in searching the solution space. The performance of different approaches is assessed by using two metrics and two termination criteria. The findings will help the decision-makers in assessing how quality-related issues impact the choice of a process plan and in understanding the trade-off among cost, quality, and modularity. Finally, conclusion and future research avenues are provided.