Manufacturing system reconfiguration towards sustainable production: a novel hybrid optimization methodology

Developing a sustainable manufacturing system is a progressively challenging issue as governments across the world have been enforcing increasingly severe regulations by promoting the reduction of environmental waste for manufacturing and energy-saving production activities. Thus, there is a need for developing a sustainable manufacturing system that can be fully examined by incorporating ecological aspects (e.g., consumed energy) for related operations of a manufacturing system using computer-based discrete event simulation tools. In this study, a combined framework of a novel hybrid fuzzy multi-objective optimization and discrete event simulation approach is presented. We combine ecological and economic data and optimization techniques that are aimed at minimizing economic and ecological objectives in a manufacturing system at an early design phase. Hence, the fuzzy multi-objective optimization model is formulated by incorporating economic and ecological parameters. Again, the discrete event simulation model is established based on a comprehensive performance evaluation of the production system. This study also supports design decisions in determining optimum machine numbers, lighting, and cooling equipment required for the production processes within the sustainable manufacturing in conjunction with the most effective level of material flows. In addition, an integrated Decision-Making Trial and Evaluation Laboratory (DEMATEL)–epsilon constraint approach is applied to handle the multiple-objective optimization problem towards a set of trade-offs among the optimization objectives. A real-life application is carried out for investigating the applicability of the created hybrid framework. The findings of this study demonstrate that this framework is useful as a decision-making tool since it can develop a sustainable manufacturing system design considering an optimal solution associated with amounts of energy usage and CO₂ emissions under economic constraints.