Enhancing scalable reconfigurable manufacturing systems through robust optimisation: energy efficiency and cost minimisation under uncertainty

Reconfigurable manufacturing systems are dynamic systems designed with scalable and flexible production capabilities to address changing market demands. This paper presents a novel multi-objective integer programming model aimed at optimising the configuration and capacity scalability of reconfigurable machine tools in uncertain environments. The model focuses on minimising three key objectives: total energy consumption, unused capacity, and total cost. It incorporates critical manufacturing constraints such as peak power thresholds and limited tool availability. To effectively manage uncertainty, particularly in demand fluctuations, a scenario-based robust optimisation approach is applied, striking a balance between solution robustness and model adaptability. A comprehensive case study demonstrates the model's effectiveness, comparing deterministic and uncertain solutions. Additionally, sensitivity analyses are performed on parameters such as peak power thresholds, risk coefficients, and infeasibility weights, highlighting their impact on system performance. The results provide insights into the efficient design and operation of scalable reconfigurable manufacturing systems under uncertainty, with recommendations for future research directions.