Decomposition-based multi-objective approach for a green hybrid flowshop rescheduling problem with consistent sublots

Rescheduling in a hybrid flowshop holds significant importance in modern industries that face uncertain events. Moreover, real-world manufacturing scenarios often utilise lot streaming to enhance market competitiveness. In light of escalating energy demands and their consequential environmental impacts, contemporary manufacturing companies are placing a heightened emphasis on energy efficiency. This study addressed a green hybrid flowshop rescheduling problem with consistent sublots (GHFRP_CS) in the context of urgent lot insertion. Initially, we establish an optimisation model aimed at minimising the makespan, total energy consumption, and system stability. To tackle this NP-hard multi-objective optimization problem, we develop a constructive heuristic generating promising solutions based on lot split, sequence, and local search rules. Further improvement is achieved through a multi-objective discrete artificial bee colony algorithm (MDABC). MDABC decomposes the problem into sub-problems, initiating solutions with the constructive heuristic and refining them through employed bee, onlooker bee, and scout bee phases. Computational experiments compare MDABC with other multi-objective evolutionary algorithms (MOEAs) on small- and large-scale problems. Results demonstrate MDABC's superiority, achieving fourfold accuracy and efficiency enhancement for small-scale instances and sixfold improvement for large-scale problems at low cost compared to other MOEAs.