A mathematical model and solution algorithms for optimising system-level configurations of reconfigurable single part flow lines

This study addresses a system-level configuration selection problem for reconfigurable single part flow lines (R-SPFLs) with parallel identical flexible machines at each stage. The problem is to determine the number of stages, the number of machines of a certain type at each stage and the assignment of operations to each stage in order to satisfy the demand of a part type. Precedence relations among the operations and space limitations are also considered. For the objective of minimising the sum of machine purchase and operation processing costs, a nonlinear integer programming model is developed that gives the optimal solutions. Then, due to the problem's complexity, a basic variable neighbourhood search algorithm is proposed that constructs an initial solution using a greedy-type heuristic and improves it using a shaking and a local search improvement methods. Moreover, the basic algorithm is extended to a general one that uses a variable neighbourhood descent method. Computational results show that the two algorithms outperform the previous one significantly in both solution quality and computation times, and the general algorithm improves the basic one significantly. Finally, the applicability of the variable neighbourhood search algorithms is shown by reporting a brief case study.