Optimisation of process plan generation for reconfigurable manufacturing systems: efficient heuristics and lower bounds

We address the process plan generation problem in a reconfigurable manufacturing environment. The objective is to minimise the total production time of a given part which includes the processing times of operations, as well as the changeover times for machines, configurations, and tools. A new efficient 0–1 mathematical programming formulation is proposed, together with a heuristic and two lower bounds. The formulation is based on one main decision variable (1MDV). It outperforms a well known two-main decision variable formulation (2MDV) from the literature. Using a commercial solver, the 1MDV formulation is on average almost five times faster than the 2MDV formulation across all instances where optimality was achieved. The proposed heuristic is a decomposition mathematical programming-based heuristic. For small benchmark instances solved to optimality using 1MDV formulation, the heuristic obtains solutions at less than 1% distance on average from optimum in few seconds. The best of the two proposed lower bounds, LB2, is obtained in less than 0.56 seconds, across all tested instances, while the 1MDV model needs about 30 seconds on average to reach the same result. These lower bounds are used to measure the performance of the heuristics on large size instances