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An analysis of the theoretical and implementation aspects of process planning in a reconfigurable manufacturing system

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Abstract

The reconfigurable manufacturing system is an advanced field of research that has surpassed the efficiency of other manufacturing systems due to its high throughput, cost-effectiveness, and ability to accommodate product variety. An important problem addressed in the field of reconfigurable manufacturing systems is process planning which assigns configurations to different operations. Process planning has been the focus of research for almost two decades; however, a comprehensive review is lacking to highlight the possible streams of future contributions to this field of research. To this end, this study presents a systematic review of the process planning in a reconfigurable manufacturing system with a focus on optimization efforts. This review is organized in two interconnected phases, i.e., a theoretical phase and an implementation phase. The theoretical phase reviews the concerned literature regarding the levels of analysis, reconfigurable manufacturing system (RMS) characteristics, different research themes, and change agents. On the other hand, the implementation phase reviews the literature regarding the use of different objective functions, constraints, solution approaches, nature of problem/solution, and the use of industrial applications. Several future research streams are provided which can guide, in a broader sense, the advancement of process planning literature. As a demonstration, quality, supply chain, and human/operator issues are highlighted to advance the scope of applicability of the concerned literature. A thorough analysis of the operator aspects in scheduling literature is presented which can benefit practitioners working in a changeable/reconfigurable manufacturing environment. Moreover, practical process planning approaches are offered to analyze the cost, time, and quality aspects. Finally, the conclusion of the study is provided.

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Abbreviations

RMS:

Reconfigurable manufacturing system

CRMS:

Cellular reconfigurable manufacturing system

VCMS:

Virtual cellular manufacturing system

CMS:

Cellular manufacturing system

GA:

Genetic algorithm

NSGA-II:

Non-sorting genetic algorithm

SA:

Simulated annealing

AMOSA:

Archived multi-objective simulated annealing

PSO:

Particle swarm optimization

MOPSO:

Multi-objective particle swarm optimization

AHP:

Analytical hierarchical process

TS:

Tabu search

SPEA-II:

Strength Pareto evolutionary algorithm

AUGECON:

Augmented e-constraint

WGO:

Weighted goal programming optimization

ILP:

Integer linear programming

MILP:

Mixed integer linear programming

MINLP:

Mixed integer non-linear programming

LB:

Lower bound

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Funding

This research was funded by the Higher Education Commission (HEC) Pakistan and Campus France under scholarship number 904180 K.

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Authors and Affiliations

  1. Arts et Métiers Institute of Technology, Université de Lorraine, LCFC, HESAM Université, 57070, Metz, France

    Abdul Salam Khan, Lazhar Homri, Jean Yves Dantan & Ali Siadat

  2. Department of Operations and Supply Chain, NUST Business School, National University of Sciences and Technology (NUST), Islamabad, Pakistan

    Abdul Salam Khan

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  1. Abdul Salam Khan
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  2. Lazhar Homri
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  3. Jean Yves Dantan
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  4. Ali Siadat
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Contributions

Conceptualization: Abdul Salam Khan and Ali Siadat; classifications and content analysis: Abdul Salam Khan and Jean Yves Dantan; formal analysis: Abdul Salam Khan and Ali Siadat; validation: Lazhar Homri; writing: Abdul Salam Khan; proof-reading and corrections: Lazhar Homri and Jean Yves Dantan.

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Correspondence to Abdul Salam Khan.

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Khan, A.S., Homri, L., Dantan, J.Y. et al. An analysis of the theoretical and implementation aspects of process planning in a reconfigurable manufacturing system. Int J Adv Manuf Technol 119, 5615–5646 (2022). https://doi.org/10.1007/s00170-021-08522-0

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