Dynamic layout design for scalable reconfigurable manufacturing systems

Fatemeh Saffar, Shokraneh K. Moghaddam and Sihan Huang

International Journal of Production Research, 2025, vol. 63, issue 17, 6530-6552

Abstract: Reconfigurable manufacturing systems (RMS) is a type of manufacturing system in which the structure and resources are changed in a fast and cost-effective way to achieve the required capacity and performance at the required time. The layout design problem in an RMS refers to the challenge of determining the optimal physical arrangement of machines, equipment, and resources within the manufacturing facility to ensure flexibility, scalability, and efficiency. The key objective is to create a layout that supports rapid reconfiguration to accommodate changes in product types, production volumes, and processes while minimising downtime, costs, and material handling. In this paper a novel approach to dynamic facility layout design within scalable RMS is proposed which focuses on reconfigurable machine tools (RMT) to accommodate varying production requirements for different products. A new mixed integer linear programming (MILP) model is proposed which enables adjustment of the facility layout to align with fluctuating production volumes and product mixes in different production periods. Hypothetical Case studies are designed to demonstrate the effectiveness of the approach, highlighting improvements in operational flexibility, system design cost, throughput, and resource utilisation. The findings contribute to the development of RMS that can adapt to changing market demands, ensuring competitive advantage in manufacturing industries.

Date: 2025
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DOI: 10.1080/00207543.2025.2474215

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