Energy-efficient distributed part programme for highly automated production systems

Distributed part programmes (PPs) across the shop-floor resources have been identified as a possible enabler of production flexibility, while the energy assessment has been recognised as a relevant factor for the global sustainability. This article proposes a distributed PP approach, identified as network part programme (NPP), while addressing the minimisation of system energy consumption. The approach, called energy-based NPP, is based on two mathematical models. The first model generates a number of alternative pallet configurations according to the minimisation of workpiece set-ups and energy consumption. The second model grants the energy consumption threshold at system level through the selection of previously-generated and alternative workplans. The application of the approach on a real case shows a reduction of the energy consumption, the respect of the system energy consumption threshold and a substantial improvement in operational costs compared to traditional workplan design methods. © 2014 © 2014 Taylor & Francis.