Energy-efficient control in multi-stage production lines with parallel machine workstations and production constraints

Nowadays, the growing interest in industry for enhancing manufacturing processes sustainability is a major trend. One of the most supported strategies to increase the energy-efficiency of manufacturing activities is the control of machine state towards the optimum trade-off between production rate and energy demand. This method is referred to as energy-efficient control and it triggers machines in a standby state with low power request. In this article, multi-stage production lines composed of identical parallel machine workstations are the systems of interest, and the energy-efficient control policies make use of buffer level information. Each machine can be switched off instantaneously and switched on with a stochastic startup time. Problem objective is to minimize the energy demand while ensuring production constraints. This article proposes a novel approach to solve the problem at hand. An exact model for two-stage system is formulated using a Markov Decision Process to be solved with a linear programming methodology. A novel technique, namely the Backward-Recursive approach, is used to address systems with more than two stages. Numerical experiments confirm the effectiveness of the proposed approach.