Modelling and Optimization of Batch Manufacturing Systems under Environmental and Economic Considerations

Abstract

Nowadays, minimization of the negative environmental impact of manufacturing processes is considered one of the most challenging problems in various industrial fields. Research communities and environmental legislators are continuously working to address these problems by placing significant efforts in devising new strategies to increase environmental sustainability. One of these problems is the lack of a comprehensive framework that can simultaneously improve economic aspects and lessen the impact on the environment. The need for a mathematical model that can assist firms in reaching suitable investment decisions has become of paramount importance. In this context, this study aims at optimizing the environmental and economic sustainability of batch production systems (i.e. a series of workstations where products are manufactured in batches). To this end, a profit maximization model was created by incorporating constraints such as budget, demand, greenhouse gas emissions and hazardous wastes within the manufacturing stage of product life cycle. Moreover, the model provides detailed guidelines on required improvements in a specific manufacturing system and calculates the investment associated with such implementations. This new approach was tested by using two different software packages and results were probed and discussed in different scenarios to investigate its validity. Sensitivity analysis and simulation results proved the consistency of the proposed mathematical model. In particular, in order to further assess the validity of the model, a pharmaceutical plant was selected as a case study, which also permitted discussion on additional aspects of the problem.