Integrated production and reconfiguration planning in modular plug-and-produce production systems

Modular plug-and-produce production systems have been proposed as promising architectures to face the challenge of evolving market requirements, large product variety and small lots. These systems enable fast reconfiguration through on-line production modules substitution. However, such capability poses challenges at planning level, as the sequencing of lots and the selection of production modules need to be performed simultaneously. This paper proposes an integrated method for production and reconfiguration planning combining stochastic lot completion time distribution analysis and lot sequence optimization to maximize the system service level. The approach is validated in a real industrial system producing hydraulic valves.