Optimizing Sustainable Production: A Mathematical Model for Energy Cost and Completion Time Minimization in Multi-State Manufacturing Systems

Abstract

The paper presents a mathematical optimization model designed to enhance sustainable production planning by minimizing both energy costs and total completion time in manufacturing processes. The model specifically addresses the complexities of multi-state single-machine systems with time-dependent electricity costs, integrating considerations such as sequence-dependent setup times and varying machine states. By optimizing job sequencing and scheduling, the model effectively aligns energy-intensive operations with periods of lower energy costs, reducing overall energy consumption and environmental impact. Validated in a real industrial environment within an Italian SME, the model demonstrated significant improvements in company operations, including a reduction in energy costs and completion time. The research contributes to the growing body of work on energy-efficient manufacturing, offering a robust framework for practical application in production systems. Future research directions include the development of advanced algorithms for larger-scale problems and the incorporation of additional factors such as renewable energy availability and the optimization of multiple machines.