Hybridization in meta-heuristic techniques for green layout design in the tyre manufacturing industry: An optimal analysis

Abstract

To stop or lessen factory pollution, many academics in the field of study have produced a vast array of strategies to achieve optimization goals. But, it is unable to follow a uniform solution for all production facilities. In this research work, green layout design (GLD) is proposed to minimize total material handling cost (TMHC) and CO₂ emissions. The green facility layout refers to the facility layout with minimum CO₂ emissions and to eliminate unnecessary energy dissipation from material handling equipments & production machineries, as well as plant re-layout in-term on material handling cost. In this study context, a Lagrangian relaxation model has been used at the allocation level. It computes a suboptimal solution to the dual problem in order to obtain a feasible solution. This enhanced algorithm method iteratively tries to minimize the gap between the dual and feasible solutions on minimal of TMHC and CO₂ emission rate. It has been experimentally simulated using the MATLAB (Matrix Laboratory) application and upgraded adaptive salp swarm optimization (ASSO), dragon fly optimization (DFO) and Hybrid (combination) of ASSO-DFO evolutionary optimization techniques. The primary focus of this implementation is to control material handling between departments or cells, production flow between departments, energy consumption (electrical and gas consumption for production), and manpower utilization within and across departments. This research has chosen an existing and acceptable designs from targeted tyre manufacturing company in South India. The hybrid ASSO-DFO implementation TMHC differs from ABC by 60%, DFO by 65%, 58% with simulated annealing (SA), and ASSO by 48%. Emission rate decreased by 26% ABC, 21% DFO, and 24% SA & 18% with ASSO. An average of 50% decrease in TMHC and 25% reduction of CO₂ emission rate in GLD have been achieved.