Managing maintenance and its impact on business results is increasingly complex, calling for more advanced operational research methodologies to address the challenge of sustainable decision-making. This problem-based research has identified a framework of methods to supplement the operations research/management science literature by contributing a hybrid simulation-based optimization framework (HSBOF), extending previously reported research.

Overall, it is the application of multi-objective optimization (MOO) with system dynamics (SD) and discrete-event simulation (DES) respectively which allows maintenance activities to be pinpointed in the production system based on analyzes generating less reactive work load on the maintenance organization. Therefore, the application of the HSBOF informs practice by a multiphase process, where each phase builds knowledge, starting with exploring feedback behaviors to why certain near-optimal maintenance behaviors arise, forming the basis of potential performance improvements, subsequently optimized using DES+MOO in a standard software, prioritizing the sequence of improvements in the production system for maintenance to implement.

Studying literature on related hybridizations using optimization the proposed work can be considered novel, being based on SD+MOO industrial cases and their application to a DES+MOO software.

• Purpose – This study aims to propose an efficient optimization algorithm to solve the assembly line balancing problem (ALBP). The ALBP arises in high-volume, lean production systems when decision makers aim to design an efficient assembly line while satisfying a set of constraints.
• Design/methodology/approach – An improved genetic algorithm (IGA) is proposed in this study to deal with ALBP in order to optimize the number of stations and the workload smoothness.
• Findings – To evaluate the performance of the IGA, it is used to solve a set of well-known benchmark problems and a real-life problem faced by an automobile manufacturer. The solutions obtained are compared against two existing algorithms in the literature and the basic genetic algorithm. The comparisons show the high efficiency and effectiveness of the IGA in dealing with ALBPs.
• Originality/value – The proposed IGA benefits from a novel generation transfer mechanism that improves the diversification capability of the algorithm by allowing population transfer between different generations. In addition, an effective variable neighborhood search is employed in the IGA to enhance its local search capability.

Lean is and will still be one of the most popular management philosophies in the Industry 4.0 context and simulation is one of its key technologies. Many authors discuss about the benefits of combining Lean and simulation to better support decision makers in system design and improvement. However, there is a lack of reviews in the domain. Therefore, this paper presents a four-stage comprehensive review and analysis of existing literature on their combination. The aim is to identify the state of the art, existing methods and frameworks for combining Lean and simulation, while also identifying key research perspectives and challenges. The main trends identified are the increased interest in the combination of Lean and simulation in the Industry 4.0 context and in their combination with optimisation, Six Sigma, as well as sustainability. The number of articles in these areas is likely to continue to grow. On the other hand, we highlight six gaps found in the literature regarding the combination of Lean and simulation, which may induce new research opportunities. Existing technical, organisational, as well as people and culture related challenges on the combination of Lean and simulation are also discussed.

Assembly line designs in manufacturing commonly face the key problem of dividing the assembly tasks among the working stations so that the efficiency of the line is optimized. This problem is known as the assembly line balancing problem which is known to be NP-hard. This study, proposes a bi-objective genetic algorithm to cope with the assembly line balancing problem where the considered objectives are the utilization of the assembly line and the workload smoothness measured as the line efficiency and the variation of workload, respectively. The performance of the proposed genetic algorithm is tested through solving a set of standard problems existing in the literature. The computational results show that the genetic algorithm is promising in providing good solutions to the assembly line balancing problem.

This study aims to bridge the gap between theory and practice by addressing a real-world assembly line balancing problem (ALBP) where task times are stochastic and there are zoning constraints in addition to the commonly known ALBP constraints. A mixed integer programming (MIP) model is proposed for each of the straight and U-shaped assembly line configurations. The primary objective in both cases is to minimize the number of stations; minimizing the maximum of stations’ mean time and the stations’ time variance are considered secondary objectives. Four different scenarios are discussed for each model, with differences in the objective function. The models are validated by solving a real case taken from an automobile manufacturing company and some standard test problems available in the literature. The results indicate that both models are able to provide optimum solutions for problems of different sizes. The technique for order preference by similarity to ideal solution (TOPSIS) is used to create reliable comparisons of the different scenarios and valid analysis of the results. Finally, some insights regarding the selection of straight and U-shaped layouts are provided.

It is widely known that the assembly line balancing problem (ALBP) is an NP-hard optimization problem. Although different meta-heuristics have been proposed for solving this problem so far, there is no convincing support that what type of algorithms can perform more efficiently than the others. Thus, using some statistical measures, the landscape of the simple ALBP is studied for the first time in the literature. The results indicate a flat landscape for the problem where the local optima are uniformly scattered over the search space. Accordingly, the efficiency of population-based algorithms in addressing the considered problem is statistically validated.

Decentralised in-house logistics areas, known as supermarkets, are widely used in the manufacturing industry for parts feeding to assembly lines. In contrary to the literature and inspired by observation in a real case, this study relaxes the assumption of using identical transport vehicles when deciding on the supermarkets’ location by considering the availability of different vehicles. In this regard, this study deals with the integrated supermarket location and transport vehicles selection problems (SLTVSP). A mixed-integer programming (MIP) model of the problem is developed. Due to the complexity of the problem, a hybrid genetic algorithm (GA) with variable neighborhood search (GA-VNS) is also proposed to address large-sized problems. The performance of GA-VNS is compared against the MIP, the basic GA, and simulated annealing (SA) algorithm. The computational results from the real case and a set of generated test problems show that GA-VNS provides a very good approximation of the MIP solutions at a much shorter computational time while outperforming the other compared algorithms. The analysis of the results reveals that it is beneficial to apply different transport vehicles rather than identical vehicles for SLTVSP.

The highly competitive automobile market requires automotive companies to become efficient by continuously improving their production systems. This paper presents a case study where simulationbased optimization (SBO) was employed as a step within a Value Stream Mapping event. The aim of the study was to promote the use of SBO to strengthen the continuous improvement work of the company. The paper presents all the key steps performed in the study, including the challenges faced and a reflection on how to introduce SBO as a powerful tool within the lean continuous improvement standards.

Using virtual models instead of physical models can help industries reduce the time and cost of developments, despite the time consuming process of building virtual models. Therefore, reusing previously built virtual models instead of starting from scratch can eliminate a large amount of work from users. Is having a virtual model enough to reuse it in another study or task? In most cases, not. Information about the history of that model makes it clear for the users to decide if they can reuse this model or to what extent the model is needed to be modified. A provenance management system (PMS) has been designed to manage provenance information, and it has been used with product lifecycle management system (PLM) and computer-aided technologies (CAx) to save and present historical information about a virtual model. This chapter presents a sequence-based framework of the CAx-PLM-PMS chain and two application case studies considering the implementation of this framework.

This study investigates the advantages and potentials of the metamodelbased multi-objective optimization (MOO) of a turning operation through the application of finite element simulations and evolutionary algorithms to a metal cutting process. The objectives are minimizing the interface temperature and tool wear depth obtained from FE simulations using DEFORM2D software, and maximizing the material removal rate. Tool geometry and process parameters are considered as the input variables. Seven metamodelling methods are employed and evaluated, based on accuracy and suitability. Radial basis functions with a priori bias and Kriging are chosen to model tool–chip interface temperature and tool wear depth, respectively. The non-dominated solutions are found using the strength Pareto evolutionary algorithm SPEA2 and compared with the non-dominated front obtained from pure simulation-based MOO. The metamodel-based MOO method is not only advantageous in terms of reducing the computational time by 70%, but is also able to discover 31 new non-dominated solutions over simulation-based MOO.