Agile factorial production for a single manufacturing line with multiple products

Industrial practices and experiences highlight that demand is dynamic and non-stationary. Research however has historically taken the perspective that stochastic demand is stationary therefore limiting its impact for practitioners. Manufacturers require schedules for multiple products that decide the quantity to be produced over a required time span. This work investigated the challenges for production in the framework of a single manufacturing line with multiple products and varying demand. The nature of varying demand of numerous products lends itself naturally to an agile manufacturing approach. We propose a new algorithm that iteratively refines production windows and adds products. This algorithm controls parallel genetic algorithms (pGA) that find production schedules while minimizing costs. The configuration of such a pGA was essential in influencing the quality of results. In particular providing initial solutions was an important factor. Two novel methods are proposed that generate initial solutions by transforming a production schedule into one with refined production windows. The first method is called factorial generation and the second one fractional generation method. A case study compares the two methods and shows that the factorial method outperforms the fractional one in terms of costs.