Modeling, analysis, and improvement of integrated productivity and energy consumption in a serial manufacturing system

The performance of a manufacturing system is measured by factors such as its productivity and energy efficiency. Current systems lack the required indices to measure its efficiency and highlight the areas of inefficiency in the system. The paper is aimed at improving the overall performance of manufacturing system by suggesting methods for integrated improvement in above two factors. This paper establishes performance indices for measuring energy efficiency and productivity of the system, which uses easily available sensor data from the production line. The energy structure and effects of downtime events on the production line has been analyzed to develop energy and productivity performance indicators. The indices are utilized to identify the machines which is most power inefficient and results in maximum production loss of the system. These indicators are utilized to illustrate our method for improving productivity and concepts of downtime-bottleneck and power-bottleneck. The methods proposed are verified by simulation studies.