Sustainable Process Planning Strategies for Reconfigurable Manufacturing Systems in Industry 4.0

Sustainable Process Planning Strategies for Reconfigurable Manufacturing Systems in Industry 4.0 | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Sustainable Process Planning Strategies for Reconfigurable Manufacturing Systems in Industry 4.0 Dr. Binayak Pattanayak, Tanveer Ahmad Wani, Guntaj J, Dr.J. JAYAPRABAKAR, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6022270/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 4 You are reading this latest preprint version Abstract Reconfigurable manufacturing systems (RMS) have become increasingly popular in modern-day that quickly changing industrial landscape with the need for adaptable, effective, and sustainable production solutions. Traditional RMS planning has difficulties in adapting to modern manufacturing's dynamic nature, leading to inefficiencies in resource utilization, scheduling, and sustainability. This research explores sustainable process planning strategies for RMS in Industry 4.0 by integrating advanced optimization techniques with real-time, reducing environmental impact while maximizing production efficiency. A Fuzzy Proportional-Integral-Derivative (PID) control fused Dynamic Shuffled Shepherd Optimization (Fuzzy PID-DSSO) algorithm is proposed to identify optimal and eco-friendly manufacturing process plans. RMS efficiency data is obtained for the effective sustainable process. In production, the fuzzy PID controller is utilized for real-time control, improving the efficacy and stability of the system. The DSSO algorithm enhances process selection, sequencing, and reconfiguration, to maximize efficiency and minimize environmental effects. Findings show that the proposed model provides efficient outcomes in terms of optimal values of tool-changing (5) and setup-changing (5) in process planning for RMS in Industry 4.0. The results highlight that integrating Industry 4.0 technologies with sustainable planning strategies enhances eco-friendly manufacturing and adaptability in modern production environments. Sustainable Process Planning Reconfigurable Manufacturing Systems (RMS) Proportional-Integral-Derivative (PID) Industry 4.0 Fuzzy PID control Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 02 Apr, 2025 Reviewers invited by journal 01 Apr, 2025 Editor invited by journal 13 Feb, 2025 First submitted to journal 13 Feb, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6022270","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":436970103,"identity":"f12fffe8-6899-41b2-bc4c-20caa53c9ad2","order_by":0,"name":"Dr. Binayak Pattanayak","email":"data:image/png;base64,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","orcid":"https://orcid.org/0009-0002-3719-258X","institution":"Siksha O Anusandhan University Institute of Business and Computer Studies","correspondingAuthor":true,"prefix":"Dr.","firstName":"Binayak","middleName":"","lastName":"Pattanayak","suffix":""},{"id":436970104,"identity":"545c55cb-a3e4-4e05-99dc-cb645be6b98c","order_by":1,"name":"Tanveer Ahmad Wani","email":"","orcid":"","institution":"Noida International University","correspondingAuthor":false,"prefix":"","firstName":"Tanveer","middleName":"Ahmad","lastName":"Wani","suffix":""},{"id":436970105,"identity":"38d409ad-1e1e-47e8-85a2-15d8cfc9620b","order_by":2,"name":"Guntaj J","email":"","orcid":"","institution":"Chitkara Institute of Engineering and Technology","correspondingAuthor":false,"prefix":"","firstName":"Guntaj","middleName":"","lastName":"J","suffix":""},{"id":436970106,"identity":"474b677e-af6e-477b-a50b-64cef0714255","order_by":3,"name":"Dr.J. JAYAPRABAKAR","email":"","orcid":"","institution":"Sathyambama Institute of Science and Technology: Sathyabama Institute of Science and Technology (Deemed to be University)","correspondingAuthor":false,"prefix":"Dr.","firstName":"J.","middleName":"","lastName":"JAYAPRABAKAR","suffix":""},{"id":436970107,"identity":"80559f17-e8fb-4d6a-9e3d-6824b79631af","order_by":4,"name":"Sujai Selvarajan","email":"","orcid":"","institution":"JAIN (Deemed-to-be-university)","correspondingAuthor":false,"prefix":"","firstName":"Sujai","middleName":"","lastName":"Selvarajan","suffix":""}],"badges":[],"createdAt":"2025-02-13 10:43:09","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6022270/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6022270/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":81098051,"identity":"c693d7aa-ac47-467f-b2d9-a8f47e51c289","added_by":"auto","created_at":"2025-04-22 08:13:11","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":490276,"visible":true,"origin":"","legend":"","description":"","filename":"ReconfigurableManufacturingPaperv112.02.25.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6022270/v1_covered_5ebdc1eb-61d6-447a-b220-58ddc47f66df.pdf"}],"financialInterests":"","formattedTitle":"Sustainable Process Planning Strategies for Reconfigurable Manufacturing Systems in Industry 4.0","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"international-journal-of-system-assurance-engineering-and-management","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"ijsa","sideBox":"Learn more about [International Journal of System Assurance Engineering and Management](http://link.springer.com/journal/13198)","snPcode":"13198","submissionUrl":"https://www.editorialmanager.com/ijsa/default2.aspx","title":"International Journal of System Assurance Engineering and Management","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Sustainable Process Planning, Reconfigurable Manufacturing Systems (RMS), Proportional-Integral-Derivative (PID), Industry 4.0, Fuzzy PID control","lastPublishedDoi":"10.21203/rs.3.rs-6022270/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6022270/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eReconfigurable manufacturing systems (RMS) have become increasingly popular in modern-day that quickly changing industrial landscape with the need for adaptable, effective, and sustainable production solutions. Traditional RMS planning has difficulties in adapting to modern manufacturing's dynamic nature, leading to inefficiencies in resource utilization, scheduling, and sustainability. This research explores sustainable process planning strategies for RMS in Industry 4.0 by integrating advanced optimization techniques with real-time, reducing environmental impact while maximizing production efficiency. A Fuzzy Proportional-Integral-Derivative (PID) control fused Dynamic Shuffled Shepherd Optimization (Fuzzy PID-DSSO) algorithm is proposed to identify optimal and eco-friendly manufacturing process plans. RMS efficiency data is obtained for the effective sustainable process. In production, the fuzzy PID controller is utilized for real-time control, improving the efficacy and stability of the system. The DSSO algorithm enhances process selection, sequencing, and reconfiguration, to maximize efficiency and minimize environmental effects. Findings show that the proposed model provides efficient outcomes in terms of optimal values of tool-changing (5) and setup-changing (5) in process planning for RMS in Industry 4.0. The results highlight that integrating Industry 4.0 technologies with sustainable planning strategies enhances eco-friendly manufacturing and adaptability in modern production environments.\u003c/p\u003e","manuscriptTitle":"Sustainable Process Planning Strategies for Reconfigurable Manufacturing Systems in Industry 4.0","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-04-22 07:57:06","doi":"10.21203/rs.3.rs-6022270/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2025-04-03T00:59:09+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-04-01T15:05:15+00:00","index":"","fulltext":""},{"type":"editorInvited","content":"International Journal of System Assurance Engineering and Management","date":"2025-02-14T02:19:39+00:00","index":"","fulltext":""},{"type":"submitted","content":"International Journal of System Assurance Engineering and Management","date":"2025-02-13T05:42:55+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"international-journal-of-system-assurance-engineering-and-management","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"ijsa","sideBox":"Learn more about [International Journal of System Assurance Engineering and Management](http://link.springer.com/journal/13198)","snPcode":"13198","submissionUrl":"https://www.editorialmanager.com/ijsa/default2.aspx","title":"International Journal of System Assurance Engineering and Management","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"dad6d53a-45d2-4427-8c10-f845dce5ec9e","owner":[],"postedDate":"April 22nd, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2025-12-09T11:02:06+00:00","versionOfRecord":[],"versionCreatedAt":"2025-04-22 07:57:06","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-6022270","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6022270","identity":"rs-6022270","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}