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Enhancing Manufacturing Cell Formation Through Availability-Based Optimization Using the Black Widow Optimizer

Paulo Figueroa-Torrez1, Orlando Duran2, Broderick Crawford3

  • 1Departamento de Ciencias Industriales, Medio Ambiente y Energía, Universidad Católica Boliviana "San Pablo", Colón 734, Tarija, Bolivia.

Biomimetics (Basel, Switzerland)
|May 26, 2026
PubMed
Summary
This summary is machine-generated.

This study introduces a manufacturing cell design model that incorporates machine availability, reliability, and repair times. The Black Widow Optimizer efficiently solves this complex problem, ensuring cost-effective and robust production layouts.

Keywords:
Black Widow Optimizeralternative routesmachine availabilitymanufacturing cell formationmetaheuristicsmulti-period optimization

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Area of Science:

  • Operations Research
  • Manufacturing Systems Engineering
  • Industrial Engineering

Background:

  • Traditional cell formation problems often overlook machine reliability and repair dynamics.
  • Equipment availability significantly impacts production efficiency and cost.
  • Dynamic changes in manufacturing systems over time require advanced modeling approaches.

Purpose of the Study:

  • To develop a multi-period Generalized Cell Formation Problem with Machine Availability (GCFP-MA) model.
  • To integrate equipment reliability (Mean Time Between Failures - MTBF, Mean Time to Repair - MTTR) and temporal degradation into cell design.
  • To optimize manufacturing cell configurations considering dynamic system behavior and downtime costs.

Main Methods:

  • Formulation of the GCFP-MA incorporating availability-based constraints and downtime penalties.
  • Utilization of Markov-Chain models to represent machine availability states.
  • Implementation and validation of the Black Widow Optimizer (BWO) metaheuristic for solving the NP-hard optimization problem.

Main Results:

  • The Black Widow Optimizer (BWO) effectively finds the global optimum for the GCFP-MA.
  • BWO demonstrates significantly reduced computational effort compared to exhaustive search benchmarks.
  • The model prevents infeasible or over-optimistic cell designs by considering availability and repair dynamics.

Conclusions:

  • Integrating machine availability and repair dynamics leads to more cost-effective and robust manufacturing cell layouts.
  • The proposed unified framework enhances production system design by incorporating availability engineering principles.
  • The BWO metaheuristic offers an efficient solution for complex cell formation problems with dynamic machine availability.