Simulation-based Design for the Layout and Operation of AGVs in Sustainable and Efficient Manufacturing Systems

Complex manufacturing systems are recently undergoing a green revolution due to manufacturing customization towards sustainable products. A key enabler for the implementation of green and energy efficient production is simulation-based design, which supports system engineers and designers in making decision choices aimed at enhancing the performance of smart and sustainable production. In this context, this work proposes a simulation approach to support the design of the layout and operation of automated guided vehicles (AGVs) in complex production lines. In particular, a case study related to the assembly of electric axles for heavy-duty vehicles is presented: a scenario analysis implemented in the Plant Simulation platform is used to determine the optimal configuration of AGVs in terms of number of vehicles and operation (e.g., definition of charging strategies, scheduling of charging stops, routing). The simulation results first show that the reduction of the AGVs' energy consumption and the increase of production throughput are competing criteria; second, the choice of AGV charging strategies has a significant influence on the energy consumption as well as on the productivity performance.