An Evolutionary Algorithm for Efficient Flexible Workstation Layout in Multi-Product Handcrafted Manufacturing

This study proposes an Evolutionary Algorithm (EA) to optimize the workstation layout in multi-product handcrafted furniture workshops with simultaneous manufacturing. The algorithm models the arrangement of workstations within a limited space, enhancing activity coordination and reducing unnecessary worker movement. The optimized solution is obtained through the application of evolutionary operators, including selection, crossover, mutation, and refinement, iterating over successive generations. To evaluate the EA’s performance, a computational simulation is conducted using ProModel®, comparing its efficiency against conventional methodologies such as Systematic Layout Planning (SLP) and the CRAFT algorithm. In a case study involving the simultaneous elaboration of three different products, each by a different artisan, the EA successfully reduces the total worker travel distance by 51.45% and the system’s total processing time by 13.2%. The results indicate that the proposed approach not only enhances operational efficiency in a smaller environment but also lays the groundwork for integrating advanced strategies. These include cellular manufacturing and hybrid production schemes, ultimately enhancing flexibility and sustainability in this sector.