Having sustainable and flexible features is crucial for manufacturing companies considering the increasing competition in the globalized world. This study considers three aspects of sustainability, namely economic, social, and environmental factors, in the design of flexible manufacturing cells. Three different multi-objective integer mathematical programming models were developed with the objective of minimizing the costs associated with carbon emissions, inter-cellular movements, machine processing, machine replacement, worker training, and additional salary (bonus). Simultaneously, these models aim to minimize the carbon emission amount of the cells within the environmental dimension scope. The developed models are a goal programming model, an epsilon constraint method, and an augmented epsilon constraint (AUGMECON) method. In these models, alternative routes of parts are considered while assigning parts to machines. The results are obtained using the LINGO 20.0 optimization program with a developed illustrative example. The obtained results are tested and compared by performing sensitivity analyses. The sensitivity analyses include examinations of the effects of changes in part demands, machine capacity values, carbon limit value, and the maximum number of workers in cells.

The study aims to design flexible manufacturing cells with routing flexibility. A weighted mixed-integer linear mathematical programming model that aims to find optimal routing of parts in flexible manufacturing cells under constraints such as minimum machine utilization rate, maximum machine utilization rate, tool capacities, the utilization rate of workers, and labor-system unbalance is developed. The mathematical programming model aims to minimize the weighted sum of five objective functions: (1) the total number of intracellular movements; (2) the total number of intercellular movements; (3) the total workload unbalance of the machine system; (4) the total number of tools in all machines in the cells; and (5) the total labor-system workload unbalance. The main contribution of this study is to obtain these five objectives simultaneously, which have not been encountered to handle together before. By integrating these factors, the study presents a comprehensive approach to optimizing the design of flexible manufacturing cells. This study also has the potential to enhance system performance by addressing these factors. An illustrative problem tests the developed model, and the LINGO 17.0 optimization program is used to solve the generated mathematical programming model. Moreover, the related sensitivity analysis is performed with some parameters to examine the obtained results.