The presented manuscript deals with the impact of manufacturing flexibility on cost-time investment as a function of sustainable production, which addresses the company’s sustainable social and environmental impact adequately. The impact of manufacturing flexibility on cost-time investment in the research sphere is not described, despite the fact that we know its key role in the high-mix low-volume production types. Recently, researchers have been addressing intensively the impacts of various parameters on the sustainable aspect and its dependence on manufacturing flexibility. The complexity of the influence parameters is reflected in the multi-criteria nature of optimization problems that can be solved with appropriate use of the evolutionary computation methods. The manuscript presents a new method of manufacturing flexibility modelling, with respect to the four-level architectural model, which reflected as a symmetry phenomena influence on the cost-time profile diagram. The solution to a complex optimization problem is derived using the proposed improved heuristic Kalman algorithm method. A new method is presented of optimization parameters’ evaluation with respect to the manufacturing flexibility impacts on cost-time investment. The large impact of appropriate multi-criteria optimization on a sustainably justified production system is presented, with the experimental work on benchmark datasets and an application case. The new method allows a comprehensive optimization approach, and validation of the optimization results by which we can provide more sustainable products, manufacturing processes, and increase the company’s total, social and environmental benefits.

In recent years, there have been more and more collaborative workplaces in different types of manufacturing systems. Although the introduction of collaborative workplaces can be cost-effective, there is still much uncertainty about how such workplaces affect the capacity of the rest of production system. The article presents the importance of introducing collaborative workplaces in manual assembly operations where the production capacities are already limited. With the simulation modelling method, the evaluation of the introduction impact of collaborative workplaces on manual assembly operations that represent bottlenecks in the production process is presented. The research presents two approaches to workplace performance evaluation, both simulation modelling and a real-world collaborative workplace example, as a basis of a detailed time study. The main findings are comparisons of simulation modelling results and a study of a real-world collaborative workplace, with graphically and numerically presented parameters describing the utilization of production capacities, their efficiency and financial justification. The research confirms the expediency of the collaborative workplaces use and emphasise the importance of further research in the field of their technological and sociological impacts.

As a well-known NP-hard problem, the dynamic job shop scheduling problem has significant practical value, so this paper proposes an Improved Heuristic Kalman Algorithm to solve this problem. In Improved Heuristic Kalman Algorithm, the cellular neighbor network is introduced, together with the boundary handling function, and the best position of each individual is recorded for constructing the cellular neighbor network. The encoding method is introduced based on the relative position index so that the Improved Heuristic Kalman Algorithm can be applied to solve the dynamic job shop scheduling problem. Solving the benchmark example of dynamic job shop scheduling problem and comparing it with the original Heuristic Kalman Algorithm and Genetic Algorithm-Mixed, the results show that Improved Heuristic Kalman Algorithm is effective for solving the dynamic job shop scheduling problem. The convergence rate of the Improved Heuristic Kalman Algorithm is reduced significantly, which is beneficial to avoid the algorithm from falling into the local optimum. For all 15 benchmark instances, Improved Heuristic Kalman Algorithm and Heuristic Kalman Algorithm have obtained the best solution obtained by Genetic Algorithm-Mixed. Moreover, for 9 out of 15 benchmark instances, they achieved significantly better solutions than Genetic Algorithm-Mixed. They have better robustness and reasonable running time (less than 30 s even for large size problems), which means that they are very suitable for solving the dynamic job shop scheduling problem. According to the dynamic job shop scheduling problem applicability, the integration-communication protocol was presented, which enables the transfer and use of the Improved Heuristic Kalman Algorithm optimization results in the conventional Simio simulation environment. The results of the integration-communication protocol proved the numerical and graphical matching of the optimization results and, thus, the correctness of the data transfer, ensuring high-level usability of the decision-making method in a real-world environment.

Presented paper investigates the application of digital twins for the optimisation of intelligent manufacturing systems and focuses on the comparison between simulation modelling results and real-world production conditions. A digital twin was created in the Simio software environment using a data-driven simulation model derived from a real-world production system. Running the digital twin in real time, which was displayed graphically, facilitated the analysis of key parameters, including the number of finished products, average flow time, workstation utilization and product quality. The discrepancies were attributed to the use of random distributions of input data in the dynamic digital twin, as opposed to the long-term measurements and averages in the real-world system. Despite the limitations in the case study, the results underline the financial justification and predictive capabilities of digital twins for optimising production systems. Real-time operation enables continuous evaluation and tracking of parameters and offers high benefits for intelligent production systems. The study emphasises the importance of accurate selection of input data and warns that even small deviations can lead to inaccurate results. Finally, the paper high-lights the role of digital twins in optimising production systems and argues for careful consideration of input data. It highlights the importance of analysing real-world production systems and creating efficient simulation models as a basis for digital twin solutions. The results encourage extending the research to different types of production, from job shop to mass production, in order to obtain a comprehensive optimisation perspective.