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An energy and productivity optimization model in Bernoulli serial lines

In this paper, an integrated model is presented to minimize energy consumption while maintaining desired productivity in serial lines with Bernoulli reliability machines. Exact analysis of optimal allocations of production capacity is carried out for three- and four-machine lines with small buffers. For lines with larger buffers, an aggregation procedure is introduced to evaluate line production rate, and then used to search optimal allocation of machine efficiency to minimize energy usage. Insights and allocation principles are obtained through the analyses.