Reconfigurable process-aware factory layout planning: a human-centric multi-objective optimization approach

Factory layout planning is central to manufacturing performance. By aligning productivity with worker well-being, factories can achieve more sustainable operations. Traditional approaches often treat the process sequence as static, limiting adaptability. This article introduces a human-centric approach that treats the process sequence as reconfigurable, enabling dynamic adjustment of resources and equipment across the assembly line. The approach integrates sequence generation with precedence constraints, block layout creation and resource positioning into a unified multi-objective optimization process. A genetic algorithm combined with digital human modelling evaluates proposals in terms of worker well-being, walking distance and area utilization, while ensuring compliance with work-environment regulations. Unlike previous studies, this method integrates reconfigurable sequencing with resource positioning into full assembly-line optimization, validated in an industrial testbed. The findings show how adaptable layouts improve performance and embed human factors and ergonomics into decision making, supporting Industry 5.0 principles of sustainable, human-centric manufacturing.