Multi-operation Optimization of Responsive Manufacturing System with Energy Objectives by

In a manufacturing unit general ly more than one product is made in certain cycle t ime, and in order to become competit ive, the progressive firms run the production facil it ies optimally. The customer also wants an optimum solution for their requirements. The energy cost const itutes a major portion of manufacturing cost. In current situation the manufacturing must be responsive to customer, vender, share-holder and all types of competit ion. The manufacturing must be flexible, easy to operate and mistake-proof, this is a robust organization. The ecosystem regulat ion and equil ibrium guide us to control variabili ty of production system also. By this paper a methodology wil l be develop for batch manufacturing organizat ion to work as responsive manufacturing system with energy considerat ions. The steel, chemical and pharmaceuticals unit follow batch type of production, because of low volume, high value products. Now the industr ies, al l over the world, whether large or small, are facing challenges on mult iple fronts, competi t ion is becoming borderless, new al l iances are being formed; internal processes are now being considered for outsourcing. Work-force mult iple-uti lization and total quali ty is the objective. The Taguchi loss function is a tool to control variabili ty of performance and energy losses are reduced to minimum and 5-E key decision areas, e.g. environmental, economy, engineering, energy, and efficiency may automatical ly control