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To improve the efficiency of end-of-life product’s disassembly process, this paper aims to propose a disassembly sequence planning (DSP) method to reduce additional efforts of removing parts when considering the changes of disassembly directions and tools.

The methodology has three parts. First, a disassembly hybrid graph model (DHGM) was adopted to represent disassembly operations and their precedence relations. After representing the problem as DHGM, a new integer programming model was suggested for the objective of minimizing the total disassembly time. The objective takes into account several criteria such as disassembly tools change and the change of disassembly directions. Finally, a novel hybrid approach with a chaotic mapping-based hybrid algorithm of artificial fish swarm algorithm (AFSA) and genetic algorithm (GA) was developed to find an optimal or near-optimal disassembly sequence.

Numerical experiment with case study on end-of-life product disassembly planning has been carried out to demonstrate the effectiveness of the designed criteria and the results exhibited that the developed algorithm performs better than other relevant algorithms.

More complex case studies for DSP problems will be introduced. The performance of the CAAFG algorithm can be enhanced by improving the design of AFSA and GA by combining them with other search techniques.

DSP of an internal gear hydraulic pump is analyzed to investigate the accuracy and efficiency of the proposed method.

This paper proposes a novel CAAFG algorithm for solving DSP problems. The implemented tool generates a feasible optimal solution and the considered criteria can help the planer obtain satisfactory results.