Human–Robot Collaborative U-Shaped Disassembly Line Balancing Using Dynamic CRITIC–Entropy and Improved Honey Badger Optimization

This paper tackles the challenge of disassembly sequence planning (DSP) in energy-efficient remanufacturing by introducing an innovative hybrid optimization framework. The proposed model integrates a Dynamic Time-Varying CRITIC–Entropy (DTVCE) decision-making framework with an Improved Honey Badger Algorithm (IHBA) to optimize disassembly sequences under key operational criteria, including idle rate, line smoothness, and energy consumption. The DTVCE framework constructs a dynamic composite score by normalizing evaluation criteria across time slices and incorporating temporal discounting to capture the evolving importance of each factor. Meanwhile, by establishing a symmetric disassembly constraint matrix to restrict the disassembly sequence and integrating exploration and exploitation mechanisms to enhance the IHBA, the solution process is empowered to efficiently generate feasible disassembly sequences and fulfill task allocation across workstations while satisfying takt time constraints. Experimental validation demonstrates that the proposed framework significantly outperforms traditional disassembly optimization approaches in both energy efficiency and line balance performance. In a case study involving an automotive drive axle, the method achieved a near-optimal configuration using only eight workstations, leading to a marked reduction in both energy consumption and idle times. Sensitivity analysis further verifies the model’s robustness, showing stable convergence and consistent performance under varying takt times and energy parameters. Overall, this study contributes to the advancement of green remanufacturing by offering a scalable, data-driven, and adaptive solution to disassembly optimization—paving the way toward sustainable and energy-aware production environments.