Loading too many or too few copies of tools may result in waste of tool magazine slots and unnecessary machine shutdowns. This is a consequence of not integrating the tool‐configuration problem with other flexible manufacturing system (FMS) planning problems. Solving part‐selection, machine‐loading and tool‐configuration problems independently may cause entire solutions to be infeasible. We propose both an approach to the explicit formulation of tool configuration problems and the simultaneous solution of part‐selection, machine‐loading and tool‐configuration problems. We developed and solved sequentially some associated bicriteria models sequentially. We also discussed the effects of considering some secondary objectives on system performance and described the concepts of critical magazine size and critical machining time using an example problem. Unnecessary allocation and under‐use of tool magazine capacity and machining time could be reduced by considering the critical magazine size and machining time. Finally, we suggest using a method based on Lagrangian relaxation for solving large size problems.
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