Production Planning and Setup Time Optimization: An Industrial Case Study

  • José Pedro Vaz
  • Leonilde Varela
  • Bruno Gonçalves
  • José MachadoEmail author
Conference paper
Part of the Lecture Notes in Mechanical Engineering book series (LNME)


Production activity control approaches, methods, and mechanisms have been widely applied over the last decades, and continue to be of utmost importance nowadays, within the context of the currently fast-growing Industry 4.0 era. In this paper, a Simio-based simulation model is proposed and its application in a printing factory is illustrated. The main aim of this work consists of providing general production planning improvements in the considered factory, with a special focus on the reduction of setup time. The proposed model is based on several distinct production activity control mechanisms, for instance, the CONWIP and the Routing Group mechanisms from Simio, which did enable to reach good improvements regarding a set of performance measures considered, including machines’ setup time reduction, along with the maximization of the percentage of products delivered on time. Future work is also planned to be carried out to improve other kinds of performance measures, and by using other types of production activity control mechanisms, to be further applied in other industrial companies and sectors.


Production planning and control Optimization Simulation Scheduling Setup 



This work has been supported by FCT – Fundação para a Ciência e Tecnologia within the Project Scope: UID/CEC/00319/2019.


  1. 1.
    Brucker, P.: Scheduling algorithms. J. Oper. Res. Soc. 50, 774 (1999)Google Scholar
  2. 2.
    Varela, M., Ribeiro, R.: Evaluation of simulated annealing to solve fuzzy optimization problems. J. Int. Fuzzy Syst. 14(2), 59–71 (2003)zbMATHGoogle Scholar
  3. 3.
    Reddy, M., Ratnam, C., Agrawal, R., Varela, M., Sharma, I., Manupati, V.: Investigation of reconfiguration effect on makespan with social network method for flexible job shop scheduling problem. Comput. Ind. Eng. 110, 231–241 (2017)CrossRefGoogle Scholar
  4. 4.
    Pinedo, M.: Scheduling, vol. 29. Springer, New York (2012)CrossRefGoogle Scholar
  5. 5.
    Gallaugher, J.: Information Systems: A Manager’s Guide to Harnessing Technology. University of Minnesota Libraries Publishing, Minneapolis (2015)Google Scholar
  6. 6.
    Browne, J.: Production activity control - a key aspect of production control. Int. J. Prod. Res. 26(3), 415–427 (1988)CrossRefGoogle Scholar
  7. 7.
    Williamson, D., Shmoys, D.: The Design of Approximation Algorithms. Cambridge University Press, Cambridge (2011)CrossRefGoogle Scholar
  8. 8.
    Mason, S., Hill, R., Mönch, L., Rose, O., Carlo, M.: Proceedings of the 2008 Winter Simulation Conference (2008)Google Scholar
  9. 9.
    Kelton, W.: Simulation with ARENA. McGraw-hill, New York (2002)Google Scholar
  10. 10.
    Kelton, W., Smith, J., Sturrock, D., Verbraeck, A.: Simio & Simulation: Modeling, Analysis, Applications. Learning Solutions, Chennai (2011)Google Scholar
  11. 11.
    Sugimori, Y., Kusunoki, K., Cho, F., Uchikawa, S.: Toyota production system and kanban system materialization of just-in-time and respect-for-human system. Int. J. Prod. Res. 15(6), 553–564 (1977)CrossRefGoogle Scholar
  12. 12.
    Spearman, M., Woodruff, D., Hopp, W.: CONWIP: a pull alternative to kanban. Int. J. Prod. Res. 28(5), 879–894 (1990)CrossRefGoogle Scholar
  13. 13.
    Framinan, J., Gonzalez, P., Ruiz-Usano, R.: The CONWIP production control system: review and research issues. Prod. Planning Control 14(3), 255–265 (2003)CrossRefGoogle Scholar
  14. 14.
    Winston, W., Jeffrey, B.: Operations Research: Applications and Algorithms. Thomson/Brooks/Cole, California (2004)Google Scholar
  15. 15.
    Varela, M., Trojanowska, J., Carmo-Silva, S., Costa, N., Machado, J.: Comparative simulation study of production scheduling in the hybrid and the parallel flow. Manage. Prod. Eng. Rev. 8(2), 69–80 (2017)Google Scholar
  16. 16.
    Simio, LLC: About Simio | Simio (2018).

Copyright information

© The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Switzerland AG 2020

Authors and Affiliations

  1. 1.University of MinhoGuimarãesPortugal

Personalised recommendations