Layout Planning Models,

Algorithms
l
h
and
d computerized
d
Layout Planning
References
1. Tompikins et al., Facility Planning, 3rd edition, John Wiley & Sons Ltd.,
Singapore,2003.
i
2003
2. Richard L.Francis et al., Facility Layout and Location: an analytical

approch,
h 2ndd edition,
diti
P
Prentice
ti
H ll of
Hall
f India
I di Ltd.,
Ltd 2002.
2002
3. Dr-Ing. Daniel Kitaw, Industrial Management and Engineering Economy
4-1

Introduction
The generation of layout alternatives is a critical step
i the
in
th facilities
f iliti
planning
l
i
process, since
i
th layout
the
l
t
selected

will

serve

to

establish

the

physical

relationships between activities.

4-2

CONTD
Which comes first, the material handling system or
the facility layout?
Centralized versus decentralized storage of work
i process(WIP),
in
(WIP) tooling,
t li
and
d supplies
li
Fixed path versus variable path handling
The degree of automation used in handling
The type of level of inventory control,
control physical
control, and computer control of materials.
4-3

Layout procedures
A number of different procedures have been developed
t aid
to
id the
th facilities
f iliti planner
l
i designing
in
d i i layouts.
l
t
Construction type
Improvement type

4-4

Apples plant layout procedure

P
Procure
th basic
the
b si data
d t

Determine storage requirements

Analyze the basic data

Design the productive process

Plan
service
activities

Plan the material flow pattern

Determine space requirements

Consider the
h dli plan
handling
l

Allocate activities to total space

Consider building type

Calculate equipment requirement

Construct master layout

Plan individual
nd v dual workstat
workstations
ons

Select specific material handling

equipment

Evaluate,, adjust,
j , and check the
layout with appropriate persons

Obtain approvals

Coordinate
C
din t
operations

Install the layout

Follow up on implementation of
the layout.
4-5

general

groups
ps

of
f

material

related
l t d

Design activity interrelationships

and

auxiliary

Reeds plant layout procedure

Analyze the product or products to be produced
Determine the process required to manufacture the product
Prepare layout planning charts
Determine workstations
Analyze
l
storage area requirements
Establish minimum aisle widths
Establish
E t bli h office
ffi requirement
i
t
Consider personnel facilities and services
Survey plant services
Provide for future expansion
4-6

Contd
Layout planning chart is the most important single
phase of the entire layout process, it incorporates the
f ll i
following:
Flow process, including operations, transportation,
storage and
d inspection
i
i
Standard time for each operation
Machine selection and balance
Material handling equipment
4-7

Contd

Layout planning
chart

4-8

Systematic Layout Planning(SLP) procedure

Systematic Layout Planning (SLP) methodology was
developed by Richard Muther.
Muther
The framework is uses activity
y relationship
p diagram
g
as
a foundation activity.

4-9

SLP contd
Based on the input data and an
understanding of the roles and
relationships
l ti
hi
b t
between
activities,
ti iti
a

material flow analysis(from-to-chart )

and
an
activity
relationship
analysis(activity relationship chart) are
performed.

y
performed,,
p
analysis
relationship diagram is developed.

From

SLP procedure

the

4 - 10

Contd
The

relationship

diagram

positions

activities spatially.
p
y
Proximities are typically used to reflect
th
the

relationship
l ti shi

b t
between

pairs
i s

of
f

activities.

Activity relationship chart

4 - 11

Contd

Relationship diagram

Space relationship diagram

Alternative block layouts

4 - 12

Algorithmic approaches
Algorithmic approach is a formal procedure that can
h l the
help
th layout
l
t analyst
l t to
t develop
d
l or improve
i
a layout,
l
t
and it provide objective criteria to facilitate the
evaluation of various layout alternatives that emerge
i the
in
th process.
ss

4 - 13

Algorithm classification
Most layout algorithms
al orithms can be classified according
accordin to
the type of input data they requires.
Qualitative flow data(such as relationship chart)
Quantitative

flow

data(such

as

flow

matrix

expressed as a from-to-chart)
from to chart)
Some
m algorithms
g
m accepts
p
both relationship
p chart
and from-to-chart
4 - 14

Contd
Layout algorithms can also be classified according to
their objective functions.
Minimizing the sum of flows times distances
Maximizing an adjacency score

4 - 15

Contd
Distance based objective

m = the number of departments

fij = the flow from department i to department j(unit
load/unit time)
cij = the
h cost of
f moving a unit load
l d one distance
d
unit
from department i to j
dij = the
th distance
di t
f
from
d
department
t
t i to
t j
4 - 16

Contd
Adjacency based objective

m = the number of departments

fij = the flow from department i to department j(unit
load/unit time)
xij = the
h adjacent
d
of
f department
d
i and
d j in the
h layout
l
The adjacency score is helpful in comparing two or
more alternative
lt
ti layouts
l
t
4 - 17

Contd
According to the primary functions layout algorithms
can be classified as:
Improvement
p
type:
yp start with an initial layout
y
and
seek to improve the objective function through
i
incremental
t l change.
h
Construction type: develop a layout from scratch
4 - 18

Modeling techniques/methods
The overall modeling techniques and/or
methods used in various layout algorithms;
Pairwise
P i i exchange
h
method
th d
A graph based method
CRAFT
BLOCPLAN
MIP
LOGIC
MULTIPLE
4 - 19

Graph-based method
The graph-based method is a constructiontype layout algorithm.
algorithm
objective
Uses the adjacency based objective.

4 - 20

Graph-based method-Considerations
The adjacency score does not account for distance,
distance
nor does it account for relationships other than those
between adjacent departments.
Dimensional specifications of departments are not
considered; the length of common boundaries between
adjacent department are also not considered.
The arcs do not intersect; this property of graphs is
called planarity.
The score is very sensitive to the assignment of
numerical weights in the relationship chart.
4 - 21

Graph-based method
Consider a company want to develop layout for
its new five departments
p
of equal
q
sizes.
1

0
9
1

2
3

13

0
2

20

13

10

0
7

20

12

10

12

Relationship chart

Relationship diagram

4 - 22

Graph-based method
Procedure
Step 1: from the relationship chart select a department
pair with the largest weight.
weight
1

9
8

10

12

13

20

0
2

Departments 3 and 4 are selected to enter the graph.

4 - 23

Graph-based method
Procedure
Step 2: Select the third department to enter, the third
department is selected based on the sum of the
weights with respect to departments 3 and 4.
3

Total

10

18

12

13

25(best)

2
13

12

4
20

D
Department
t
t 2 is
i chosen
h
with
ith a value
l off 25.
25
4 - 24

Graph-based method
Procedure
Step 3: Pick the fourth department to enter by
evaluating the value of adding one of the
unassigned departments represented by a node
graph
p
on a face of the g
2
2

Total

1 9

10

27(Best)

5 7

12

13

1
8

10
20

Department 1 is chosen with a value of 27.

4 - 25

Graph-based method
Procedure
Step 4: Determine on which face to insert the last
department.
department
2
1

5 0

Faces

12

13

Total

1-2-3

1-2-4

9(best)

1-3-4

2-3-4

9(best)

5
0

10

20
4 - 26

Graph-based method
Procedure
Step 5: Construct a corresponding block layout.
13

2
7

12
8

10
20

4
4 - 27

Computerized Relative Allocation of Facility Technique(CRAFT)

Introduced in 1963 by Armour, Buffa, and Vollman.

CRAFT is a tool used to help improve the existing
layout of the facilities.
The facility
f cilit is improved
impr ved by
b switching
s itchin two
t
orr three
departments to help arrange the facility in an optimal
floor plan.
plan

4 - 28

Computerized Relative Allocation of Facility Technique(CRAFT)

This procedure requires the following inputs:

o From-To Chart,
o Cost Matrix,
o Distances ((determined for a g
given layout)
y
) and an
Initial layout.
Craft is used when the number of departments is so
large that the computation by hand would be very
intensive and make the improvement not worth the
time for many companies.
4 - 29

Computerized Relative Allocation of Facility Technique(CRAFT)

The major features of CRAFT are:

o Attempts to minimize transportation cost,

T
Transportation
i cost=flow*distance*unit
fl *di
* i cost
o CRAFT is a path-oriented method, the final layout is
dependent on the initial layout.
o Requires
q
an assumption
p
that:
i.

Move costs are independent of the equipment

utilization and

ii. Move costs are linearly related to the length of

4 - 30
the move

Computerized Relative Allocation of Facility Technique(CRAFT)

CRAFT requirements:
i
t
o Initial layout
o Flow data
o Cost per unit distance
o Total number of departments
o Fixed
F d departments
d
and
d their
h
l
location
o Area of departments
4 - 31

Computerized Relative Allocation of Facility Technique(CRAFT)

The
Th procedures
d
adopted
d t d for
f using
i CRAFT are:
o Determine department centroids.
o Calculate rectilinear distance between centroids.
o Calculate transportation cost for the layout.
layout
o Consider department exchanges of either equal area
departments or of departments sharing a common
boarder.

4 - 32

Computerized Relative Allocation of Facility Technique(CRAFT)

o D
Determine
t
i transportation
t
t ti costt of
f each
h departmental
d
t
t l
interchange.
o Select
l
and
d implement
l
the
h departmental
d
l interchange
h
that offers the greatest reduction in transportation
cost.
cost
o Repeat the procedure for the new layout until no
int
interchange
h n
is able
bl to
t reduce
d
th ttransportation
the
nsp t ti n
cost.

4 - 33

Computerized Relative Allocation of Facility Technique(CRAFT)

Major
M j disadvantages
di d
t
of
f using
i CRAFT
o Because the basis is the cost of material handling,
only
l production
d
d
departments
are considered.
d
d No
N
service departments are considered.
o An initial idea of the layout is required. Therefore
the technique is only applies to the modification of
an
n existing
xistin layout.
l
t
o The distances between the departments is taken as
straight
t i ht lines
li
whereas
h
i practice
in
ti
movementt is
i
usually rectangular along ortagonal lines.

4 - 34

Computerized Relative Allocation of Facility Technique(CRAFT)

Example: consider the following layout problem with unit

cost matrix. Use Craft algorithm to obtain layout. The
initial layout and the flow matrix is shown below

Initial layout

Flow matrix
4 - 35

COmputerized RElationship LAyout Planning (CORELAP)

D
Developed
l
d for
f main
i frame
f
computers
t
Adjacencybased method
o CORELAP uses A=4,
A=4 E=3,
E=3 I=2,
I=2 O=1,
O=1 U=0 and X=1
values
Selection of the departments
p
to enter the layout
y
is
based on Total Closeness Rating.
Total Closeness Rating (TCR) for a department is the
sum of
f the
h numericall values
l
assigned
d to the
h closeness
l
relationships between the department and all other
departments
departments.
4 - 36

COmputerized RElationship LAyout Planning (CORELAP)

Department
D
t
t selection
l ti
1. The first department placed in the layout is the one
with the greatest TCR value.
value If there is a tie,
tie then
choose the one with more As (Es, etc.).
2. If a department
p
has an X relationship
p with the first
one, it is placed last in the layout. If a tie exists,
choose the one with the smallest TCR value.
3. The
h second
d department
d
is the
h one with
h an A
relationship with the first one (or E, I, etc.). If a tie
exists choose the one with the greatest TCR value.
exists,
value
4 - 37

COmputerized RElationship LAyout Planning (CORELAP)

4 If a department
4.
d
t
t has
h an X relationship
l ti
hi with
ith the
th second
d
one, it is placed nexttothelast or last in the layout.
If a tie exists,
exists choose the one with the smallest TCR
value.
5. The third department
p
is the one with most A ((E,, I,,
etc.) relationships with the already placed
departments. If a tie exists, choose the one with the
greatest TCR value.
l
6. The procedure continues until all departments have
been placed.
placed
4 - 38

COmputerized RElationship LAyout Planning (CORELAP)

D
Department
t
t placement
l
t
Placing rating(PR) is the sum of the weighted closeness
ratings between
b
the
h department
d
to enter the
h layout
l
and its neighbors.

, where k-{departments already placed}

4 - 39

COmputerized RElationship LAyout Planning (CORELAP)

Th
The placement
l
t of
f departments
d
t
t is
i based
b
d on the
th
following steps:
1 The
1.
h first
f
d
department
selected
l
d is placed
l
d in the
h
middle.
2. The placement of a department is determined by
evaluating PR for all possible locations around the
current
nt layout
l
t in counterclockwise
nt
l k is order
d beginning
b innin
at the western edge.
3 The
3.
Th new department
d
t
t is
i located
l
t d based
b
d on the
th
greatest PR value.

4 - 40

Example

4 - 41

4 - 42

4 - 43

4 - 44

4 - 45

4 - 46

4 - 47

ALDEP Procedure
Department selection
o Randomly selects the first department
o Out of those departments which have A
A
relationship with the first one (or E, I, etc. min
level of importance is determined by the user) it
selects randomly the second department.
o If no such department exists it selects the second
one
n completely
c mpl t l randomly
r nd ml
o The selection procedure is repeated until all the
departments are selected
4 - 48

Department placement
Starts from upper left corner and extends it
downward
Vertical sweep pattern
Sweep width is determined by the user
Adjacencybased evaluation
If minimum requirements met,
met it prints out the layout
and the scores
Repeats
p
the p
procedure (m
(max 20 layouts
y
per run))
p
User evaluation
4 - 49

4 - 50

4 - 51

4 - 52