LAYOUT

Chapter 6

Fixed product layout

Advantages
Reduced material moves Highly flexible Job enrichment Promotes pride & quality Responsibility

Limitations
Personel-equipment moves Equipment duplicates Greater skill Close control& coordination Increased space & greater work-in-process

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Product Layout
Advantages
Smooth, simple, direct flow Small work-in-process inv. Short production time/unit Reduced material handling Less skill Easy production control

Limitations
Line stoppage Product design changes
Slowest station paces the line

General supervision High equipment investment

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Group Layout
Advantages

Limitations

By grouping, higher machine Greater labor skills for team utilizations Balancing individual cells Smoother flow lines and Unbalanced flow may result shorter travel distances in work-in-process Team spirit and job enlargement

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Process Layout
Advantages

Limitations

Increased machine utilization Increased material handling General purpose equipment Complicated production control Highly flexible Increased work-in-process Diversity of tasks Longer production lines Higher skills required

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Apples plant layout procedure

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Procure the basic data. Analyze the basic data. Design the productive process. Plan the material flow pattern. Consider the general material handling plan. Calculate equipment requirements. Plan individual workstations. Select specific material handling equipment. Coordinate groups of related operations. Design activity interrelationships. Determine storage requirements. Plan service and auxiliary activities. Determine space requirements. Allocate activities to total space. Consider building types. Construct master layout. Evaluate, adjust, and check the layout with the appropriate persons. Obtain approvals. Install the layout. Follow up on implementation of the layout.
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Reed's Plant Layout Procedure

1. 2. 3. Analyze the product or products to be produced. Determine the process required to manufacture the product. Prepare layout planning charts. 1. Flow process, including operations, transportation, storage, and inspections. 2. Standard times for each operation. 3. Machine selection and balance. 4. Manpower selection and balance. 5. Material handling requirements. 4. Determine workstations. 5. Analyze storage area requirements. 6. Establish minimum aisle widths. 7. Establish office requirements. 8. Consider personnel facilities and services. 9. Survey plant services. 10. Provide for future expansion.
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Muther's Systematic Layout Planning (SLP) Procedure

1. 2. 3. 4. 5. 6. 7. 8. 9. Flow of materials Activity relationships Relationship diagram Space requirements&Space available Space relationship diagram Modifying considerations Practical limitations Develop layout alternatives Evaluation
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ACTIVITY RELATIONSHIP CHART

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Relationship diagram

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Space relationship diagram

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Alternative Block Layout-1

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Alternative Block Layout-2

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Facility Layout Objectives (efficiency):

Layout improvement
versus Layout construction

QAP???

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Problems
6.12 Suppose five departments labeled A through E are located as shown in the layout below. Given the corresponding flow-between chart, compute the efficiency rating for the layout.
A C D E B

A A B C D E

B 5

C 0 6

D E 4 -1 -6 -3 2 0 3

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Relationship Diagramming for New Layouts-1

Code Function 1 2 3 4 Receiving Milling Press Screw M. Area(sqft) No.of unit area templates 12000 6 8000 4 6000 3 12000 6

5
6 7

Assembly
Plating Shipping

8000 4
12000 6 12000 6
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Relationship Diagramming for New Layouts-2

1. 2. 3. 4. Select the first department to enter layout (using
diagramming worksheet)

5.

Select the second dept. to enter the layout. Select the third department to enter the layout Select the fourth department to enter the layout Place dept. n similar to 3rd and 4th steps.

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Relationship Diagramming for New Layouts-3

1 4 4 4 4 4 2 1 1 3 3 1 1 1 3

4
5 5 5 5

2
6 6 7 7

2
6 6 7 7

2
6 6 7 7

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Pairwise Exchange Method for Layout Improvement-1

A heuristic method
TC1234 = 10(1) + 15(2) + 20(3) + 10(1) + 5(2) + 5(1) = 125

Material Flow Matrix

Distance Matrix Based on Existing Layout

To From

1
-

2
10 -

3
15 10 -

4
20 5 5 -

To From

1 -

2 1

3 2

4 3

1 2 3 4

2
3 4

1
-

2
1 -

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Pairwise Exchange Method for Layout Improvements-2

FIRST ITERATION(based on the existing solution:1-2-3-4) TC2134(1-2)=10(1)+15(1)+20(2)+10(2)+5(3)+5(1)=105 TC3214(1-3)=10(1)+15(2)+20(1)+10(1) +5(2)+5(3)=95 TC4231(1-4)=10(2)+15(1)+20(3)+10(1) +5(1)+5(2)=120 TC1324(2-3)=10(2)+15(1)+20(3)+10(1) +5(1)+5(2)=120 TC1432(2-4)=10(3)+15(2)+20(1)+10(1) +5(2)+5(1)=105 TC1243(3-4)=10(1)+15(3)+20(2)+10(2)+5(1)+5(1)=125 New layout: 3-2-1-4

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Pairwise Exchange Method for Layout Improvements-3

SECOND ITERATION (based on the previous layout: 3-2-1-4) TC3124(1-2)=10(1)+15(1)+20(2)+10(1)+5(1)+5(3)=95 TC1234(1-3)=10(1)+15(2)+20(3)+10(1)+5(2)+5(1)=125 TC3241(1-4)=10(2)+15(3)+20(1)+10(1)+5(1)+5(2)=110 TC2314(2-3)=10(2)+15(1)+20(1)+10(1)+5(3)+5(2)=90 TC3412(2-4)=10(1)+15(2)+20(1)+10(3)+5(2)+5(2)=105 TC4213(3-4) =10(1)+15(1)+20(2)+10(2)+ 5(1)+5(3)=105 New Layout: 2-3-1-4

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Pairwise Exchange Method for Layout Improvements-4

THIRD ITERATION (based on the previous layout:2-3-1-4) TC3214(1-2)=10(1)+15(2)+20(1)+10(1)+5(2)+5(3)=95 TC1324(1-3)=10(2)+15(1)+20(3)+10(1)+5(1)+5(2)=120 TC3421(1-4)=10(1)+15(3)+20(2)+10(2)+5(1)+5(1)=125 TC2134(2-3) =10(1)+15(1)+20(2)+10(2)+5(3)+5(1)=105 TC3142(2-4) =10(2)+15(1)+20(1)+10(3)+5(1)+5(2)=100 TC4123(3-4) =10(1)+15(2)+20(1)+10(1)+5(2)+5(3)=95
Since the possible changes resulted in increase then the previous layout is the best. Therefore the best is:

2-3-1-4
Local best Global best: 90 (1-2;2-4;3-3;4-1) (By using QAP in Lingo)

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Graph-based construction method for new layouts

Total Weight:63

Total Weight: 71

Rel-chart

Adjacency graphs for alternative block layouts

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Graph-based construction methods for new layouts

STEPS (node insertion algorithm in building adjacency graph):
1. Select the department pair with the largest weight. 2. Select the other depts consecutively based on the sum of the weights with respect to the depts already selected. 3. Place the selected dept on one of the faces of the graph) 4. Build the block layout based on the final adjancency graph.

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Graph-based construction method for new layout

Example

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Mixed Integer Programming in continuous facility layout problems

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CRAFT

(Computerized Relative Allocation of Facilities Technique) 1963-Armour, Buffa, Vollman Improvement-type algorithm
Initial solution Rectilinear distances between department centroids CostxDistances All-possible two-way and three-way department exchanges Determine the best exchange (that yields the best reduction in the layout cost)

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CRAFT
Updates the layout according to the best exchange-calculates layout efficiency Exchanges departments that either adjacent or equal in area. If the area is not equal, the algorithm may result in split department.

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6.24Consider four departments labeled A, B, C, and D. Each department is represented by a 1X1 square. The following data are given:
Location of department A is fixed. Answer the following questions using CRAFT with two-way exchanges only. a. List all the department pairs that CRAFT would consider exchanging. (Do not compute their associated cost.) b. Compute the actual cost of exchanging departments C and D. c. Given that department A is fixed and that each department must remain as a 1 X 1 square, is the layout obtained by exchanging departments C and D optimum? Why or why not? (Hint: examine the properties of the resulting layout and consider the objective function of CRAFT.)

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6.25 The following layout is an illegal CRAFT layout. Nevertheless, given that the volume of flow from A to B is 4, A to C is 3, and B to C is 9, and that all move costs are 1, what is the layout cost?

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6.26 (Revised) When CRAFT evaluates the exchange of departments, instead of actually exchanging the departments, it only exchanges the centroids of departments.
a. What is the impact of this method of exchanging if all departments are the same size? b. Given the following fromto-chart and scaled layout (each square is 1 X 1), what does the evaluation of the exchange of departments B and C A indicate should be saved over the existing layout A and what is actually saved once this exchange is A made?
To From A B C

A
B C

2 0

10
0

6
7

A A A

A A A

C C C

B B B

B B B

B B B

B B B

B B B

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6.27 Explain the steps CRAFT would take with the following problem and determine the final layout. Only twoway exchanges are to be considered. (Use CRAFT DSS.)

To From

A B C D E A 3 C 1 2 1 3 0 0 0 B 0 1 AAA AAA AAA DDD DDD BBB CCC CCC EEE EEE

0 4

D 0 0 0 0 E 0 0 0 0 From-to chart

Initial Layout

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A Continuous Algorithm: BLOCPLAN

BLOCPLAN
2 or 3 bands Building length Construction or improvement

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A Continuous Algorithm: LOGIC

LOGIC
Vertical or Horizontal cuts Construction or improvement Example

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Another discrete algorithm: MULTIPLE

(1)

MULTI-floor Plant Layout Evaluation Developed by Bozer, Meller, and Erlebacher Initially multi-floor facilities but can also be used for single floor facilities Similar to CRAFT Uses a From-To (or Flow-Between) Chart Departments are not restricted to rectangular shapes Like Craft, improvement-type layout algorithm Two-way exchanges are sought Exchange with the largest reduction is selected Steepest-descent procedure

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Multiple

(2)

Can exchange any two departments Use spacefilling curves (SFCs) Reconstruct a new layout when any two departments are exchanged Also known as Hilbert curve

Connects each grid such that always an adjacent grid is visited. Each grid is visited only once.

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Multiple:

Building Hilbert curve

(Fill Sequence: 1-2-3-4-5-6)

(3)

Dept Area 1 2 3 4 5 16 8 4 16 8

12

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Multiple: Building Hilbert curve

(4)

(Fill sequence: 5-2-3-4-1-6 following the exchange 1 and 5)

Dept Area 5 2 3 4 1 6 8 8 4 16 16 12

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