CHAPTER 3 COMPUTER PROGRAMME 3.1 Introduction to Computer Programme ‘Computerized layout algorithms can be classified according to the way final layout is generated. Construction algorithms consist of the successive selection and placement of activities {departments} until a layout design is achieved. The second type of an algorithm is of the improvement type. In this case complete existing layout is required initially, and locations of activities {departments] are interchanged as so to improve the layout design. A few known and most widely available computer programmes are ALDEP, COFAD, COMP2, COMPROPLAN, COMSBUL, CORELAP, COSFAD, RAFT, GRASP, IMAGE, MAT, OFFICE, PLANET, RMA COMPI, SUMI, etc. We shall describe a few improvement algorithms such as: a) CRAFT [Computerized Relative Allocation of Facility Techniques} b) ALDEP [Automated Layout Design Program] ) CORELAP [Computerized Relationship Layout Planning] d) COFAD [Computerized Facilities And Design] e) PLANET [Plant Layout Evaluation Technique) 3.2 CRAFT [Computerized Relative Allocation of Facility Techniques: CRAFT was the first computerized impairment facilities design techniques, which was presented in 1963 by Armour and Buffa is probably the most widely known, widely used and written about computerized facilities design technique in existence. ‘The main criterion employed in CRAFT is minimization of total cost of movement of items, where this cost is expressed as a liner function of distance traveled. Although CRAFT was originally developed for designing layouts where material handling costs wee a major consideration, by broadening the interpretation of material flow CRAFT can be used as an aid in designing layout for non-manufacturing activities also and develop office layouts. CRAFT is an improvement programme. As such it seeks an optimum design by making improvements in the layout in a sequential fashion. CRAFT first evaluates a given layout and then considers what the effect will be if departments under considerations are interchanged. If improvement can be made by making pair wise exchange, the exchange producing the greatest improvement is made. The process continues until no improvement can be made by pair-wise exchange. Only departments with common border or of the same are considered for exchange of locations.o1 CRAFT has the flexibility of allowing certain departments to give fixed location in the layout. Also craft can be used to evaluate individual layouts without searching for improved design. Input Requirements: 1. Initial layout configuration, showing the size of departments arranged, so that one line can be represented by an 80 column punch card. The initial layout may be arbitrary or an existing one, 2. Inter departmental flow matrix with gives the number of unit load moving between all departments over a given period of time. The data may be in terms of some unit of measure [tons/days, units/years skids/week]. These matrix need not be symmetrical 3. Inter departmental cost matrix giving the cost per unit distance of movement [per unit moved per unit distance] between all departments. This matrix need not be symmetrical, so that volume in different directions can be given different costs. 4. Area or space requirements for each department. $. Number and locations of fixed departments if any. The algorithm by which the programme operates is as follows: a) Determine which pairs of departments may be interchanged. Departments are considered for interchange when they are either adjacent, or of equal area, or bordering upon a common third department. 6} Calculate the distance between departments, the distance being taken as those between the centers of the departments. °) Calculate the reduction in total movement costs resulting from the interchange of all possible pairs of departments. d) Interchange the two departments, which provide the greatest saving in total movement costs. Calculate the total movement cost and print out the revised layout. Figure shows a simplified flow chart for CRAFT programme. This procedure is repeated until no further cost saving is possible, whereupon the final layout is printed. Though CRAFT seldom yields an optimum solution in terms of minimizing costs or distances, it does provide fairly good solution and offers the facilities designer a starting point for improving and evaluating an initial block area layout of greater complexity. It can generate and evaluate layouts having as many as 40 departments’ in less than one minuet of computer time.Calculate Dept. centers and distance matrix ‘Calculate total movement cost for layout it initial layout and Cost Output new layout total cost, changes Fig3.1 :Simplified Flow Chart for the CRAFT Programme93 Advantages of CRAFT 1 1 2. 3. 4, 5. 6. . Permits fixing specific locations. Input shapes can vary Short Computer time Mathematically sound Can be used for office layouts. Can check previous interactions Cost and saving print out. Limitations for CRAFT The major disadvantages of CRAFT, apart from the fact that it is of relevance only where movement cost is an appropriate criterion, are: ewe re Since an initial layout is required, the programme applies only to either the modification of existing layouts, or the planning of new layouts where the outline shape of the layout is known. . The distance between the departments is taken asa straight line between departmental centers, whereas movement is often rectangular along orthogonal aisles. . Requires hand adjustments [output not directly usable} . The use of CRAFT does not guarantee that the least cost layout will be found. . CRAFT is a sub-optional, heuristic procedure which produces a layout that cannot be easily improved upon. Departments can be interchanged, which are |. Input data needs careful structuring. |. Better adapted to rearrangements. . Craft solution obtained is path dependent. 10. Undesirable relationships taken into account. 1 33 |. Limited to 40 departments. ALDEP [Automated Layout Design Program]: ALDEP was developed within IBM and was originally presented by Seehof and Evans: ALDEP primarily is a construction programme; however due to evaluation process94 employed in accepting or rejecting a given layout, it can also be considered to be an improvement program, It constructs layouts without any existing layout. ALDEP jis used when activity relationships are a major consideration and when constantly changing conditions prohibit the collection of precise numerical data. The layout is developed by locating the most related activities and then progressively adding other activities based on closeness desired (i.e. A or E) and in the required size, until all activities have been placed. This process is continued until either all departments are placed or no departments are available for placements have a high closeness rating with departments already placed. In the latter situation a department is randomly selected from among these departments available for placement, and it is placed in the layout. The score for the layout is determined by totaling for adjacent departments, the numerical values assigned to the closeness ratings. The entire process is repeated a specified number of times, The values assigned for ALDEP Are: A=4=64 O=4=1 E=#=16 U=0 I=4'=4 X=-45=-1,024 ALDEP has the capability of handling up to 63 departments or activities and can generate multistory layouts up to three floors. It is possible to place restrictions on the solution such that layout is designed around such areas as aisles, elevator shafts, stairwells, lobbies, and existing departments. Input Requirements: 1, Length, width and area requirements for each floor. 2. Scale of layout printout. 3. Number of department in the layout. = |. Number of layouts to be generated. inimum allowable score for an acceptable layout. . Minimum department preference, 5. 6. 7. REL Chart for the departments. 8. Location and size of restricted area for every floor. 9. .. The building outline must be known, The scale of layout is partially determined by the maximum dimensions of the layout printout and the area of the individual departments. ALDP scores the layouts it generates and compares the score for the layout to be acceptable. On the first run the minimum allowable score is set equal to zero. The program95 is designed to generate a specified number of layouts. Layouts having score of at least zero given in the printout. For the second run the maximum layout score achieved on the first run is used on the minimum allowable score on the second run. Thus process is continued until no layouts are found that have scores at least as great as the minimum allowable score. Once a department is placed in the layout all the remaining departments are candidates for the next placement in the layout. If one of these department has the desired minimum department preference [i.e., an E rating) with a department already located in the building, then it is placed in the layout, otherwise, a department is selected randomly. ‘The minimum department preference is given as either an A or an E rating. ALDEP ~ designed layouts can have irregularly shaped department. ALDP designed to avoid extreme zigzag borders by using vertical scan method of placing departments. Basically the layout area is filled by using vertical strips having a specified width and length ‘equal to the depth of the layout. Advantaged of ALDEP 1. Can fix specific locations within confined of space available. 2. Solution is within specified area 3, Many alternatives are developed. 4. Have most inter-relationships. 5, Has multiple-level capability. Limitations of ALDEP 1, Cost of movement not calculated 2. Undesirable (x) relationships not honored _ [is not questioned] 3. Evaluation scoring method questionable. 4. Difficulty in evaluating production process. 5. Mandatory space configuration not taken into account 6. Limited to 63 departments. 3.4 CORELAP [Computerized Relationship Layout Planning]: CORELAP is a construction program. Like ALDEP, CORELAP employs the REL chart in constructing layouts. Up to 70 departments can be handled, and the scale of the layout is limited by the maximum dimension allowable for the final layout, 40 by 40. A building outline is not required for CORELAP. Additionally, it is possible to place a constraint on the length-to-width ration of the final layout. Another feature of CORELAP is the ability to pressing some departments in the layout. However, this can be done only along the periphery, of the layout.96 CORELAP constructs layouts by locating rectangular — shaped departments when the departmental area and layout scale permit a rectangular representation of the departmental area. The REL chart provides the basis for the order in which departments enter the layout. ‘The placement of the department within the layout is based on the REL chart and the numerical weighted rating assigned to the closeness ratings. The Minimum Input Requirements for CORELAP Inch 1. Relationships chart for the department, . Number of departments. |. Area of each department = yn }. Weight for REL chart entries. Optional Input Parameters for CORELAP include: 1. Scale of output printout. vy . Building length to width ratio }. Plotting of the final layout Department pre assignment. Lee and Moore, who developed this programme, adopted the following rather unusual terminology: >» Victor: a department which has earned the\privilege of being next to be placed in the layout Winner: a victor which has been placed earlier in the layout. Each of the closeness ratings used in the relationship chart, ic. A.E.LO.U,X are assigned a numerical value A = 6, E = 5,1- 4, 0 = 3, U=2, X= 1 and the total closeness rating [TCR] for each department is calculated by adding together the value for that department's relationships with all other departments. If V [rj] be the numerical values assigned to closeness rating for the departments I and j. there are m departments then the total closeness rate [TCR] for the department is defined as TRCi="£ Viry] J=1summed dV TIYOD 495 wed Moly paydins Tey WIAGiy euo Aq Sunes conpoy,Where V[rj] equals zero. Departments are listed in descending order of TCR, and he department with the highest TCR is the first to be placed in the layout, i.e. it becomes the first Winner. This department is placed in the middle of the layout and the programmed then asks. “Which department is to be placed next?” and, ‘Where is the Victor to be placed in the layout?” The programmed searches the relationship with the first Winner. If there are any departments with A relationships then the one with the highest TCR become the first Victor and it is positioned in the layout as close as possible to the Winner. Other departments with A relationships with the Winner are placed in the layout, those with the highest TCR first. They are placed as close as possible to the Winner, and also as close as possible to any other departments already in the layout with which they have a desired relationship. When all departments with A relationship with the first Winner have been placed, the first Victor becomes the second Winner and the procedure I repeated until all departments with an A relationship with the first and subsequent Winners have been placed, the complete procedure is repeated for E, I, O and finally U relationships. A simplified flow diagram for the programme is shown in Figure. Advantages of CORELAP 1. Since layouts are developed from stated, preferred relationships, all the necessary reasons for a desired relationship between departments can be taken into account in developing the layouts, unlike CRAFT, which depends solely upon product flow. 2. An initial layout is not required, the only constraint being the maximum building length to width ratio. This ratio is necessary to ensure that the programme does not develop unrealistic layout configurations, i.e., very long, thin layouts, 3. Input and output terms are the same. 4. Easy to get going on, to complete and 5. Each step is visible during the process of layout development Limitations of CORELAP 1. The system cannot specify fixed activity locations. 2. It does not calculate specify fixed activity locations. 3. It does snot allow layout of facilities in irregular format. ALLOCATION METHOD ‘The assignment problem is actually a special case of the general linear programming procedure, in which it is usually desired to assign n jobs to n facilities. The effectiveness of each facility for each job is given, and the objective is to optimize the measure of effectiveness in assigning to one and only one job. The assignment problem can be expressed mathematically as that of optimizing the effectiveness function.Subject to the constraints EL ey. xy 5 Exg=l As the linear programming technique, optimization requires the minimization or maximization of the measure of effectiveness chosen. The user has control of the assignments xj, but the effusiveness coefficients ej, are not directly under his control, Although the assignment problem may be solved by the simplex method, probably the most efficient routine is the one proposed by Kuhn, known as the Hungarian method. It required the problem to be set up in the form of a square effectiveness matrix. However, problems of a matrix form that are not square, or have prohibited assignments, are often encountered and may be converted into a square matrix. : Three new machines, A, B, and C are to-be installed in all existing layout and is such that a lift truck can carry only one at a time. Truck movement is restricted to aisles to rectangular directions. Fig.6.31 shows the locations for the possible new machine as X, Y and Z. It also shows the existing machines and their location at 1, 2, 3, 4, and 5. Table gives the expected traffic between the new and the existing machines. Notice that some of the new machines do not have a handling relationship with all existing machines. Taking rectangular distance from Figure yields distance data as shown in Table 1. Metric multiplication of the traffic data and distance data develop effective metric which is shown in Table 2. Table 3.1 Table 32 Traffic Data Matrix Distance Data Matrix Developed from Table 3.1 Existing Machine New mic Candidate Area 1 2| 3 als Existing m/e |X] ¥ |Z T A |25/8]| 4 | 0 | 30 ait ls6 2 2/3 |4 B o]7] 10} 12] 8 3 4/3 ]2 | 4 6|7]2 c 8 |5]|6| 0 | 10 3 o| 6 [3s3.5 COFAD [COMPUTERIZED FACILITIES AND DESIGN] The modification of CRAFT It considers various material handling equipment and their alternatives. It attempts to select both the layout as well as the material handling equipment. iv. It evaluates the layout for varying product volumes and product mix. V. Italso analysis the flexibility in the design. 3.6 PLANET [Plant Layout Evaluation Technique] This utilize inter departmental flow data and computes penalty cost for separation of departments this requires two basic type of input data they are - Department information + Flow information Each of the above is determined and area requirements are stated. During the analysis of the movement of material following information are noted + Frequency of Move - Method of Movement - Cost of Movement = Sequence of Movement Using all these flow cost is determined. Along with this other characteristics such as size, shape weight and durability of materials must be considered in selecting handling methods and estimating cost. PLANET is mainly based on material flow pattem. It fixes each department in the layout in such a way as to keep the material handling cost as low as possible this is done by keeping two questions. 1. Which department should be selected for placement? 2. Where should this dept be placed? ‘Three alternative methods evaluate the relationship between dept not yet selected for placement and those that have been selected. Strong interrelationship between department pairs or with in a department group will imply early selection. A search routine finds a location for each dept as itis selected, The location having smallest placement penalty with respect to the then existing partial layout. Like CORELAP, PLANET prints a layout in an irregular format. The program attempts to keep the department shape square in order to avoid elongated shapes, But very101 small departments may not appear in a desirable shape. It uses two character symbol to be used to represent with of are on the final layout. So shipping. Advantages - Based on From- to Chart = Uses material handling cost for specified method of handling for each move in a predetermined operation sequence. + Requires interaction between computer routine and Engineer, to exercise his judgment. - Applicable to any problem involving quantifiable relationship between activities. = Can fix specific activity locations and building features. = No input layout required. = Uses normal plant terminology and data as input. - Allows choice of method of selecting placing departments.