Facilities and Process Planning

Course Code: MEE1018

Lecture - 17
18-Sep-2018

Dr. R. Mohan
Associate Professor
SMBS
 TOPICS

• Computer Aided Plant Layout

• Data Requirement
Plant Location and Site Selection
Plant Location and Site Selection
Data Requirement
 Layout Design procedure
Manual Method: Conventional methods like travel chart, Apple’s
Plant Layout Procedure, Reed’s Plant Layout Procedure and
Muther’s Systematic layout Planning (SLP)

Computerized Method:
Construction type Algorithm: layout methods basically involve developing a new layout “from scratch”
Automatic Layout Design Program (ALDEP)
Computerized Relationship Layout Planning (CORELAP)
Improvement Type Algorithm: generate layout alternatives based on an existing layout
Computerized Relative Allocation of Facilities Technique (CRAFT)
Layout Design procedure

Plant layout of Easy Light, Inc

 Data Requirement

1. The area of each department expressed in square feet or as

a number of unit squares

2. The rectilinear distances between candidate locations or

between departments, usually measured between their centers

3. Departmental relationship measures that can be expressed

either quantitatively in a from–to chart or qualitatively in a
relationship chart (rel-chart).

4. A scale for plotting the layout by the computer, required in

some of the procedures.

In addition, departmental shapes, location, and layout outline

Mathematical Programming Procedure

Distance Based Objective

Let
m – number of departments

fij = flow from department i to department j (no. of unit loads

moved per unit time)

cij = cost of moving a unit load one distance unit from

department i to department j

The objective is minimize the cost per unit time for moving
among the departments
Mathematical Programming Procedure
The objective is minimize the cost per unit time for moving
among the departments

dij = distance from department i to department j

It is rectilinear distance between department centroids

Mathematical Programming Procedure
The objective is maximize the adjacency score

xij = “1” if departments i and j are adjacent and “0” otherwise

Layout Generation
 Pairwise Exchange Method

• For layout improvement

• Distance-based objective
• The objective is to minimize the total cost of
transporting materials among all departments
in a facility
• Based on rectilinear distance from centroid to
centroid
• Since the final outcome is based on the initial layout,
we might not converge to the optimal solution
 Pairwise Exchange Method
Procedure
• Calculate total cost for the existing layout
• For each iteration evaluate all feasible exchanges in
the locations of department pairs
• Select the pair that results in the largest reduction in
total cost
• Re-compute the distance matrix each time an
exchange is performed
• If the lowest total cost for your next iteration is worse
than the total cost for the previous iteration, the
procedure is terminated
Pairwise Exchange Method
 Pairwise Exchange Method

Switching
Pairwise Exchange Method
 Pairwise Exchange Method

The method does not guarantee the optimality, only local

optimum
The procedure may cycle back to one alternative
Symmetric layout may occur
Pairwise exchange can be easily accomplished only if the
departments are of the same size
 Graph-Based Method
For layout construction
Adjacency-based objective

Adjacency graphs for alternative block layouts

 Graph-Based Method

Relationships are given by weights, rather than the alphabetic closeness

ratings
•The score is very sensitive to the assignment of weights
•Relationship can have a positive value only when departments are
adjacent. Other relationships are ignored
•The adjacency score does not account for:
The distance
All the relationships (except those between adjacent departments)
Dimensional specifications
The length of common boundaries between adjacent departments
• The arcs do not intersect (planarity)
 Graph-Based Method
Procedure

1.Select the department pair with the largest weight

◦Ties are broken arbitrarily

2.Select the third department to enter based on the largest sum

of the weights with the first two departments

3.Pick the fourth department to enter on a face of the graph (a

bounded region of a graph)

4.Determine an adjacency graph

5.Construct a corresponding block layout

Graph-Based Method
Graph-Based Method
Graph-Based Method
Thanks