FACILITY LOCATION AND LAYOUT

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Layout Design Procedures

Manual methods

Travel chart
Systematic Layout Planning

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Computerized methods
Constructive type algorithms
Automated Layout Design Program (ALDEP)
Computerized Relationship Layout Planning
(CORELAP)
Improvement type algorithms
Computerized Relative Allocation of Facilities
Technique (CRAFT)
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
Computerized Relative Allocation of Facilities
Technique (CRAFT)
It is an improvement algorithm
It starts with an initial layout
In improves the layout by interchanging the
departments pairwise so that the transportation
cost is minimized
The algorithm continues until no further
interchanges are possible
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
 The solution is not optimum
It is a heuristic algorithm

Requirements
Initial layout Flow data
Cost per unit distance Total number of
departments
Area of departments

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
CRAFT procedure

S1: Input the details

S2: Compute centroids of departments in the present
layout
S3: Form distance matrix using the centroids
S4: Compute the total handling cost

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
S5: Find all the possible pairwise interchanges of
departments based on common border or equal
area criterion
For each possibility, interchange the
corresponding centroids and compute
approximate costs
S6: Find the pair of departments corresponding to the
minimum handling cost from among all the
possible pairs of interchanges
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
S7: Is the cost in the previous step less than the total
cost of the present layout? If yes, go to S8. If not,
go to S11
S8: Interchange the selected pair of departments
Call this as NEW LAYOUT
Compute centroids, distance matrix and total cost
S9: Is the cost of new layout less than the cost of the
present layout?
If yes, go to S10
If not, go to S11
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University
13-09-2019
S10: The new layout is here after considered as the
PRESENT LAYOUT
Its data on centroids, layout matrix, and the
total cost is retained
Go to S5
S11: Print the present layout as the FINAL LAYOUT
S12: Stop

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Example
S1:
Initial layout – 5 departments

size 4 2 4
4 1 5 4
4 2 3
size 4 6

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Cost matrix [cij] – transportation cost per unit distance
from dept. i to dept. j

From 1 2 3 4 5
/ To
1 - 1 1 1 1
2 1 - 1 1 1
3 1 1 - 1 1
4 1 1 1 - 1
5 1 1 1 1 -
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
Flow matrix [fij] – number of trips in a given period of
time from dept. i to dept. j

From 1 2 3 4 5
/ To
1 - 5 2 4 0
2 0 - 2 5 0
3 2 0 - 0 5
4 3 0 1 - 0
5 0 0 2 0 -
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
Area of departments

Departm 1 2 3 4 5
ent
Area 16 16 24 16 8
(sq.units)

S2: Centroids
(X1, Y1) = 2,6 (X2, Y2) = 2,2
(X3, Y3) = 7,2 (X4, Y4) = 8,6
(X5, Y5) = 5,6
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
S3: Rectilinear distance between the centroids of two
departments
dij = |Xi - Xj| + |Yi - Yj|
Distance
matrix [dij] From 1 2 3 4 5
/ To
1 - 4 9 6 3
2 4 - 5 10 7
3 9 5 - 5 6
4 6 10 5 - 3
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 3 7 6 3 -
13-09-2019
S4: Total cost of handling for the present layout
5 5
Total cost [Tcij] = 𝑖=1 𝑗=1 𝑓𝑖𝑗 × 𝑑𝑖𝑗 × 𝑐𝑖𝑗 = 205

From 1 2 3 4 5
/ To
1 - 20 18 24 0
2 0 - 10 50 0
3 18 0 - 0 30
4 18 0 5 - 0
5 0
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
0 12 0 -
13-09-2019
University
S5: Possible department interchanges
departments having common border and
departments having equal area
1 and 2 2 and 5
1 and 3 3 and 4
1 and 4 3 and 5
1 and 5 4 and 5
2 and 3
2 and 4
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
Interchange between two departments would mean
that their present centroids are interchanged

Interchange between 1 and 2

Centroids after interchange
(X1, Y1) = 2,2 (X2, Y2) = 2,6
(X3, Y3) = 7,2 (X4, Y4) = 8,6
(X5, Y5) = 5,6

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Distance 4 2 4
4 2 5 4
matrix [dij]
4 1 3
TC = 205 4 6

From 1 2 3 4 5
/ To
1 - 4 5 10 7
2 4 - 9 6 3
3 5 9 - 5 6
4 10 6 5 - 3
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 7 3 6 3 - 13-09-2019
Interchange between two departments would mean
that their present centroids are interchanged

Interchange between 1 and 4

Centroids after interchange
(X1, Y1) = 8,6 (X2, Y2) = 2,2
(X3, Y3) = 7,2 (X4, Y4) = 2,6
(X5, Y5) = 5,6

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Distance 4 2 4
4 4 5 1
matrix [dij]
4 2 3
TC = 193 4 6

From 1 2 3 4 5
/ To
1 - 10 5 6 3
2 10 - 5 4 7
3 5 5 - 9 6
4 6 4 9 - 3
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 3 7 6 3 - 13-09-2019
Interchange between two departments would mean
that their present centroids are interchanged

Interchange between 1 and 5

Centroids after interchange
(X1, Y1) = 5,6 (X2, Y2) = 2,2
(X3, Y3) = 7,2 (X4, Y4) = 8,6
(X5, Y5) = 2,6

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Distance 2 4 4
4 5 1 4
matrix [dij]
4 2 3
TC = 208 4 6

From 1 2 3 4 5
/ To
1 - 7 6 3 3
2 7 - 5 10 4
3 6 5 - 5 9
4 3 10 5 - 6
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 3 4 9 6 - 13-09-2019
Interchange between two departments would mean
that their present centroids are interchanged

Interchange between 2 and 3

Centroids after interchange
(X1, Y1) = 2,6 (X2, Y2) = 7,2
(X3, Y3) = 2,2 (X4, Y4) = 8,6
(X5, Y5) = 5,6

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Distance 4 2 4
4 1 5 4
matrix [dij]
4 3 2
TC = 197 4 6

From 1 2 3 4 5
/ To
1 - 9 4 6 3
2 9 - 5 5 6
3 4 5 - 10 7
4 6 5 10 - 3
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 3 6 7 3 - 13-09-2019
Interchange between two departments would mean
that their present centroids are interchanged

Interchange between 2 and 4

Centroids after interchange
(X1, Y1) = 2,6 (X2, Y2) = 8,6
(X3, Y3) = 7,2 (X4, Y4) = 2,2
(X5, Y5) = 5,6

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Distance 4 2 4
4 1 5 2
matrix [dij]
4 4 3
TC = 201 4 6

From 1 2 3 4 5
/ To
1 - 6 9 4 3
2 6 - 5 10 3
3 9 5 - 5 6
4 4 10 5 - 7
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 3 3 6 7 - 13-09-2019
Interchange between two departments would mean
that their present centroids are interchanged

Interchange between 3 and 4

Centroids after interchange
(X1, Y1) = 2,6 (X2, Y2) = 2,2
(X3, Y3) = 8,6 (X4, Y4) = 7,2
(X5, Y5) = 5,6

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Distance 4 2 4
4 1 5 3
matrix [dij]
4 2 4
TC = 178 4 6

From 1 2 3 4 5
/ To
1 - 4 6 9 3
2 4 - 10 5 7
3 6 10 - 5 3
4 9 5 5 - 6
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 3 7 3 6 - 13-09-2019
Interchange between two departments would mean
that their present centroids are interchanged

Interchange between 3 and 5

Centroids after interchange
(X1, Y1) = 2,6 (X2, Y2) = 2,2
(X3, Y3) = 5,6 (X4, Y4) = 8,6
(X5, Y5) = 7,2

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Distance 4 2 4
4 1 3 4
matrix [dij]
4 2 5
TC = 183 4 6

From 1 2 3 4 5
/ To
1 - 4 3 6 9
2 4 - 7 10 5
3 3 7 - 3 6
4 6 10 3 - 5
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 9 5 6 5 - 13-09-2019
Interchange between two departments would mean
that their present centroids are interchanged

Interchange between 4 and 5

Centroids after interchange
(X1, Y1) = 2,6 (X2, Y2) = 2,2
(X3, Y3) = 7,2 (X4, Y4) = 5,6
(X5, Y5) = 8,6

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Distance 4 2 4
4 1 4 5
matrix [dij]
4 2 3
TC = 163 4 6

From 1 2 3 4 5
/ To
1 - 4 9 3 6
2 4 - 5 7 10
3 9 5 - 6 5
4 3 7 6 - 3
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 6 10 5 3 - 13-09-2019
Pairwise interchange with cost
1 and 2 205
1 and 4 193
1 and 5 208
2 and 3 197
2 and 4 201
3 and 4 178
3 and 5 183
4 and 5
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT 163 13-09-2019
University
The interchange between 4 and 5 results in the
minimum cost of 163

This cost is compared with the cost of the present

layout and is found to be less

Interchange is made between departments 4 and 5

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
 *

Distance 4 4 2
4 1 4 5
matrix [dij]
4 2 3
TC = 181 4 6

From 1 2 3 4 5
/ To
1 - 4 9 4 7
2 4 - 5 8 11
3 9 5 - 5 6
4 4 8 5 - 3
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
University 5 7 11 6 3 - 13-09-2019
The new layout cost is 181 which is less than the
present layout cost of 205
Treat the new layout as the present layout
Apply the rule of common border or equal area
All possible pairwise interchanges are considered

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
Pairwise interchanges
1 and 2 CB 181 3 and 4 CB 166
1 and 3 - 3 and 5 CB 183
1 and 4 CB 169 4 and 5 RECENT
1 and 5 -
2 and 3 CB 209
2 and 4 EA 181
2 and 5 -
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
 *

Distance 4 4 2
4 1 5
matrix [dij] 3
4 2
4
TC = 187
4

8×6 +(8×9)
𝑋4 = = 7.5
8+8
8×1 +(8×2)
𝑌4 = = 1.5
8+8

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
The formula to compute centroid for irregular shaped
department is

𝑋𝑖 is the X-coordinate of the centroid of the ith

portion of the department
𝑌𝑖 is the Y-coordinate of the centroid of the ith
portion of the department
𝑎𝑖 is the area of the ith portion
n is the number of regular shaped portions
Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT
13-09-2019
University
If the shape of a particular department is irregular,
then that is divided into several regular shaped
portions

𝑎1 𝑋1 +𝑎2 𝑋2 + ...+𝑎𝑖 𝑋𝑖 + ...+𝑎𝑛 𝑋𝑛

𝑋=
𝑎1 +𝑎2 + ...+𝑎𝑖 + ...+𝑎𝑛
𝑎1 𝑌1 +𝑎2 𝑌2 + ...+𝑎𝑖 𝑌𝑖 + ...+𝑎𝑛 𝑌𝑛
𝑌=
𝑎1 +𝑎2 + ...+𝑎𝑖 + ...+𝑎𝑛

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University
 *

Distance 4 4 2
4 1 4 5
matrix [dij]
4 2 3
TC = 181 4 6

The total cost of the new layout is compared

with the cost of the present layout
Since the cost (187) is not less (181), present
layout is taken as the final layout

Dr.T.Sampath Kumar, Asso. Prof. SMEC, VIT

13-09-2019
University