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IE 302
Layout Planning Models
1

2 Motivation

 Generation and evaluation of a number of layout

alternatives is critical step in facilities planning process
because it will determine material flow and physical
relationships between activities

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3 Basic Layout Types

 In previous chapters, we talked about four planning

departments
 Product / Production Line
 Product family
 Fixed material
 Process

Product Layout
4
 Advantages  Limitations
 Smooth, simple, direct  Line stoppage
flow
 Product design
 Small work-in-process changes
inv.
 Slowest station paces
 Short production the line
time/unit
 General supervision
 Reduced material
handling  High equipment
investment
 Less skill
 Easy production
control

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5 Fixed Product Layout

 Advantages  Limitations
 Reduced material
moves
 Highly flexible
 Job enrichment
 Promotes pride &
quality
 Responsibility
 Personnel-equipment
moves
 Equipment duplicates
 Greater skill
 Close control&
coordination
 Increased space &
greater work-in-
process

6 Product Family Layout

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

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

8 Layout Procedures
ORIGINAL
APPROACHES TO
LAYOUT PROBLEM

Muther's
Apple’s Plant Reed’s Plant
Systematic
Layout Layout
Layout Planning
Procedure Procedure
(SLP) Procedure

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9 Apple’s Plant Layout

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

10 Apple’s Remark
 “Since no two layout design projects are the same, neither are the
procedures for designing them. And, there will be always a
considerable amount of jumping around among the steps, before it is
possible to complete an earlier one under consideration. Likewise,
there will be some backtracking going back to a step already done –
to recheck or possibly re-do a portion, because of a development not
foreseen”

Plant Layout and Material Handling

J.M. Apple

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11 Layout Procedures
ORIGINAL
APPROACHES TO
LAYOUT PROBLEM

Reed’s Plant
Layout
Procedure

12 Reed’s Plant Layout

Procedure
1. Analyze the product or products 9. Determine workstations.
to be produced.
10. Analyze storage area .
2. Determine the process required to requirements.
manufacture the product.
11. Establish minimum aisle
3. Prepare layout planning charts. widths.
4. Flow process, including 12. Establish office requirements.
operations, transportation, storage,
and inspections. 13. Consider personnel facilities
and services.
5. Standard times for each
operation. 14. Survey plant services.
6. Machine selection and balance. 15. Provide for future expansion.
7. Manpower selection and
balance.
8. Material handling requirements.

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13 Layout Procedures
ORIGINAL
APPROACHES TO
LAYOUT PROBLEM

Muther’s
Systematic
Layout Planning
(SLP) Procedure

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15 Systematic Layout Planning

(SLP) Procedure
Materials Flow Analysis

from-to chart

RELATIONSHIP DIAGRAM

Activity Relationship
Analysis

activity relationship chart

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Activity Relationship
Chart

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17 Relationship Diagram

18 Space Relationship Diagram

Space
Relationship Alternative
Relationship
Diagram Block Layouts
Diagram

Space
Requirements

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19 Space Relationship Diagram

20 Alternative Block Layout I

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21 Alternative Block Layout II

22 Systematic Layout
Planning(SLP) Example

A: Absolutely Necessary
E: Especially Important
I: Important
O: Ordinary

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23 Systematic Layout
Planning(SLP) Example

24 Algorithmic Approaches

 Relative placement of departments on the basis of

their
 closeness ratings
 material flow intensities

There are two basic objectives:

1. one aims at minimizing the sum of
flows times distances,
2. the other aims at maximizing an
adjacency score

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25 Distance based Objectives

m m
min Z   f ij cij d ij
i 1 j 1

m : number of departments
fij : flow from department i to j
cij : cost of moving a unit load one distance unit from
department I to deparment j
dij: distance from i to j

26 Measuring Distance
Between Two Points
 Euclidean [(xi-xj)2 + (yi-yj)2]0.5
 Rectilinear |xi-xj| + |yi-yj|

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27 Adjacency score

 the adjacency score is computed as the sum of all the

flow values (or relationship values) between those
departments that are adjacent in the layout.
 Letting xij = 1 if departments i and j are adjacent in the
layout, and 0 otherwise, the objective is to maximize
the adjacency score; that is,

28 Discrete versus Continuous

Layout

the area of each department is

rounded off to the nearest integer
number of grids.

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29 Split vs. Unsplit Departments

30 Adjacency Score

Maximize Adjacency Score

Relative Efficiency

Relative Efficiency
with negative flow

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31 Test Problem

 Suppose five A B
departments labeled A C
through E are located
D E
as shown in the layout
below. Given the
corresponding flow- A B C D E
between chart,
compute the efficiency A — 5 0 4 -3
rating for the B — 6 -1 2
layout.(What about cost
minimization?) C — -6 0

D — 3

E —

32 Solution

 Adjacent Positive Flow: 14

 Non Adjacent Negative Flow: -4
 Total Positive Flow: 20
 Total Negative Flow: -10
 z=(14-(-4))/(20-(-10) = 18/30 = 0.60

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33 Pairwise Exchange Method

 1. Construction algorithms
 2. Improvement algorithms
 3. Hybrid algorithms

34 Heuristic Approach

 Try to find the best solution when time and resources

are limited
 “Optimum” solution is not guaranteed.
 Examples:
 local search
 tabu search
 simulated annealing
 genetic algorithms

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35 Pairwise Exchange Method -

Example
Material Flow Matrix Distance Matrix Based on
Existing Layout

To 1 2 3 4 To 1 2 3 4
From From
1 - 10 15 20 1 - 1 2 3

2 - 10 5 2 - 1 2

3 - 5 3 - 1

4 - 4 -

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

Distance between adjacent departmants is 1.

36 Pairwise Exchange Method –

Example
Iteration 1
 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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37 Pairwise Exchange Method –

Example
Iteration 2
 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

38 Pairwise Exchange Method –

Example
Iteration 3
 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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39 Graph Based Method

 It has roots in graph theory

 Adjacency based objective
 Numeric value representing the “weight” of
adjacency
 Adjacency score does not account for distance
 No dimensional considerations for departments
 Arcs do no intersect: this property of graph is
called planarity

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41

Relationship (REL) Graph

 Given a (block) layout with M activities, a corresponding planar

undirected graph, called the Relationship (REL) Graph, can
always be constructed.

1 2 1 2

3 4 5 3 4 5

(Exterior) 6
Block
REL
Layout
Graph

• A REL graph has M+1 nodes (one node for each activity and a node for the
exterior of the layout. The exterior can be considered as an additional activity.
The arcs correspond to the pairs of activities that are adjacent.
• A REL graph corresponding to a layout is planar because the arcs connecting
two adjacent activities can always be drawn passing through their common
border of positive length.

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Relationship (REL) Diagram

 A Relationship (REL) Diagram is also an undirected graph,
generated from the REL chart, but it is in general
nonplanar.

 A REL diagram, including the U closeness values, has

M(M-1)/2 arcs. Since a planar graph can have at most
3M-6 arcs, a REL diagram will be nonplanar if M(M-1)/2 >
3M-6.

M(M-1)/2 > 3M-6  M  5.

 A REL graph is a subgraph of the REL diagram.

44 Algorithm for Graph-based

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

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45 Alternative Layouts

Total Weight:63 Total Weight: 71 Rel-chart

Adjacency graphs for alternative block layouts

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