Facilities Planning

ENIE 453
Layout Planning Models and Design Algorithms

OCTOBER 12th, 2022

 Algorithms

• SLP
• Pairwise Exchange Methods
• Craft
• Graph-Based method
• BlocPlan
• Mcraft
• MIP
• Logic

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 Classification of algorithms- Layout
Representation:

• Discrete
• The area of each department is rounded off to the nearest integer number of grids.
• A smaller grid size yields a finer resolution and gives more flexibility in department shapes, but
• Results in a larger number of grids which complicates computations. Why?

• Continuous
• Does not use a grid
• More flexible but more difficult to use
• Usually limited to rectangular building and departments
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 Graphical Representation

• “Points and lines” representation is • Most procedures employ a “unit

not convenient for analysis
area square” representation as an
approximation
• Space available and space required for
each activity are expressed as an
integer multiple of the unit area.

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 Graphical Representation (cont.)

• Unit Square Area approximation • Examples of Split and Unsplit

can also be represented by a two departments
dimensional array or matrix of
numbers
• Easy to manipulate (e.g., determine
adjacency) but difficult to visually
interpret

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 Classification of Algorithms –
Primary functions
• Optimal solution procedures are difficult to solve for realistic size problems.
Therefore, two types of heuristic procedures are considered.
• Improvement-based
• Start with an initial layout and try to improve it through incremental changes
• Example
• Pair-wise exchange
• CRAFT (Computerized Relative Allocation of Facilities Technique)
• Construction-based
• Develop ‘from scratch' and progressively build layout
• Example
• ALDEP (Automated Layout Design Program)
• CORELAP (Computerized Relationship Layout Planning)

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 Pairwise Exchange Method

• This is an improvement type algorithm.

• Usually it has distance based objective.
 Improvement-based:
Pairwise Exchange Method

• Compute the total cost of existing layout based on initial from-to chart and distance matrix
(c = f *d)
• Exchange two departments
• Recompute the total cost
• Consider all pairwise interchanges and evaluate the cost of each
• Perform the one that yields the greatest reduction in total cost
• Continue until no further improvement is obtained
• Not guaranteed to find the optimal solution but will be locally optimal.
• The method assumes departments areas are equal sizes

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 Example: Initial Layout
1 2 3 4
To Department
Flow
1 2 3 4
From 1 – 10 15 20
Department 2 – 10 5
3 – 5
4 –

Distance To Department

1 2 3 4
From 1 – 1 2 3
Department 2 – 1 2
3 – 1
4 –
 FLOW To Department

1 2 3 4
From 1 – 10 15 20
Department 2 – 10 5
3 – 5
1 2 3 4 4 –

Solution:
TC1234 = 10(1) + 15(2) + 20(3) + 10(1) + 5(2) + 5(1) = 125
Iteration 1
TC 2134 (1-2) = 10(1) + 15(1) + 20(2) + 10(2) + 5(3) + 5(1) =105

TC 3214 (1-3) = 10(1) + 15(2) + 20(1) + 10(1) + 5(2) + 5(3) = 95

TC 4231 (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
Iteration 2 3 2 1 4

TC 3124 (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
TC 2314 (2-3) = 10(2) + 15(1) + 20(1) + 10(1) + 5(3) + 5(2) = 90
TC 3412 (2-4) = 10(1) + 15(2) + 20(1) + 10(3) + 5(2) + 5(2) =105
TC 4213 (3-4) = 10(1) + 15(1) + 20(2) + 10(2) + 5(1) + 5(3) =105

Iteration 3 2 3 1 4
TC 1324 (1-2) = 10(2) + 15(1) + 20(3) + 10(1) + 5(1) + 5(2) = 120
TC 2134 (1-3) = 10(1) + 15(1) + 20(2) + 10(2) + 5(3) + 5(1) = 105
TC 2341 (1-4) = 10(3) + 15(2) + 20(1) + 10(1) + 5(2) + 5(1) = 105
TC 3214 (2-3) = 10(1) + 15(2) + 20(1) + 10(1) + 5(2) + 5(3) = 95
TC 4312 (2-4) = 10(1) + 15(2) + 20(2) + 10(2) + 5(3) + 5(1) = 120
TC 2413 (3-4) = 10(2) + 15(1) + 20(1) + 10(3) + 5(1) + 5(2) = 100
(a) Iteration 0 1 2 3 4

(b) Iteration 1 3 2 1 4

(c) Iteration 2 2 3 1 4 is the best layout with the

Total cost of 90
 Remarks
• The Pairwise Exchange method is not guaranteed to yield the optimal layout
because the final layout is dependent on the initial layout.
• If the departments have unequal areas it becomes difficult to apply this
method.
 Case Activity
Due: October 18th, 2022
• Flow-between matrix and area requirements A B C D E Area Requirements
are given for a new facility that you would like A 0 25 50 35 600 m2
to construct. B 45 30 20 600 m2
C 60 35 600 m2
• Your task is find good assignment of
departments in the Layout. D 10 600 m2
E 600 m2
• First develop a layout (any acceptable)
• Then randomly assign departments.
• Use pairwise algorithm to find the optimal
assignment.
• Write a report that shows your initial
assignment, your iterations and calculations,
and your final assignment.
• Report how much the cost improved.

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 20 m

30 m
A B C
50 m

D E

60 m
 Case Activity
Due: October 21st, 2022
• Flow-between matrix and area requirements A B C D E Area Requirements
are given for a new facility that you would like A 0 25 50 35 600 m2
to construct. B 45 30 20 600 m2
C 60 35 600 m2
• Your task is find good assignment of
departments in the Layout. D 10 600 m2
E 600 m2
• First develop a layout (any acceptable)
20 m
• Randomly assign departments.
• Use pairwise algorithm to find the optimal
assignment.
30 m
A B C
• Write a report that shows your initial 50 m
assignment, your iterations and calculations,
and your final assignment. D E
• Report how much the cost improved.
60 m

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Algorithmic Approaches
CRAFT
Chapter 6.4.4

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 Algorithm Approaches
• SLP
• Pairwise Exchange Method
• Craft
• Graph-Based method
• Mcraft
• Blocplan
• Logic

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 Algorithm Approaches- CRAFT
• Computerized Relative Allocation of Facility Technique
• Improvement algorithm.
• Discrete Representation
• From- to Matrix
• Distance-Based objective
• Pairwise exchange

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 Algorithm Approaches- CRAFT
• Computerized Relative Allocation of Facility Technique
• Introduced in 1963 by Armour, Buffa, and Vollman.
• Craft is a tool used to help improve the existing layout of the facilities.
• The facility is improved by switching two or three departments to help
arrange the facility in an optimal floor plan.

Craft method required three things:

• From to chart
• Cost matrix
• Initial layout with distances.

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 Algorithm Approaches- CRAFT
• Computerized Relative Allocation Of Facility Technique
• The major features of CRAFT are:
• Attempts to minimize transportation cost
• Transportation cost= Flow X distance X Unit Cost
• Craft is a path-oriented method, the final layout is dependent on the initial
layout.
• Requires an assumption that:
• Move cost is independent of the equipment utilization
• Move cost are linearly related to the length of move.

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 Algorithm Approaches- CRAFT
• Craft Algorithm:
1. Determine the department centroids.
2. Calculate the inter department rectilinear distance.
3. Calculate the initial cost of the layout by multiplying the from to chart with the cost
matrix
4. Craft then considers all possible two way or three ways department exchanges and
identifies the best exchange
5. Update the layout and calculate the new department centrodes
6. The above procedure is repeated until no further reduction in the cost can be obtained.

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 2
1

Dept x y
4 3 1 3 3
5 2 13 2
3 16.5 8
7 8 4 9.5 7
6 5 3 7
6 9.5 11
7 1.5 10
8 4.5 10
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 Cell labeled with red is the one that
2 Has follow
1

From to Matrix
4 3

5
dist 1 2 3 4 5 6 7 8
1 0
7 8 2 0
3 0
6 4 0
5 0
6 0
7 0
8 0

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 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 1 2
2 Cell labeled with red is the one that
3
4
Has follow
5 4
6 3
7 5
8
9 7 8
10
11 6 dist 1 2 3 4 5 6 7 8
12 1 0 18.5
2 0
3 0
4 0
5 0
6 0
7 0
8 0

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 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 1 2
2
3
4
5 4
6 3
7 5
8
9 7 8
10
11 6
12 dist 1 2 3 4 5 6 7 8
1 0 18.5 8.5
2 0
3 0
4 0
5 0
6 0
7 0
8 0

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 CRAFT
• Calculate the initial cost of the layout by multiplying from to chart with the
cost matrix:
• Cost= 20 X 18.5 + 2 X 8.5 + 1 X 16.5 + 2 X 14.5 + 1 X 8.5 + 2 X 11 + 1 X
4.5 + 10X 14.5 + 5 X 10 + 2 X 8= 678.5

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• Only equal areas or adjacent depts are feasible exchanges

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Dept x y 1 1 2
1 3 3 2
3
2 13 2 4
3 16.5 8 5 4
6 3
4 9.5 7 7 5
5 3 7 8
9 7 8
6 9.5 11 10
7 1.5 10 11 6
12
8 4.5 10

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New cost after changing 1 and 4

Cost= distance X cost

20 X 7.5 + 2X 11.5 + 1X 16.5 + 2 X 14.5 + 1X 11.07 + 2 X 8.43 + 1 X 4.5 +

10 * 4+
10X 5 + 2X 7.43= 355.79

Saving= 678-355.79/ 678.5 = 47.56

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 Algorithm Approaches- Craft
• 2- Computerized Relative Allocation of Facility Technique (CRAFT)
The procedures adopted for using CRAFT are:
• Determine transportation cost each department interchange.
• Select and implement the departmental interchange that offers the greatest
reduction in transportation cost.
• Repeat the procedure for the new layout until no interchange is able to
reduce the transportation cost.

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 Craft Pros
• Evaluates many Exchanges very quickly.
• Initial layout can be captured accurately.
• Craft allows:
• Flexible department shapes
• Dummy departments
• Fixed departments
• Non-rectangular buildings

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 Craft Cons
• Results in odd department shapes
• Limited exchange options

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 Example
2: CRAFT

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 Example 2: Possible Swaps

• CRAFT does not actually swap and re-calc centroids

• Swaps centroids and looks for best improvement
• Iteration #1 - Possible Swaps
• A-B Cost = 2650, C-D Cost = 2650, A-C Cost = 2270 *
• Iteration #2 - Possible Swaps
• C-B Cost =1950, C-A (already did this), A-D Cost=1950
• Break tie abitrarily and select A-D swap,
actual Cost=1870
• Iteration #3 – Possible Swaps
• C-B Cost =2270, A-D (already did this one),
A-C Cost =2500
• No improvement found
• STOP

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Example 3:

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 Example 3: CRAFT

New Layout - after exchanging

Initial Layout
E and F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18
1 A A A A A A A A A A G G G G G G G G 1 A A A A A A A A A A G G G G G G G G
2 A Receiving D. A G Shipping D. G 2 Shipping
A Receiving D. A G G
Shipping D.
3 A A A A A A A A A A G G G G Department
3 A A A A A A A A A A G G G G
4 B B B B B C C C C C E E G G G G G G 4 B B B B B C C C C C F F G G G G G G
5 B B C C E E E E E E E E 5 B B C C F F F F F F F F
6 B B C C C C C E E E E E E E E 6 B B C C C C C F F F F F F F
7 B B B B B D D D D F F F F F F F E E 7 B B B B B D D D D E E E E E E F F
8 D D D D D D D F F F 8 D D D D D D D E E F F
9 D D F F F F F F 9 D D E E E E E E F F
10 D D D D D D D D H H H H H F F F F F 10 D D D D D D D D H H H H H E E F F F
Initial CRAFT Layout
Dummy Department Exchanging departments E & F
(z=2974*20=59,480 units)
(z=2953*20=59,060 units)

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 Final Layout

After exchanging B and C Manual Adjustment on

CRAFT Output
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 A A A A A A A A A A G G G G G G G G
2 A Receiving D. A G G
Shipping D.
3 A A A A A A A A A A G G G G
4 C C C B B B B B B B F F G G G G G G
5 C C C B B F F F F F F F F
6 C C B B B B B B F F F F F F F
7 C C C C B D D D D E E E E E E F F
8 D D D D D D D E E F F
9 D D E E E E E E F F
10 D D D D D D D D H H H H H E E F F F

Final CRAFT Layout

(z=2833,5*20=56,670 units)

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 CRAFT Facts
• A heuristic solution procedure for the more generalize “quadratic assignment
problem”
• CRAFT only exchanges departments that are
• Adjacent (share at least one common edge)
• Have equal areas
• Adjacency is a necessary but not sufficient criteria for swapping
departments
• CRAFT simplistically assumes cost is linearly related to distance;
• 1’=1$ means 100’=$100
• In real life, you have fixed cost of investment in MH
• 0’=$100 1’=$101 100’=$200

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Limitations in Exchanging

Exchange dept.#2 with dept. # 4

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 CRAFT Facts...
• Quality of final solution depends on the initial layout
• CRAFT is a path-oriented method so the final layout is dependent on the initial layout.
• Therefore, a number of different initial layouts should be used as input to the CRAFT
procedure.
• CRAFT allows the use of dummy departments to represent fixed areas in the
layout.
• Final solution may be locally optimal, not globally optimal
• Many derivatives have emerged
• MCRAFT, BLOCPLAN, MULTIPLE, etc.
• Mixed Integer Programming Models

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