Process Choice 1

Production & Operations Management

LAYOUTS
(methods)

Prof. Ajith Kumar J

XLRI, Jamshedpur
Process Choice 2

Layout planning methods

Production & Operations Management

❖ Intuitive approach.
❖ Simplified Systematic Layout Planning (SSLP).
❖ Trip-Distance Method (TDM).
Process Choice 3

Intuitive approach
Production & Operations Management

Final
Shipper Duties and
Stamp
Clearance Taxes
and
Signature

Entrance
and Exit
Initial Document
Check

Surface Photo-
Movement verification
Registration

Final
Stamp
and
Signature Photo-
verification Shipper
Entrance
and Exit

Clearance

Initial Document Duties and

Surface
Check Taxes
Movement
Registration
Process Choice 4

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Ambar Training Institute is planning a layout to accommodate

the offices of the Director, the Dean, the Accounts department, the
Librarian and the Sports Coach. The space available has
dimensions of 15 metres x 30 metres.

Space available
15 m x 30 m
Process Choice 5

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Step 1: Partition the given space into boxes of roughly uniform size
and assign coordinates to their centres.

15 m

30 m

❖ Since we need 5 offices, we need at least 5 boxes.

❖ It is convenient to make 6 boxes of 10 m x 7.5 m each.

Process Choice 6

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Step 2: Using a closeness rating scale, construct a closeness matrix

using the inputs of experienced members in the organization.
CLOSENESS RATING SCALE CLOSENESS MATRIX

Accounts

Librarian
Director
Value Closeness

Coach
Dean
A Absolutely necessary
E Very important Director -- E A U U

I Important Dean -- U A I
O Ordinary importance Accounts -- E E
U Unimportant Librarian -- X
X Undesirable Coach --

A O
E U
I X
Process Choice 7

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Step 3: Make an initial relationship diagram, keeping the box-wise

partitioning of the space in mind.
❖ First establish the ‘A’ links, then the ‘E’ links, the ‘I’ links and so on.
❖ Use lines of different thicknesses and dashes to represent closeness.
❖ Rely on trial and error and expert input to avoid conflicts.

DIRECTOR

ACCOUNTS

COACH
LIBRARIAN

DEAN
Process Choice 8

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Step 4: Make an initial layout based on this relationship diagram.

DIRECTOR ACCOUNTS

15 m

COACH DEAN LIBRARIAN

30 m
Process Choice 9

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Step 5: Refine the layout based on area considerations.

❖ Suppose, the areas needed for the offices are not all equal.
❖ For example:
Area needed
Office
(m2)
Director 75
Dean 75
Accounts 120
Librarian 45
Coach 30

❖ It is also required, aisle width = minimum 3 meters.

Process Choice 10

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Step 5: Refine the layout based on area considerations.

Process Choice 11

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

IDEAL DIAGNOSTICS
Process Choice 12

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

STEP 1
Process Choice 13

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

STEP 2
Process Choice 14

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Reception
STEP 3

Waiting
Washrooms

X-Ray Blood Test

Ultrasound
Process Choice 15

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

STEP 4
X-Ray
Ultrasound Blood
Test

Waiting Washrooms

Reception
Process Choice 16

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

STEP 5
Ultrasound X-Ray Blood Test

Waiting Washrooms

Reception
Process Choice 17

Simplified Systematic Layout Planning (SSLP)

Production & Operations Management

Visually examine the trip numbers. Are there pairs of departments with
high trip numbers placed far apart or low trip numbers placed close by? Is
there a conflict between the closeness ratings and the trip numbers? How
can we deal with this?
Process Choice 18
Production & Operations Management

Trip Distance Method (TDM)

Ambar Training Institute is planning a layout to accommodate
the offices of the Director, the Dean, the Accounts department, the
Librarian and the Sports Coach. The space available has
dimensions of 15 metres x 30 metres.

Space available
15 m x 30 m
Process Choice 19

Trip Distance Method (TDM)

Production & Operations Management

Relies on the frequency of travel between pairs of offices & the

distances between them.
Suppose, the expected number of weekly trips between each
pair of the five offices is as shown in the table below:

Accounts

Librarian
Director
OFFICES

Coach
Dean
Director 0 45 20 25 5

Dean 0 30 40 10

Accounts 0 10 5

Librarian 0 0

Coach 0
Process Choice 20

Trip Distance Method (TDM)

Production & Operations Management

Step 1: Partition the given space into boxes of roughly uniform size
and assign coordinates to their centres.

(5, 11.25) (15, 11.25) (25, 11.25)

15 m

(5, 3.75) (15, 3.75) (25, 3.75)

(0, 0)
30 m
❖ Since we have 5 offices, we need at least 5 boxes.

❖ It is convenient to make 6 boxes of 10 m x 7.5 m each.

❖ Take the bottom left corner to be (0, 0) and assign (x, y) coordinates to
the centre of each box as shown.
Process Choice 21

Trip Distance Method (TDM)

Production & Operations Management

Step 2: Compute the distances between each pair of boxes

(5, 11.25) (15, 11.25) (25, 11.25)

15 m

(5, 3.75) (15, 3.75) (25, 3.75)

(0, 0)
30 m
❖ Here, the rectilinear distance between each pair of points (1, 2) can be
used to represent the distance between the corresponding boxes:
𝑟12 = 𝑥1 − 𝑥2 + 𝑦1 − 𝑦2

❖ For example: 𝑟16 = 5 − 25 + 3.75 − 11.25 = 27.5

Process Choice 22

Trip Distance Method (TDM)

Production & Operations Management

Step 3: Make an (arbitrary) initial assignment of offices to the boxes

and work out the initial distance matrix for that assignment.

INITIAL ASSIGNMENT INITIAL DISTANCE MATRIX

Accounts

Librarian
Director

Dummy
Coach
Dean
OFFICE Box X Y
OFFICE

Director 1 5 3.75
Director 0 7.5 10 17.5 20 27.5
Dean 2 5 11.25
Dean 7.5 0 17.5 10 27.5 20
Accounts 3 15 3.75
Accounts 10 17.5 0 7.5 10 17.5
Librarian 4 15 11.25 Librarian 17.5 10 7.5 0 17.5 10
Coach 5 25 3.75 Coach 20 27.5 10 17.5 0 7.5

Dummy 6 25 11.25 Dummy 27.5 20 17.5 10 7.5 0

A dummy office is created since

we have one office less than the
number of boxes to be filled.
Process Choice 23

Trip Distance Method (TDM)

Production & Operations Management

Step 4: Compute the initial trip distance score.

❖ Sumproduct of the trip matrix and the distance matrix.

TRIP MATRIX INITIAL DISTANCE MATRIX

Accounts

Accounts
Librarian

Librarian
Director

Director
Dummy

Dummy
Coach

Coach
Dean

Dean
Director 0 45 20 25 5 0 Director 0 7.5 10 17.5 20 27.5

Dean 45 0 30 40 10 0 Dean 7.5 0 17.5 10 27.5 20

Accounts 20 30 0 10 5 0 Accounts 10 17.5 0 7.5 10 17.5

Librarian 25 40 10 0 0 0 Librarian 17.5 10 7.5 0 17.5 10

Coach 5 10 5 0 0 0 Coach 20 27.5 10 17.5 0 7.5

Dummy 0 0 0 0 0 0 Dummy 27.5 20 17.5 10 7.5 0

Initial trip distance score = 2400

Process Choice 24

Trip Distance Method (TDM)

Production & Operations Management

Step 5: Minimize the trip distance score using Excel solver.

❖ Choose the option – “Evolutionary Solver”.

SOLVER SOLUTION FINAL DISTANCE MATRIX

Accounts

Librarian
Director

Dummy
Coach
Dean
Box X Y

Director 4 15 11.25
Director 0 7.5 10 17.5 20 27.5
Dean 3 15 3.75
Dean 7.5 0 17.5 10 27.5 20
Accounts 1 5 3.75
Accounts 10 17.5 0 7.5 10 17.5
Librarian 5 25 3.75 Librarian 17.5 10 7.5 0 17.5 10
Coach 2 5 11.25 Coach 20 27.5 10 17.5 0 7.5

Dummy 6 25 11.25 Dummy 27.5 20 17.5 10 7.5 0

Final trip distance score = 2287.5

❖ Since we are using a heuristic procedure, this may not be the optimal
solution, but it is certainly better than the initial solution.
Process Choice 25

Trip Distance Method (TDM)

Production & Operations Management

Step 6: Assign the offices to the boxes, referring to the solution.

COACH DIRECTOR

15 m

ACCOUNTS DEAN LIBRARIAN

30 m
Process Choice 26

Trip Distance Method (TDM)

Production & Operations Management

Step 7: Refine the layout based on area considerations.

Area needed
Office
(m2)
Director 75
Dean 75
Accounts 120
Librarian 45
Coach 30

❖ It is also required, aisle width = minimum 3 meters.

Process Choice 27

Trip Distance Method (TDM)

Production & Operations Management

Step 7: Refine the layout based on area considerations.

Process Choice 28

Comparing the TDM and the SSLP solutions

Production & Operations Management

Solution
obtained
with the
TDM

Solution
obtained
with the
SSLP
Process Choice 29

Conclusions
Production & Operations Management

❖ The TDM is suitable when the number of trips between the

locations matters most. E.g. the movement of people and
materials between work centers in a factory, restaurant,
bank, hospital and so on.

❖ The SSLP is better suited when there are also other

objectives (considerations) to consider, simultaneously, such
as shared resources, environmental influences and so on.

❖ The SSLP captures subjective judgements; TDM does not.

❖ In general, all objectives will not be perfectly satisfied.

Production & Operations Management Process Choice

YOU
THANK
30