MODULE 7

DETERMINATION OF RELATIONSHIP BETWEEN ACTIVITIES AND

LOCATION OF DEPARTEMENT

LABWORK SUBTANCE

Determining the layout of the facility and the additional unit.

LABWORK OBJECTIVES

1. Students are able to analyze the relationship between each process in a

factory.
2. Students are able to determine the position of each department in accordance
with the relationship between activity and material flow.

LABWORK TOOLS

Microsoft Excel
DOSBox Virtual Machine
BLOCPLAN

LABWORK REQUIREMENTS

Guideline
DOSBox Virtual Machine and BLOCPLAN successfully installed
LITERATURE

1. Activity Relationship Chart

Activity Relationship Chart (ARC) is a diagram that illustrates the strength of

connections between various departments, offices, or service areas within an
industrial organization. It depicts the level of interaction between each unit,
providing a visual representation of their relationships. (Stephens, 2013). ARC
essentially maps the intensity of interactions between activities, reflecting the
degree of interdependence between departments. (Richard Muther 1973:
Systematic Layout Planning). These are functions and utilities of ARC:

1. Arranging work centers or departments in an office.

2. Positioning of activities in a service organization.

3. Positioning of work center in maintenance or repair process.

4. Illustrates the connection between activities.

5. Establishing a foundation for planning the subsequent area.

Example of Activity Relationship Chart:

How to read ARC: Using triangle between department Example:

Relationship code between Welding Parts and Exhaust Parts is E. Painting and
Finishing Parts is U. Closeness codes are used to reflect the importance of each
relationship. You may need to talk with many people to determine these codes, and
once they are set, your arrangement of departments, offices, and service facilities
are nearly determined for you.

The technique for analyzing relationships between existing activities are as follows:
a. Determining the Interrelationships between Activities Based on the Degree
of Association Evidenced by Letter Codes

A Pareto analysis approach to assigning the relationship codes may be helpful. Here
are the percentages for a given code:

Source: (James M. Apple, 1990)

The reason of the relationship is divided into three kinds of linkages, for production,
employees and flow of information (Apple, 1990):
1) Production

a. Workflow sequence.

b. Using the same equipment.

c. Using the same note.

d. Using the same room.

e. Noisy, dirty, dust, vibration, odor, etc.

f. Facilitate the transfer of materials.

2) Employees

a. Using the same employee.

b. The importance of touch.

c. The degree of employment relationship.

d. Groove normal trip.

e. Ease supervision.

f. Carry out similar work.

g. Favored employees.

h. The transfer of personnel.

i. Disorder employee.
3) Information Flow

a. Using the same note

b. The degree of relationship paperwork

c. Using the same communication tools

You would write a reason code key below the diagram (Stephens, 2013):

You would write a reason code key below the diagram (James A. Tompkins, 2010)
2. ARC Normalization

ARC Normalization is a technique that converts qualitative data into quantitative

data. This conversion is useful in determining the proximity between facilities and
can be taken into account in the next layout proposal. The normalization value is
obtained from the approximate scales of each grade so that every problem has the
same multiplier. By observing the linkage between departments at the ARC, the
letter grade (A, E, I, O, U, X) will be transformed into quantitative form. The code
number will be useful to be input on Unit Flow Distribution (UFD).

Grade Value

A 1

E 0.8

I 0.6

O 0.4

U 0.2

X 0
 3. Unit Flow Distribution (UFD)

UFD is the result of multiplying the FTC with ARC. The UFD data will be input at
WINQSB software:

4. Worksheet

The worksheet can also be used as a summary of the activity relationship chart. It
interprets the basic data for area allocation diagrams. Stephens (2013) provides a
step-by-step procedure for creating the worksheet:
1. List all the activities down the left-hand side of a sheet of paper.

2. Create six columns to the right of the activity column and label them A, E, I,
O, U, and X (relationship codes).
3. Select an activity and list the number from ARC normalization where activity
1 has a code of E.

Activities A E I O U X

Fabrication 2,6 3,10 9,11,13,14 4,5,12 7,8

Welding 1,3 6 9,10,12,13,5 7,8,4,11,14

Paint 2,4 1 6 12, 13, 9 5,7,8,10,11,14

Assembly and 3,7 6,8 9,12,13,14 1,5 2,10,11

P.O
Receiving 6 14 4,2,1,9,12,1 3,7,10,11 8
3
Stores 5,1 4 3,2,14 9 8,1011,12,13 7

Warehouse 4,8 14 5,3,2,1,9,10,1 6

1,12,13
Shipping 7 4 14 9,12,13 6,3,2,1,10,11 5

Restrooms 12 13,14 4,1 8,6,5,11,3,2, 7

10
Maintenance 11 1 9,2 8,7,6,4,3,12,1
3,14
Tool room 10 1 9,14 8,7,6,5,4,3,2,1
2,13
Locker room 9 13 4 8,5,3,2,1 11,10,7,6,14

Cafeteria 14,12,9 4,1 8,5,3,2 10,11,7,6

Office 13,9 8,6,5,4,1 11,7 12,10,2,3

5. Area Allocation Diagram (AAD)

The Area Allocation Diagram (AAD) is a global pattern that depicts the conclusions
of the Activity Relationship Chart (ARC) (Apple, 1990). The AAD is a continuation
of the ARC, where after ensuring the interests between activities in the ARC, some
activities must be close together while others should not be adjacent to each other.
The relationship between activities affects the level of proximity between the
layouts of these activities, which can then be determined by the AAD (Arif, 2016).
5.1 The Purpose of Making AAD

a. Designing an efficient production space that is integrated into a single unit.

b. AAD organizes efficient workstations on the production floor by taking into

account the proximity relationships specified in the ARC.

c. Determine linkages between the facility and the reasons.

d. Estimates translate into an initial layout area.

e. Provides an estimate of the total area that is close to the actual conditions.

f. Became the basis for further planning.

5.2 Type of AAD:

a. AAD Powram Approach

Depicts AAD in block diagram form that coincides between activity

facilities.
b. AAD Muther Approach

A diagram has been created to illustrate the relationship between AAD and
the level of correlation between different activities. The diagram consists
of activities that are connected by lines or bands of varying thicknesses.

The thickness of the line represents the flow volume between activities,
which helps planners to connect each activity appropriately during the
early stages of layout planning. In the Muther approach, conventional
process symbols are used, and intersymbol line numbers indicate the
importance of proximity.
6. Template

Template is an overview of plant layout will be made based on the result of

previous AAD workmanship. Template is a depiction of all activities of the plant
and the linkages activities. In the manufacture of the template should be held
account floor area of predetermined and given alley (Apple, 1990). With the
templates, it can be seen:

a. Office layout.
b. Location of service facilities such as a canteen, roads, etc.
c. Production floor layout.
d. Material flow from receiving to shipping template is flexible, making it
possible to obtain a lot of alternative layouts

7. Office

Office is a location where a specific type of business is conducted or a service

is provided. The primary objectives of designing an office layout, according
to Heragu, are as follows:
1. Reducing the distance traveled by employees.

2. Allowing flexibility so that the current layout can be easily changed or

expanded.
3. Creating a safe and comfortable environment for people to work in.

4. Minimizing the capital and operational costs of the facility.

Office planning typically involves four major phases:

1. Evaluation

This phase involves a thorough evaluation of customer service,

marketing, operational aspects, and strategic plans. It also determines the
cost of building, renting, or leasing, along with interior decoration and
furnishing. This is a necessary first step because it tells whether the new
office plan is justified.
2. Planning

This phase involves reviewing current space utilization by examining

each department within the organization. It also involves determining
 space projections, the level of interaction between departments, and
identifying special considerations such as the need for being within a
reasonable distance from restaurants.
3. Design and Layout

This phase involves drawing an activity relationship diagram, a space

relationship diagram, and a pre-architectural layout using the relationship
chart and space requirement tables.
https://www.youtube.com/watch?v=PVpo0lpUF0U

Four types of office (Stephens, 2013):

1. Supervisor Office
Manufacturing plant supervisors’ offices are ideal starting points
for office discussions because they are small and provide an early sense
of space. Supervisors should be located where they are easily accessible
to their employees.

2. Open Office Space

Open Offices, also known as Bull pen, are large rooms that
accommodate many people. Open offices are popular because
communication is easier, and talking to someone only requires lifting the
head and speaking.
 3. Conventional Office
Conventional offices, also known as fixed walled offices, are the
opposite of open offices. A conventional office has independent furniture,
four walls, and a door. More than one person can be assigned to an office.

4. Modern Office
The modern office design concept tailors individual work areas to satisfy
the needs of the organization. The modern office will provide private
office space where needed without negatively affecting the cost of
utilities, maintenance, and accessibility.

8. FACILITY LAYOUT

A facility layout is an arrangement of everything needed for production of goods or

delivery of services. A facility is an entity that facilitates the performance of any
job. It may be a machine tool, a work centre, a manufacturing cell, a machine shop,
a department, a warehouse, etc. (Heragu, 1997)
9. FACILITY LAYOUT

A facility layout is an arrangement of everything needed for production of goods or

delivery of services. A facility is an entity that facilitates the performance of any
job. It may be a machine tool, a work centre, a manufacturing cell, a machine shop,
a department, a warehouse, etc. (Heragu, 1997)

10. BLOCPLAN

The BLOCPLAN algorithm is a layout design approach that generates efficient

layouts using a heuristic algorithm to maximize the R-Score value. It is commonly
applied in industries to create efficient facility layouts by arranging departments,
workstations, or production units within a given area. Its effectiveness has made it
widely adopted across various industries, as it consistently delivers more optimized
layouts compared to initial designs. The algorithm seeks to achieve optimal spatial
arrangements to improve workflow, reduce material handling costs, and maximize
space utilization.

11. PURPOSE OF USING BLOCPLAN

The primary purpose of BLOCPLAN is to develop a layout that balances efficiency
and practicality. By using heuristic principles, it focuses on optimizing the relative
placement of departments or facilities based on interaction or relationship values,
such as material flow, adjacency preferences, and operational connectivity.
12. BENEFITS OF USING BLOCPLAN
a. Improved Layout Performance

BLOCPLAN layouts are often significantly better than initial

configurations in terms of space utilization and operational flow.
BLOCPLAN creates layouts that streamline operations, reduce movement,
and minimize costs.
b. Data-Driven Decision-Making

It relies on quantifiable relationship values of each departement which

offers a systematic approach to layout design.
c. Flexibility

BLOCPLAN can adapt to a variety of industrial scenarios, making it useful

for diverse sectors. By using BLOCPLAN, we have the flexibility to apply
specific constraints to departments based on various requirements. For
instance, certain existing departments may need to remain fixed in their
current locations, while others might be manually assigned to specific areas
to meet strategic or operational goals. This adaptability allows for tailored
layouts that address unique conditions and preferences effectively.
13. BLOCPLAN INPUT
• Total number of desired facilities

BLOCPLAN will demand the total number of desired facilities whether it’s
from the production process itself or supporting facilities such as office,
parking lot, security office, et cetera.

• Space Requirements.

After inserting the total number of desired workstations, BLOCPLAN will

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demand the space requirements from each of every one of the desired
facilities with the same order when we input the total number of desired
facilities.

• Data from Activity Relationship Chart (ARC)

After inserting space requirements, BLOCPLAN will show a table that

indicates the relationship between facilities. This table can be filled by only
inserting relationships data from Activity Relationship Chart (ARC) such
as A, E, I, U, O, X that have been made before.

14. BLOCPLAN OUTPUT

• Generated Layout

A visual arrangement of the relative positions of each departements. The

generated layout should be considered a preliminary suggestion, as it can
still be refined and adjusted further along. We can generate up to 20 layout
iterations with different R-Scores and rankings that will be analyzed and
chosen later.

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 • R-score value

An evaluation metric indicating the efficiency of the proposed layout

compared to the initial design. The R-Score has a value between 0 to 1, with
higher values indicating a better and more efficient layout.

15. DOSBox
DOSBox is an emulator software designed to run MS-DOS operating
system on modern operating systems such as Windows, macOS, and Linux.
DOSBox allows users to run software that only works in MS-DOS
operating systems such as BLOCPLAN, on a modern operating system.