CRAFT: Distance Between Two

Departments

10 20 30 40 50 60 70 80 90 100
Centroid of A A D
= (30,75)
(80,85)

Centroid of C C
= (80,35)

B
Distance (A,C)
= 90

(30,25)

10 20 30 40 50 60 70 80 90 1100
 CRAFT: Total Distance Traveled

• If the number of trips between two departments are very

high, then such departments should be placed near to
each other in order to minimize the total distance traveled.
• Distance traveled from department A to B = Distance
(A,B)  Number of trips from department A to B
• Total distance traveled is obtained by computing distance
traveled between every pair of departments, and then
summing up the results.
• Given a layout, CRAFT first finds the total distance
traveled.

2
CRAFT: Total Distance Traveled
(a) Material handling trips(given)
To
F ro m A B C D
A 2 7 4
B 3 5 7
C 6 7 3 (b)
D 7 7 3

(b) Distances (given)

To
F rom A B C D
A 50 90 60
B 50 60 110
C 90 60 50
D 60 110 50
3
 To
A B C D
CRAFT: Total F ro m

A 2 7 4
Distance Traveled B 3 5 7 (a)
C 6 7 3
(a) Material handling D 7 7 3
trips (given) To
F ro m A B C D
(b) Distances (given)
A 50 90 60
B 50 60 1 1 0 (b)
(c) Sample computation:
C 90 60 50
distance traveled (A,B)
= trips (A,B)  dist (A,B) D 60 110 50
=……….. F ro m
To
A B C D
Total distance traveled A 100 630 240
= 100+630+240+…. B 150 300 7 7 0 (c)
= 4640 C 540 420 150
D 420 770 150
4
CRAFT: Savings
• CRAFT then attempts to improve the layout by pair-wise
interchanges.
• If some interchange results some savings in the total distance
traveled, the interchange that saves the most (total distance
traveled) is selected.
• While searching for the most savings, exact savings are not
computed. At the search stage, savings are computed
assuming when departments are interchanged, centroids are
interchanged too. This assumption does not give the exact
savings, but approximate savings only.
• Exact centroids are computed later.

5
CRAFT: Savings
• Savings are computed for all feasible pairwise interchanges.
Savings are not computed for the infeasible interchanges.
• An interchange between two departments is feasible only if the
departments have the same area or they share a common
boundary.
– Feasible pairs are {A,B}, {A,C}, {A,D}, {B,C}, {C,D}
– and an infeasible pair is {B,D}
• In this example savings are not computed for interchanging B and
D. Savings are computed for each of the 5 other pair-wise
interchanges and the best one chosen.
• After the departments are interchanged, every exact centroid is
found. This may require more computation if one or more shape is
composed of rectangular pieces.

6
CRAFT: A Sample Computation of Savings from a
Feasible Pairwise Interchange

• To illustrate the computation of savings, we shall compute the savings

from interchanging Departments C and D
• New centroids:
A (30,75) Unchanged
B (30,25) Unchanged
C (80,85) Previous centroid of Department D
D (80,35) Previous centroid of Department C
• Note: If C and D are interchanged, exact centroids are C(80,65) and
D(80,15). So, the centroids C(80,85) and D(80,35) are not exact, but
approximate.

7
 CRAFT: A Sample Computation of Savings from a
Feasible Pairwise Interchange

• The first job in the computation of savings is to reconstruct the

distance matrix that would result if the interchange was made.
• The purpose of using approximate centroids will be clearer now.
• If the exact centroids were used, we would have to recompute
distances between every pair of departments that would include one
or both of C and D.
• However, since we assume that centroids of C and D will be
interchanged, the new distance matrix can be obtained just by
rearranging some rows and columns of the original distance matrix.

8
 CRAFT: A Sample Computation of Savings from a
Feasible Pairwise Interchange

• The matrix on the left is the previous matrix, before interchange. The
matrix on the right is after.
• Dist (A,B) and (C,D) does not change.
• New dist (A,C) = Previous dist (A,D)
• New dist (A,D) = Previous dist (A,C) Interchange
• New dist (B,C) = Previous dist (B,D) C,D
• New dist (B,D) = Previous dist (A,C)

To To
F ro m A B C D F ro m A B C D
A 50 90 60 A 50 60 90
B 50 60 110 B 50 110 60
C 90 60 50 C 60 110 50
D 60 110 50 D 90 60 50 9
CRAFT: A Sample To
F ro m A B C D
Computation of
Savings A 2 7 4
B 3 5 7 (a)
C 6 7 3
(a) Material handling trips
(given) D 7 7 3
To
F ro m A B C D
(b) Distances (rearranged)
A 50 60 90
(c) Sample computation: B 50 110 60 (b)
distance traveled (A,B) C 60 110 50
= trips (A,B)  dist (A,B)
D 90 60 50
=
Total distance traveled F ro m
To
A B C D
= 100+420+360+… A 100 420 360
= 4480 B 150 550 420 (c)
Savings C 360 770 150
=
D 630 420 150 10
 CRAFT: Improvement Procedure

• To complete the exercise

1. Compute savings from all the feasible interchanges. If there is
no (positive) savings, stop.
2. If any interchange gives some (positive) savings, choose the
interchange that gives the maximum savings
3. If an interchange is chosen, then for every department find an
exact centroid after the interchange is implemented
4. Repeat the above 3 steps as longs as Step 1 finds an
interchange with some (positive) savings.

11
 CRAFT: Exact Coordinates of Centroids

• Sometimes, an interchange may result

in a peculiar shape of a department; a

10 20 30 40 50 60 70 80 90 100
shape that is composed of some D A
rectangular pieces
• For example, consider the layout (from
example) and interchange departments C
A and D. The resulting picture is shown
on the right. B
• How to compute the exact coordinate of
the centroid (of a shape like A)?

10 20 30 40 50 60 70 80 90 100

12
CRAFT: Exact Coordinates of Centroids

50 60 70 80 90 100
Let
A1  Area A1  A A1
A2  Area A2 
 x1 , y1 
 Centroid of A1 A2

 x2 , y2 
10 20 30 40 50 60 70 80 90 100
 Centroid of A1

Find the centroid of A

13
 CRAFT: Exact Coordinates of Centroids

X-coordinate Multiply
Rectangle Area of centroid (2) and (3)
(1) (2) (3) (4)
A1
A2
Total

X-coordinate of the centroid of A

A1 x1  A2 x2

A1  A2


14
CRAFT: Exact Coordinates of Centroids

Y-coordinate Multiply
Rectangle Area of centroid (2) and (3)
(1) (2) (3) (4)
A1
A2
Total

Y-coordinate of the centroid of A

A1 y1  A2 y2

A1  A2


15
CRAFT: Exact Coordinates of Centroids

50 60 70 80 90 100
A A1

A2

10 20 30 40 50 60 70 80 90 100

Exact coordinate of area A is

16
 CRAFT: Some Comments

• An improvement procedure, not a construction procedure

• At every stage some pairwise interchanges are considered and the best
one is chosen
• Interchanges are only feasible if departments have the same area; or they
share a common boundary
• Departments of unequal size that are not adjacent are not considered for
interchange
• Estimated cost reduction may not be obtained after interchange (because
the savings are based on approximate centroids)
• Strangely shaped departments may be formed

17
 Computerized Layout Planning
Graphical Representation
“Points and lines” representation is not convenient for analysis

18
 Layout Evaluation
– An Algorithm needs to distinguish between “good” layouts
and “bad” ones
– Develop scoring model, s = g (X )
– Adjacency-based scoring (Komsuluk Bazli Skorlama)
• Based on the relationship chart and
6 diagram
Max s   wi X i
i 1

• Xi is the number of times an adjacency i is satisfied, i=A, E, I, O, U, X

• Aldep uses (wi values) A=64, E=16, I=4, O=1, U=0, and X=-1024
• Scoring model has intuitive appeal; the ranking of layouts is sensitive to the
weight values. Layout “B” may be preferred to “C” with certain weights but not
with others.
• Therefore, the specification of the weights is very important.
• The weights wi can also be represented by the flow amounts between the
adjacent departments instead of scores assigned to A, E, I, O, U, X. 19
Exampl 1 2 3 4 5 6 7
eReceiving 1
2
1 I O 4+1=5
Milling
E
O
3
4 2 E I U 16+4+0=20
I 5
Press
U
E O 6 3 O U 1+0=1
U I U 7
Screw Machine
I
U
O
I
U
U
1
4 ----
Assembly
A
U
U
U
3
2
5 A 64 =64
Plating I 4
E 5 6 E
Shipping 6 16 =16
7 7
Total Score 106

4
U 7 U 2 E
Screw
Shipping Milling
Machine

3 E I I
Press
O 6 A 5 O 1
Plating Assembly Receiving

20
 1
Receiving 2
E 3
Milling O 4
U I 5
E O 6 Exercise: Find the score of the layout shown
Press
U I U 7
Screw Machine U I U below. Use A=8, E=4, I=2, O=1, U=0 and X=-
I O U 1
Assembly U U 2 8.
A U 3
Plating I 4
E 5
Shipping 6
7

3 1 2 4
Press Receiving Milling Screw
Machine

7 6 5
Shipping Plating Assembly

21