Lecturenotes 8

Layout Planning
- Standard Layout Planning -
EIN4364
Chapter 6 - Layout Planning Models and Design Algorithms
Location of one item

The item can be a person, a machine, or a building. Minimize
Distance moved
o o
Total weighted distance The maximum distance
The amount of energy loss Time to reach a customer
In real life, there are only a few possible places to put the item.
EIN4364
Locating one item: example

40 4
30
20
3 5 10
B
2
0 0
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10
20
30
40
50
60
70
3

Straight line (Euclidean distance) 40 4
30
20
3 5 10
B
2
0 0
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10
20
30
40
50
60
70
4

Rectilinear (rectangular) distance 40 4
30
20
3 5 10
B
2
0 0
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10
20
30
40
50
60
70
5

40 Measured on a map (actual distance) 4
30
20
3 5 10
B
2
0 0
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10
20
30
40
50
60
70
6
Distance formulas
Between (x1,y1) and (x2,y2)

The rectilinear distance is|x1 x2| + |y1 y2|.
o
It is used with right angle street and aisle networks.
The Euclidean distance is
x1 x2 2 y1 y2 2
The actual distance (on the map) can be a combination of rectilinear distance and Euclidean distance.
EIN4364
7. Modifying considerations 9. Develop layout alternatives
8. Practical limitations
10. Evaluation
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Selection 8
Search
SLP: Overview
Input data and activities Analysis 1. Flow of materials 2. Activity Relationships
3. Relationship diagram 4. Space Requirements 5. Space available
6. Space relationship diagram
Steps
1. 2. 3.
4.
5.
Determine the flow between departments and form the relationship chart Develop a graphical representation of the relationship chart Determine the space requirement for each department Develop templates to represent each area Arrange the templates in the same fashion as the graphical representation
EIN4364
An Example
Determine a good layout for a small manufacturing firm consisting of the following departments:
Production (Pr) Warehouse (WH) Office (Of) Toolroom (TR) Food Services (FS) Maintenance (Mn) Locker Room (LR) Shipping/Receiving (SR)
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10
Warning!
This is not a precise method. Rather, it is an approach to help find a good layout. Any two people applying the approach, working independently, will probably not obtain the same layout. This problem is a design problem not an analysis problem.
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11
From-to chart
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12
From-to Chart Example

A company produces 3 components Components 1 and 2 have same size and same weight and are similar in movement Component 3 is twice is large as 1 and 2, and moving two units of 1 or 2 is equivalent to moving one unit of component 3 Unit of flow measure = production quantities per day Departments: A, B, C, D, E
Component 1 2 3 Production Quantities (per day) 30 12 7 Routing A-C-B-D-E A-B-D-E A-C-D-B-E Production Quantity Factor 1 1 2
Component 3 is twice as large as component 1 or 2
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13
From-to Chart Construction
Component
1 2 3
Production Quantities (per day) 30 12 7
Routing
A-C-B-D-E A-B-D-E A-C-D-B-E
Production Quantity Factor 1 1 2 14
Component 3 is twice as large as component 1 or 2 EIN4364 Chapter 6 - Layout Planning Models and Design Algorithms
Flow-between chart
From\To A C B D E 14 A C 44 B 12 30 14 42 14 42 D E
Flow Btwn A C B D E
C 44
B 12 30
D 14 56
14 42
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15
Flow Between Chart
A A C B D E
Flow Btwn A C B D E A C 44
C 44 12 30 14 56 42 0 14 0 0 B D E
Creating a Flow Between Chart

Calculate Total Flow Between Departments
Flow Between Chart can be used to create your Activity Relationship Chart
B 12 30 14 56 14 42 D E
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16
Qualitative Flow Measurement
Record closeness relationship values and reasons for between activities (or define areas of activity: departments, workstations, etc.) in an Activity Relationship Chart
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17
Activity Relationship Chart
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18
Activity Relationship Chart Using Just Flow Information

Flow Between Chart Activity Relationship Chart
A A C B D E
Start with highest flow: Flow of 56 =A
C 44 12 30 14 56 0 14 42 0 0
B D E
B D E
A C
C E O I O A O E U U U B D E
Flow of 44 and 42 = E Flow of 30 =I
Flow of 12 and 14 = O EIN4364 Chapter 6 - Layout Planning Models and Design Algorithms 19
Relationship chart (Example 1)

Relationship chart priority codes A 4, E 3, I 2, O 1, U 0, X -1
Nodes
Pr Production WH
Warehouse
Pr
-
WH
A -
Of
E O -
TR
A O
FS
E
Mn
A O
LR
E
Sr
E A O
Total
24 11 7 10 5
Of
Office
O O -
O A
TR
Toolroom
FS
Food Services
Mn
Maintenance
11 3
LR
Locker Room
SR
Shipping Receiving
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20
Relationship chart (Example 1)

Nodes
Pr Production WH
Warehouse
Pr
A E A E A E E
WH
A O O
Of
E O -
TR
A O
FS
E
Mn
A O
LR
E
Sr
E A O
Total
24 11 7 10 5
Of
Office
O O -
O A
TR
Toolroom
FS
Food Services
O O O
O A
Mn
Maintenance
11 3
LR
Locker Room
SR
Shipping Receiving
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21
Nodal representation
Pr Pr WH Of TR FS Mn LR SR WH A Of E O TR A O O O O FS E Mn A O O A LR E Sr E A O 24 11 7 10 5
Objective: To arrange the nodes so that there is a minimum number of depts crossed when going from one dept. to another.
SR
WH
Of
Pr
FS
EIN4364
LR
Method: 1) Select the dept. with the 9 highest total, place it in the center 2) Locate around it any depts that have 4-rel with it. 3) After all 4-rel.s are exhausted, if some depts. are not in the diagram, continue with 3-rels, then 2-rels and TR 1-rels. 4) Continue the procedure with each dept. in the diagram until all dept.s are Mn in the diagram. Chapter 6 - Layout Planning Models 22
11 3 -
and Design Algorithms
Nodal representation
Activity Relationship Chart
A A C B D E C E O I O A O E
A
A smaller example
B D U U U
C E
E
B D
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23
Space Requirements
Department Pr Wh Area (sq ft) 4800 3050 Blocks 12 8
LR Mn FS TR
Pr
Of Tr
Fs Mn Lr Sr Total
2400 1150
750 800 600 1900
6 3
2 2 2 5 40
Of
SR
One grid = 20x20 = 400 ft2
WH
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24
Departmental templates
WH SR
Of
Pr
TR
FS LR
Mn
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25
Layout
SR Of
Doing this well is more difficult than it looks. Expect a mess the first few times you try it.
WH
Pr TR
FS LR Mn
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26
Example 2: Using a different scale

Nodes
Pr Production WH
Warehouse
Pr
-
WH
A -
Of
E O -
TR
A O
FS
E
Mn
A O
LR
E
Sr
E A O
Total
24 23 9 22 7
Of
Office
O O -
O A
TR
Toolroom
FS
Food Services
Mn
Maintenance
23 5
LR
Locker Room
SR
Shipping Receiving
17
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27
Example 2: Create a Relationship Diagram

Select the dept. with the highest total, place it in the center of the page Locate around it any depts that have 10-rel (code A) with it After all 10-rels are exhausted, continue with 5-rels, then 2rels and 1-rels Continue the procedure with dept. with the next highest total, until all depts are in the diagram Objective: To arrange the nodes so that there is a minimum number of depts crossed when going from one dept. to another
Value A E I O U X Closeness Absolutely Necessary Especially Important Important Ordinary Closeness OK Unimportant Undesirable Numerical Value 10 5 2 1 0 -10 Line Code
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Example 2: Create a Relationship Diagram

Node s Pr WH Of TR FS
A Value Closeness Absolutely Necessary Especially Important Important Ordinary Closeness OK Unimportant Undesirable
Pr -
WH A -
Of E O -
TR A O
FS E
Mn A O
LR E
Sr E A O
Line Code
Total 24 23 9 22 7 23 5 SR WA
O O 10 5 2 1 0 -10
O A
Numerical Value
Mn E
I LR O U X
SR
17 OF PR
MA
FS LR EIN4364 Chapter 6 - Layout Planning Models and Design Algorithms
TR
29
Example 2: Step-by-step
Pr -
WH A -
Of E O -
TR A O
FS E
Mn A O
LR E
Sr E A O
Line Code
Total 24 23 9 22 7 23 5 SR WH
O O 10 5 2 1 0 -10
O A
Numerical Value
Mn E
I LR O U X
SR
17 PR
Mn
TR
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30
Pr -
WH A -
Of E O -
TR A O
FS E
Mn A O
LR E
Sr E A O
Line Code
Total 24 23 9 22 7 23 5 SR WH
O O 10 5 2 1 0 -10
O A
Numerical Value
Mn E
I LR O U X
SR
17 OF PR
Mn
TR
31
Pr -
WH A -
Of E O -
TR A O
FS E
Mn A O
LR E
Sr E A O
Line Code
Total 24 23 9 22 7 23 5 SR WA
O O 10 5 2 1 0 -10
O A
Numerical Value
Mn E
I LR O U X
SR
17 OF PR
MA
TR
32
Example 2: Space Requirements

Space Requirements Table
Office Production (PR) Warehouse (WA) Office (OF) Tool Room (TR) Food Services (FS) Maintenance (MA) Locker Room (LR) Shipping/Receiving (SR) Current Area (sq ft) 3800 3050 2500 1150 850 800 500 1600 Required Increase (Decrease) 1000 0 -100 0 -100 200 100 300 Total Total Required Area (sq ft) 4800 3050 2400 1150 750 1000 600 1900 15650
EIN4364
33
Example 2: Determine Block Size and Quantity

Office Production (PR) Warehouse (WA) Office (OF) Tool Room (TR) Food Services (FS) Maintenance (MA) Locker Room (LR) Shipping/Receiving (SR) Current Area (sq ft) 3800 3050 2500 1150 850 800 500 1600 Required Increase (Decrease) 1000 0 -100 0 -100 200 100 300 Total 1 Block = Total Required Area (sq ft) 4800 3050 2400 1150 750 1000 600 1900 15650 400 sq ft No. Blocks 12 8 6 3 2 3 2 5 41
Block Linear Feet 10 20 30 40 Block Area (sq ft) 100 400 900 1600
20 20
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34
SLP Example: Determine Block Size

Office Production (PR) Warehouse (WA) Office (OF) Tool Room (TR) Food Services (FS) Maintenance (MA) Locker Room (LR) Shipping/Receiving (SR) Current Area (sq ft) 3800 3050 2500 1150 850 800 500 1600 Required Increase (Decrease) 1000 0 -100 0 -100 200 100 300 Total 1 Block = Total Required Area (sq ft) 4800 3050 2400 1150 750 1000 600 1900 15650 400 sq ft No. Blocks 12 8 6 3 2 3 2 5 41
PR PR PR PR
PR PR PR PR
PR PR PR PR
OF OF OF
OF OF OF
FS FS
LR
LR
MA TR MA MA SR SR SR SR SR
35
WA WA
EIN4364
WA WA
WA WA WA WA
TR TR
Create Space Relationship Diagram

WA WA WA WA SR SR SR SR SR WA WA WA WA
OF OF OF
OF OF OF
PR PR PR PR
PR PR PR PR
PR PR PR PR
MA MA MA
FS FS LR LR
TR TR TR
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36
Example 2: Create Alternative Block Layouts

Alternative 1 Alternative 2
SR
SR WA WA WA WA SR SR OF OF OF OF

SR SR SR WA WA SR PR PR WA WA OF OF OF OF OF OF PR PR WA WA PR PR WA WA PR PR MA MA PR PR PR PR FS FS TR MA TR LR TR LR
SR WA WA WA WA SR OF OF FS FS PR PR PR PR LR PR PR PR PR LR PR MA PR MA PR MA PR TR TR TR
Modify considerations Identify practical limitations Develop alternative block layouts
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37
Material handling
To add hallways/aisles:
Add some percent of the department area to be assigned as the hallway in front of that department. Define the hallway/aisle as a separate department
o o
Assign type-A relationship with each dept. Start assign from E for the rest of the relationships
Space requirement for dept 1
Dept 1
2 1 2 Dept 1
hallway
3 O I -
h A A A
E -
hallway
Dept 3
Dept 2
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38
Flow with respect to material handling

Spine flow pattern
Inner loop pattern
Outer loop pattern
Tree flow pattern
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39
conventional
Flow between departments

tandem
spine
segmented
loop
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40
Workstation Space Specifications
Workstation components requiring space are:

Equipment Materials Personnel
Equipment requires space for: The equipment Machine travel Machine maintenance Plant services
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41
Workstation design
An important workstation decision element:

I/O points
o
Do not forget to consider the visual management of the facility.
Affect or are affected by the facility layout
Assume that department D is responsible of the final packaging, and it uses a machine of the following type: C
90o B B C
A D
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42
Effectiveness of the Layout 1

Assume rectilinear distance: Measure the distance between two depts as the number of grids crossed.
If they have a common edge the distance is zero.
Multiply the distance by the value of the Relationship between the corresponding departments.
SR WH
Nodes Pr WH Of Pr WH 4*0 Of 3*0 1*1 TR 4*0 1*0 1*0 1*3 FS 3*0 Mn 4*0 1*3 1*4 4*0 LR 3*0 Sr 3*0 4*0 1*0 Row 0 1+3=4 4 3 0 1*5 5 0 0
Of Pr
TR
TR
FS Mn
FS
LR
EIN4364
LR
Mn
SR
We assumed that I/O points are not unique.
Total:
16
43
Evaluating Layouts
Total effectiveness:
sum(relationship value * distance)
Total flow:
sum(flow between * distance)
Total flow cost

sum(flow between * cost per unit flow * distance
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44
Objective function
Distance-based Algorithms
Minimize (flow * distance) Called a distance-based objective Distance is measured rectilinearly from the department centroid Input is a from-to chart
fij = amount of flow (or, number of trips or unit loads) between departments i and j cij = cost of moving a unit load between departments i and j dij = distance between departments i and j
EIN4364 Chapter 6 - Layout Planning Models and Design Algorithms 45
Adjacency-based Algorithms
Objective function
Maximize adjacency Input is an activity relationship chart Sum of all adjacent relationship values Easy to use and intuitive But disregards distance between non-adjacent departments Means you can generate layouts with similar scores but vastly different travel distances
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46
Adjacency-based Algorithms Contd

Compare adjacency of two or more layouts Normalized adjacency score Or Efficiency Rating Normalized adjacency score formula for negative flow Or Efficiency Rating
fij = flow (relationship values) between departments i and j xij = 1 if department i is adjacent to department j = 0 otherwise F = set of department pairs with positive flow F = set of department pairs with negative flow
EIN4364
Where 0 z 1 If z = 1, all department pairs with positive flow are adjacent in the layout
47
Flow Between Chart
Example

A A C B D E
B B D D
C 44 12 30 14 56 42 0 14 0 0 B D E
A-B = 12*1 (adjacent) A-C = 44*1 (adjacent) A-D = 0*0 (not adjacent) A-E = 0*0 (not adjacent) B-C = 30*1 (adjacent) B-D = 56*1 (adjacent) B-E = 14*0 (not adjacent) C-D = 14*1 (adjacent) C-E = 0*1 (adjacent) D-E = 42 *1 (adjacent)
A Total = 198 Total flow = 212 Efficiency = 198/212 = 0.93 93%
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48
Classification of Algorithms - Layout Representation Format
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
Discrete
EIN4364
Continuous
49
An Improvement Algorithm
A construction algorithm (e.g. SLP) starts from scratch; however, improvement algorithms need an initial solution. Pairwise Exchange Method for Layout Improvement Exchanging the locations of pairs of departments and calculating the benefit Useful in redesigning an existing facility, which is typically triggered by:
Addition of a new machine o Changes in the product mix o Decisions related to the contraction and expansion of storage areas o Simple realization that the old layout is no longer adequate for its needs
o
EIN4364 Chapter 6 - Layout Planning Models and Design Algorithms 50
An improvement algorithm
PAIRWISE EXCHANGE METHOD
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51
Pairwise Exchange Method
Shortcomings:
In order to exchange two departments, they need to be of the same size or share a common border. The quality of the proposed layout depends on the initial layout:
o
cannot find the global optimum, but it finds a local optima.
Possibility of cycling
Assumptions:
Rectilinear distance is used. The distance between two departments is measured from the department centroids.
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52
Pairwise Exchange Method Example

Consider four departments of equal sizes Material flows between departments are given
Material Flow Matrix (Flow Between Chart) To Department 1 2 3 4 From 1 10 15 20 Department 2 10 5 3 5 4 Distance Matrix To Department 1 2 From 1 1 Department 2 3 4
3 2 1 -
4 3 2 1 -
Iteration 0
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4
53
Objective Function Value (Total Cost) for existing layout:
Material Flow Matrix (Flow Between Chart) To Department 1 2 3 4 From 1 10 15 20 Department 2 10 5 3 5 4 Distance Matrix To Department 1 2 From 1 1 Department 2 3 4
3 2 1 -
4 3 2 1 -
TC = f12d12 + f13d13 + f14d14 + f23d23 + f24d24 + f34d34
TC 1234 = 10(1) + 15(2) + 20(3) + 10(1) +5(2) + 5(1) =125
Iteration 0

Iteration 1 Exchanges:
TC = f12d12 + f13d13 + f14d14 + f23d23 + f24d24 + f34d34 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 TC 1324 (2-3) = 10(2) + 15(1) + 20(3) + 10(1) + 5(1) + 5(2) = 120 TC 1432 (2-4) = 10(3) + 15(2) + 20(1) + 10(1) + 5(2) + 5(1) = 105 TC 1243 (3-4) = 10(1) + 15(3) + 20(2) + 10(2) + 5(1) + 5(1) = 125
Iteration 0 Exchange 1-2 Exchange 1-3 1 2 3 4 1 1 2 1 2 2 3 4 3 3 1 3 2 3 4 4 4 1 4 2
Min TC from iteration 1
Select pair 1-3 to perform next exchange
Iteration 1 Exchanges
Exchange 1-4 Exchange 2-3 Exchange 2-4
EIN4364
Exchange 1Models 2 and 3 Design 4 Chapter 6 - Layout3-4 Planning Algorithms
55

TC = f12d12 + f13d13 + f14d14 + f23d23 + f24d24 + f34d34 TC 3124 (1-2) = 10(1) + 15(1) + 20(2) + 10(1) + 5(1) + 5(3) = 95
TC 1234 (1-3) = 10(1) + 15(2) + 20(3) + 10(1) + 5(2) + 5(1) = 125 TC 3241 (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
Min TC from iteration 2
TC 4213 (3-4) = 10(1) + 15(1) + 20(2) + 10(2) + 5(1) + 5(3) = 105

Iteration 1 Selection Exchange 1-2 3 3 1 3 2 3 2 1 2 2 3 4 1 2 3 4 1 1 4 4 4 1 4 2
Exchange 1-3 Exchange 1-4 Exchange 2-3 Exchange 2-4
Select pair 2-3 to perform next exchange
EIN4364
Chapter 6 - Layout 3-4 Planning 4 Models Exchange 2 and 1 Design 3 Algorithms
56

TC = f12d12 + f13d13 + f14d14 + f23d23 + f24d24 + f34d34 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(2) + 15(1) + 20(1) + 10(1) + 5(3) + 5(2) = 95 TC 4312 (2-4) = 10(1) + 15(1) + 20(2) + 10(2) + 5(3) + 5(1) = 105
95 > TC = 90 in Iteration 2, so layout selected from iteration 2 is the best
TC 2413 (3-4) = 10(2) + 15(1) + 20(1) + 10(3) + 5(1) + 5(2) = 100

Iteration 2 Selection Exchange 1-2 Exchange 1-3 2 1 2 2 3 4 3 3 1 3 2 3 1 2 3 4 1 1 4 4 4 1 4 2
Exchange 1-4 Exchange 2-3 Exchange 2-4
EIN4364
Exchange 4 and 1 Design 3 Algorithms Chapter 6 - Layout 3-4 Planning2Models
57

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Layout Planning

- Standard Layout Planning -

Chapter 6 - Layout Planning Models and Design Algorithms

Location of one item

Total weighted distance The maximum distance

The amount of energy loss Time to reach a customer

Chapter 6 - Layout Planning Models and Design Algorithms

Locating one item: example

Chapter 6 - Layout Planning Models and Design Algorithms

Locating one item: example

Chapter 6 - Layout Planning Models and Design Algorithms

Locating one item: example

Chapter 6 - Layout Planning Models and Design Algorithms

Locating one item: example

Chapter 6 - Layout Planning Models and Design Algorithms

Between (x1,y1) and (x2,y2)

It is used with right angle street and aisle networks.

The Euclidean distance is

Chapter 6 - Layout Planning Models and Design Algorithms

7. Modifying considerations 9. Develop layout alternatives

Chapter 6 - Layout Planning Models and Design Algorithms

Input data and activities Analysis 1. Flow of materials 2. Activity Relationships

3. Relationship diagram 4. Space Requirements 5. Space available

6. Space relationship diagram

Chapter 6 - Layout Planning Models and Design Algorithms

Chapter 6 - Layout Planning Models and Design Algorithms

Chapter 6 - Layout Planning Models and Design Algorithms

Chapter 6 - Layout Planning Models and Design Algorithms

From-to Chart Example

Component 3 is twice as large as component 1 or 2

Chapter 6 - Layout Planning Models and Design Algorithms

From-to Chart Construction

Production Quantities (per day) 30 12 7

Production Quantity Factor 1 1 2 14

Chapter 6 - Layout Planning Models and Design Algorithms

Flow Between Chart

Creating a Flow Between Chart

Chapter 6 - Layout Planning Models and Design Algorithms

Qualitative Flow Measurement

Chapter 6 - Layout Planning Models and Design Algorithms

Activity Relationship Chart

Chapter 6 - Layout Planning Models and Design Algorithms

Activity Relationship Chart Using Just Flow Information

Flow of 44 and 42 = E Flow of 30 =I

Relationship chart (Example 1)

Chapter 6 - Layout Planning Models and Design Algorithms

Relationship chart (Example 1)

Chapter 6 - Layout Planning Models and Design Algorithms

and Design Algorithms

Chapter 6 - Layout Planning Models and Design Algorithms

One grid = 20x20 = 400 ft2

Chapter 6 - Layout Planning Models and Design Algorithms

Chapter 6 - Layout Planning Models and Design Algorithms

Chapter 6 - Layout Planning Models and Design Algorithms

Example 2: Using a different scale

Chapter 6 - Layout Planning Models and Design Algorithms

Example 2: Create a Relationship Diagram

Chapter 6 - Layout Planning Models and Design Algorithms

Example 2: Create a Relationship Diagram

FS LR EIN4364 Chapter 6 - Layout Planning Models and Design Algorithms

Chapter 6 - Layout Planning Models and Design Algorithms

FS LR EIN4364 Chapter 6 - Layout Planning Models and Design Algorithms