Professional Documents
Culture Documents
Preliminaries
From-To Chart / Flow-Between chart
REL Chart
Layout Scores
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
f12 f13
f21
f31
f23
where
gij = material flow between activities i and j.
f32
where
fij = material flow from activity i to activity j.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
r12
r13
r23
where
rij {A, E, I, O, U}: Closeness Value
(CV) between activities i and j; rij is an
ordinal value.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Adjacency
Two activities are (fully) adjacent in a layout if they share a common border of positive
lenght, i.e., not just a point.
Two activities are partially adjacent in a layout if they only share one or a finite
number of points, i.e., zero length.
Example:
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Layout Scores
Two ways of computing layout scores:
LS d V(rij ) d ij
i 1 ji 1
LS a V(rij ) a ij
i 1 ji 1
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Legend
A Rating
E Rating
I Rating
O Rating
U Rating
X Rating
Example
REL chart:
1. Offices
2. Foreman
3. Conference Room
4. Parcel Post
5. Parts Shipment
6. Repair and Service Parts
7. Service Areas
8. Receiving
9. Testing
10. General Storage
O
4
I
5
U
E
5
O
4
U
U
U
O
3
I
2
U
O
4
E
3
I
2
O
2
U
U
I
4
U
U
U
E
3
A
1
Reason
Flow of material
Ease of supervision
Common personnel
Contact Necessary
Conveniences
U
I
2
U
I
1
Code
U
I
2
Rating
Definition
Absolutely Necessary
Especially Important
Important
Ordinary Closeness OK
Unimportant
E
3
X
Undesirable
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material
Handling Education
Example (Cont.)
5
10
Activity Relationship
Diagram
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
5
(500)
7
(575)
8
(200)
9
(500)
6
(75)
10
(1750)
4
(350)
Space Relationship
Diagram
3
(125)
2
(125)
1
(1000)
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
V(O) =
10,
V(U) =
1,
V(X) = -10,000.
For each department, the Total Closeness Rating (TCR) is the sum of the absolute
values of the relationships with other departments.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
For each position, Weighted Placement (WP) is the sum of the numerical values for all
pairs of adjacent departments.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example
1. Receiving
A
2. Shipping
A
E
E
A
5. Manufacturing
8. Offices
9. Maintenance
E
U
A
7. Assembly
6. Work-In-Process Storage
CV values:
V(A) = 125
V(E) = 25
V(I) = 5
V(O) = 1
V(U) = 0
V(X) = -125
Partial adjacency:
= 0.5
O
A
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Department
Summary
Dept.
1
2
3
4
5
6
7
8
9
TCR Order
1 2 3
A E I O U X
A
A
E
U
U
U
A
O
E
A
E
E
O
A
E
U
O
U
A
E
A
A
O
A
U
O
U
O
A
A
O
O
U
U
U
A
A
A
X
A
A
E
E
E
O
O
X
X
O
A
A
U
A
O
A
X
-
3
2
3
2
4
2
4
1
3
A
E
A
O
O
U
E
U
A
E
E
A
U
U
E
A
1
2
3
4
1
0
0
3
0
0
0
0
0
0
0
0
0
0
2
1
0
1
2
4
0
2
2
2
3
2
1
1
2
3
0
2
0
0
0
0
0
0
1
2
1
402
301
450
351
527
254
625
452
502
(5)
(7)
(4)
(6)
(2)
(8)
(1)
(9)
(3)
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (cont.)
62.5 125
125
62.5 125
62.5 125
62.5
125
125
62.5
125
62.5
1.5
0.5
187.5
125
187.5
187.5
62.5 126.5
62.5 125
62.5
0.5
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (cont.)
12.5 37.5 100 137.5 62.5
37.5
37.5
12.5
25
12.5
12.5
25
12.5
125
87.5
62.5
137.5 62.5
137.5
125
62.5 125
125
125
62.5
62.5 125
188 62.5
0.5
125
63.5
0.5
1.5
1.5
0.5
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (cont.)
0.5
0.5
-61.5
-112
-37.5
12.5 112.5
25
12.5 87.5
75
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Planar Graph
Assumption:
A Planar Graph is a graph that can be drawn in two dimensions with no arc crossing.
Planar
Nonplanar
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
1
4
(Exterior)
Block Layout
2
4
6
REL Graph
A REL graph has M+1 nodes (one node for each activity and a node for the exterior of
the layout. The exterior can be considered as an additional activity. The arcs correspond
to the pairs of activities that are adjacent.
A REL graph corresponding to a layout is planar because the arcs connecting two
adjacent activities can always be drawn passing through their common border of
positive length.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
A Relationship (REL) Diagram is also an undirected graph, generated from the REL
diagram, but it is in general nonplanar.
A REL diagram, including the U closeness values, has M(M-1)/2 arcs. Since a planar
graph can have at most 3M-6 arcs, a REL diagram will be nonplanar if M(M-1)/2 >
3M-6.
M(M-1)/2 > 3M-6
M 5.
An upper bound on LSa, LSaUB, is the sum of the 3M-6 longest V(rij)s.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
A planar graph with exactly 3M-6 arcs is called Maximally Planar Graph (MPG).
Not MPG since
has only 5 arcs
(5 < 6 = 3M-6)
MPG since
has 6 arcs
The interior faces of a graph are the bounded regions formed by its arcs, and its
exterior face is the unbounded region formed by its outside arcs.
EF
IF1
IF2
IF3
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
The interior faces and the exterior face of an MPG are triangular, i.e., the faces are
formed by three arcs.
Not triangular
Not an MPG
Not an MPG
REL Graph
Layout
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
An MPG whose sum of arc weights is as large as any other possible MPG is called a
Maximally Planar Weighted Graph (MPWG).
Using the V(rij)s as arc weights, a REL graph that is a MPWG has the maximum
possible LSa, close to LSaUB.
Given a graph G, its dual graph GD has a node for each face of G and two nodes in GD
are connected with an arc if the two corresponding faces in G share an arc.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Layout Graph
Example.
GD
The number of nodes in G (primal graph) is the same than the number of faces in G D
(dual graph), and vice versa. In addition,
(GD)D = G.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Given a layout, the corresponding layout graph can always be constructed by placing
the nodes at the corners of the layout where three or more activities meet (including the
exterior of the layout as an activity). The arcs in the graph are the remaining portions of
the layout walls. E.g.,
a
3
d
g
f
Activities 3, 5, and
exterior meet here
(Exterior)
Layout
Layout Graph
Given a REL graph (RG), its corresponding layout graph (LG) is LG = RGD. E.g.,
6
RGD
LGD
RG
LG
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
If LG is given, then RG = LGD, but for layout construction, the layout is not known
initially, so LG cannot be constructed without RG.
If a planar REL graph (primal graph) exist, the corresponding layout graph (dual graph)
is also planar. Therefore, it is possible theorectically to construct a block layout that will
satisfy all the adjacency requirements. In practice, this is not straightforward because the
space requirements of the activities are difficult to handle.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example
Space Requirements:
Dept.
Area
300
200
100
200
100
(exterior)
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Layout graph (Dual graph):
6
A
B
4
1
8
3
2
C
5
D
7
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Square Block Layout:
(areas are not considered)
Block Layout:
8
8
C
7
E
5
A corner point is a point where at least three departments meet, including the exterior
department.
Note that each corner point in the block layout corresponds to a node in the layout
graph. In the first block layout, each corner point is defined by exactly three
departments. In this case, there is a one-to-one correspondence between corner points
and nodes in the layout graph. In the square block layout, there are two corner points
defined by four departments, i.e., (A, B, C, D) and (B, D, E, F). Each of these two corner
points corresponds to two nodes in the layout graph.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
TCRk =
Max{0, V(r
i 1
ik
)}
Max{0, V(r
kj
)}.
j=k+1
(Note that the negative values of V(rik) and V(rkj) are not included in TCRk).
2. Form a tetrahedron using activities 1 to 4 (i.e., the activities with the four largest TCR ks).
3. For k = 5, , M, insert activity k into the face with the maximum sum of weights (V(r ij))
of k with the three nodes defining the face (where insert refers to connecting the inserted
node to the three nodes forming the face with arcs).
4. Insert (M+1)th node into the exterior face of the REL graph.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example
REL chart:
CV values:
A
B
I
O
X
D
E
F
I
O
U
E
E
U
E
E
V(A) = 81
V(E) = 27
V(I) = 9
V(O) = 3
V(U) = 1
V(X) = -243
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Summary
Dept.
TCR Order
A
105
38
58
39
35
165
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Step 2:
A
O
I = rAD V(rAD) = 9
A
C
E
F
U
E
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Step 3: Insert B.
A
I
EF
IF1
IF2
X C
E
E
X
E
Face
IF3
U
U
LSa
EF
9 + 1 + 27 = 37
IF1
9 + 27 - 243 = -207
IF2
9 - 243 + 1 = -233
IF3
27 - 243 + 1 = -215
Insert B in EF
U
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Step 3 (Cont.): Insert B.
A
EF
IF1
IF3
IF2
C
IF4
D
IF5
Face
LSa
EF
IF1
IF2
33
IF3
31
IF4
31
IF5
Insert E in IF2
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Step 4: Call exterior activity EX.
A
EX
B
E
C
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Using the Heuristic procedure, the generated REL graph will always be an MPG since
each face is triangular.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
3. Convert (by hand) the layout graph into an initial layout taking into consideration the
space requirement of each activity.
REL Chart
REL Graph
Layout Graph
Initial Layout
Space
Requirements
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example
Step 1: (from before)
EX
B
E
C
REL Graph
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Step 2: take the dual of RG
A
B
EX
E
C
F
D
Layout Graph
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Example (Cont.)
Step 3:
A
D
F
Initial layout is
drawn as a square,
but could be any
other shape.
Only A and B are
nonrectangular.
Initial Layout
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Comments
1. If an activity is desired to be adjacent to the exterior of a facility (e.g., a shipping/receiving
department), then the exterior could be included in the REL chart and treated as a normal
activity, making sure that, in step 1 of the general procedure, its node is one of the nodes
forming the exterior face of the REL graph.
2. The area of each interior face of the layout graph constructed in step 2 does not correspond to
the space requirements of its activity.
3. In step 3, the overall shape of the initial layout should be usually be rectangular if it
corresponds to an entire building because rectangular buildings are usually cheaper to
build; even if the initial layout corresponds to just a department, a rectangular shape would
still be preferred, if possible.
4. In step 3, the shape of each activity in the initial layout should be rectangular if possible, or at
most L- or T-shaped (e.g., activities A and B), because rectangular shapes require less wall
space to enclose and provide more layout possibilities in interiors as compared to other
shapes.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education
Comments (Cont.)
5. All shapes should be orthogonal, i.e., all corners are either 90 or 270 (e.g., a triangle is not
an orthogonal shape since its corners could all be 60 ).
6. In step 1, if the LSa of the REL graph is less than LSaUB, then the REL graph may not be
optimal. The following three steps may improve the REC graph for the purpose of increasing
LSa:
a) Edge Replacement: replace an arc in the REL graph with a new arc not previously
in the graph, without losing planarity, if it increases LSa.
b) Vertex Relocation: move a node in the REL graph connected to three arcs to
another triangular face if it increases LSa.
c) Use a different activity to replace one of the four activities of the tetrahedron
formed in step 2 of the Heuristic procedure to construct a new REL graph.
Copyright 1999. Created by Jose Ventura for the College-Industry Council for Material Handling Education