Systematic Layout
Planning
Objectives of Plant Layout
Minimise investment in equipment
Minimise overall production time
Utilise space most effectively
Minimise material handling cost
Facilitate manufacturing process
Facilitate organisational structure
Types of Layout
Fixed Position Layout: Product stays and resources move to it.
Product Oriented Plant layout: Machinery and Materials are
placed following the product path.
Dictated by the product
Assembly lines
Process Oriented layout: Machinery is placed according to what
they do and materials go to them.
Cell layout: Hybrid Layout that tries to take advantage of
different layouts types.
P-Q Analysis
Quantity Product
Layouts
Mixed Layouts Process Layouts
Number of Different Products
Systematic Layout Planning (SLP)
To arrange a workplace by locating two areas with high
frequency and logical relationships close to each other.
The process permits the quickest material flow in processing the
product at the lowest cost and least amount of handling.
Methods for Layout design
Layout Evaluation
Distance based evaluation
Adjacency based evaluation
Layout Generation
Construction Algorithms
Building a block layout by iteratively adding departments
Improvement Algorithms
Incrementally improving an initial block layout
Systematic Layout Planning (SLP)
Objectives of SLP:
Improvement ion process flow
Space Optimisation
All Layout Planning rests on:
Relationship: Among activities in the layout
Space: For each activity –area, kind and shape
Adjustment: Relationships and space into effective plan
By Applying three fundamentals: Planner assures better
decisions and layouts
Why It is Important…?
Process Flow optimisation
Space optimisation:- Space- One of the most constraint resource
Activity Relationship:
Value Closeness
A Absolutely
necessary
E Essentially
Important
I Important
O Ordinary close
U Unimportant
X Undesirable
Value Reason of closeness
1 Same deck
2 Flow of materials
3 Service
4 Convenience
5 Inventory control
6 Communications
REL 1 2 3 4 5
Case Study 1
2
-
-
9
-
8
12
10
13
0
7
3 - - - 20 0
4 - - - - 2
5 - - - - -
Graph-based construction method
construction => new layout
Steps:
1. Build a graph that represents adjacency
2. Convert to block layout
3. Evaluate block layout (usually A-based)
Step 1: Construct the graph.
1. Select the two departments with the largest weights,
break ties arbitrarily.
2. Select the third department based on the sum of the
weights relative to the two departments already
selected.
3. Select the fourth department based on maximizing
the value to the first three departments in the graph.
4. Add departments maximizing value to a face until
all departments have been added to the graph.
We begin with a relationship chart with weights,
instead of letter ratings.
REL 1 2 3 4 5
1 - 9 8 10 0
2 - - 12 13 7 Select the two departments
with the largest weights.
3 - - - 20 0
4 - - - - 2
5 - - - - -
(A direct link between two
departments means that they
will be adjacent)
Form graph with departments 3 & 4
3 20 4
Select the 3rd department to enter
the graph.
REL 1 2 3 4 5
1 - 9 8 10 0 Select the next department
2 - - 12 13 7 with the largest sum of
weights with 3 & 4.
3 - - - 20 0
4 - - - - 2
5 - - - - -
12 13
Add department 2 to
graph
3 20 4
Select the 4th department to enter the
graph.
REL 1 2 3 4 5
1 - 9 8 10 0 Select the next department
with the largest sum of
2 - - 12 13 7
weights with 2, 3 & 4.
3 - - - 20 0
4 - - - - 2
5 - - - - -
9
12 13
Add department 1 to
1
graph 8 10
3 20 4
Select the 5th department to enter the
graph.
REL 1 2 3 4 5 Assign the next department
1 - 9 8 10 0 with the largest sum of
weights to a face.
2 - - 12 13 7
3 - - - 20 0
4 - - - - 2
5 - - - - -
2
2
Add department 5 7
13
to face 1-2-4
9 5
12
9
12 13 0
1 2
1
8 10
8 10
3 20 4
3 20 4
Construct Block Layout from graph
Total Weight
2 =
7
(9+8+10+0) +
13
5 (12+13+7) + 20
12 9
+ 2 = 81
0
1 2
8 10
3
20
4
Improvement Procedures
Pairwise exchange method
Find a feasible solution
Consider all pairwise interchanges
Perform the interchange that yields greatest total cost reduction
Continue until no more reduction
FL1 :
20
Pairwise Exchange
FL1
: 21
Pairwise Exchange
FL1
: 22
Pairwise Exchange
FL1
: 23
Pairwise Exchange
FL1
: 24
A(1), B(2), C(3), D(4) A(2), B(1), C(3), D(4)
FL1 :
25
A(2), B(1), C(3), D(4) A(3), B(1), C(2), D(4)
