Systematic Layout Planning (SLP)

 Phase I: Determining the location of the area

where the facilities will be laid out
 Phase II: Establishing the general overall
layout
 Phase III: Establishing detailed layout plans
 Phase IV: Installing the selected layout
Muther’s Systematic Layout Planning
(SLP)
Muther’s Systematic Layout Planning
(SLP) – Contd.
A More Detailed Representation
Algorithmic Approaches (ii)
 Types of input
 Qualitative “flow” data (i.e. relationship chart)
 Quantitative data (i.e. from-to chart, flow-between)
 Both
 Classification of algorithms
 Based on objective function
 Distance based
 Adjacency based
 Format of layout representation
 Discrete representation
 Continuous representation
 Primary function
 Improvement
 Construction
Adjacency-based rating
 The layout score is computed as:
6
s  wi X i
i 1

where,
Xi is the number of adjacencies in class i, and
wi is the weighting factor for class i.

 Typical weights: A (64), E(16), I(4), O(1), U(0) and X(-1024)

 Larger the score, better is the layout.
Distance-based scoring
 The scoring model for m activities:
m 1 m
s  c D ij ij
i 1 j i 1

Cij is the cost per unit distance of flow between activities i and
j. (same as i-to-j and j-to-i)
Dij is the distance between activities i and j.
Classification of Algorithms
- Layout Representation Format
 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
Examples of Split and Unsplit
departments
 Classification of Algorithms - Primary
functions
 Construction-based
 Develop ‘from scratch' and progressively build layout
 Example
 ALDEP (Automated Layout Design Program)
 CORELAP (Computerized Relationship Layout Planning)
 Improvement-based
 Start with an initial layout and try to improve it through
incremental changes
 Example
 Pair-wise exchange (TWOWAYX)
 CRAFT (Computerized Relative Allocation of Facilities Technique)
Pairwise Exchange Method (i)
 Compute the total cost of existing layout based on
initial from-to chart and distance matrix
 Exchange two departments
 Recompute the total cost
 Continue until you find the lowest total cost
 Not guaranteed to find the optimal solution but will
be locally optimal.
 The method assumes departments areas are equal
Pairwise Exchange Method (ii)
Pairwise Exchange Method (iii)
 TCABCD = 5(15)+8(35)+10(50)+5(20)+3(35)+2(15)=1090

 TCBACD = 5(15)+8(20)+10(35)+5(35)+3(50)+2(15)=940

 TCCBAD = 5(20)+8(35)+10(15)+5(15)+3(35)+2(50)=810

 TCDBCA= 5(35)+8(15)+10(50)+5(20)+3(15)+2(35)=1010

 TCACBD = 5(35)+8(15)+10(50)+5(20)+3(15)+2(35)=1010

 TCADCB= 5(50)+8(35)+10(15)+5(15)+3(35)+2(20)=900

 TCABDC= 5(15)+8(50)+10(35)+5(35)+3(20)+2(15)=1090

C-B-A-D
Basic Algorithms for
The Layout Problem
Introduction
 A model by itself does not provide a solution
to a problem
 An algorithm is a step by step procedure that
finds a solution to a model
 A number of algorithm may be classified as:
 Optimal algorithm
 Heuristic algorithm
Heuristic Algorithms
 3 classes :
 Construction Algorithms:
 Starting with empty layout and they add one facility after another until all
the facilities
 The main difference among various construction algorithms :

First facility to enter the layout

Subsequent facility or facilities added to the layout

Location of the first (and subsequent) facilities in the layout
Ex: Modified Spanning Tree, CORELAP (Computerized Relationship Layout
Planning)
 Improvement Algorithms
 Improve a user provided starting solution, which must be feasible
 Modify the starting solution and evaluate the resulting modified solution
Ex: 2-OPT, 3-OPT, CRAFT(Computerized Relative Allocation of Facilities
Technique)

 Hybrid Algorithms
Construction Algorithms
 Modified Spanning Tree (MST) Algorithm
 Attempts to find a sequence of machines that
maximizes the sum of the edges corresponding to
adjacent machines
Construction Algorithms
Example Construction Algorithms
Machine
Machine Lengths (in feet)
1 2 3 4 5 6
1 - 12 3 6 0 20 20
2 12 - 5 5 5 0 10
Machine

3 3 5 - 10 4 2 16
4 6 5 10 - 2 12 20
5 0 5 4 2 - 6 10
6 20 0 2 12 6 - 10
Example Construction Algorithms
Machine
1 2 3 4 5 6
1 - 204 60 132 0 340
2 204 - 75 85 60 0
Machine

3 60 75 - 200 60 30
4 132 85 200 - 34 204
5 0 60 60 34 - 72
6 340 0 30 204 72 -
Step 2
Machine
1 2 3 4 5 6
1 - 204 60 132 0 -∞
2 204 - -∞ -∞ 60 -∞
Machine

3 60 -∞ - 200 -∞ 30
4 132 -∞ 200 - 34 204
5 0 60 -∞ 34 - 72
6 -∞ -∞ 30 204 72 -
5 2 1 6 4 3
Single Row Layout
Multirow Layout
Example
solution
ALDEP: ILLUSTRATIVE Example

Example 2: Develop a layout for the following problem. Layout

& area requirements are shown in Table2.1
Department Area (sq.ft) No. of unit squares
1 1200 30
2 800 20
3 600 15
4 1200 30
5 800 20
6 1200 30
7 1200 30
Total 7000 175

Table.2.1
ALDEP: ILLUSTRATIVE Example
Solution:
Assume One square in the layout to be equal 40 sq.ft.
No. of unit squares for dept = dept.area in sq.ft/area per square
Let the size of layout be 15x12, & the sweep width be 2 (this means that we will
fill 2 columns simultaneously).
The Relationship chart for the example is follows:
Department 1 2 3 4 5 6 7
1 E O I O U U
2 E U E I I U
3 O U U U O U
4 I E U I U U
5 O I U I A I
6 U I O U A E
7 U U U U I E
CORELAP
 Inputs

Relationship chart

Number of departments

Area of each department

Weight of REL chart entries
 Calculates a total closeness rating (TCR) from
the relationship chart
 Department with highest TCR is placed in the
center
 Next department chosen by the relationship with
first department

Start with A relationships

If no A’s, then E’s, I’s, etc.
 Calculate the placement rating

Based on relationship weights

Sum of weights of adjacent departments
 An Example of CORELAP
Adjacency relationship and Areas for Six Facilites Facility Areas (in
square feet)
Facility
1 2 3 4 5
1 - U I A U 12,000
Facility

2 U - U E U 18,000
3 I U - O I 10,000
4 A E O - E 24,000
5 U U I E - 12,000
A= 25 ; E= 24 ; I = 23 ; O = 22 ; U = 21 ; X = -32
Calulation of TCR Values
Number
Facility TCR Area
of squares
1 2 + 8 + 32 + 2 = 44 12,000 2
2 2 + 2 + 16 + 2 = 22 18,000 3
3 8 +2 + 4 + 8 = 22 10,000 2
4 32 + 16 + 4 + 16 = 68 24,000 4
5 2 + 2 + 8 + 16 = 28 12,000 2
Layout Developed by CORELAP for
Numeric Example

* 13 13 * * *
* 15 11 11 * *
* 15 14 14 * *
* 12 14 14 * *
* 12 12 * * *
* * * * * *
Exercise : CORELAP
 Build a layout based on this information
Improvement Algorithms
 Very simple and easy to understand and
implement
 Give a good solution
 It will be discussed 2-opt and 3-opt Algorithm
 The method assumes departments areas are
equal
2-opt Algorithm
The steps are in the following :
 Step 1 : let S be the initial solution provided by the
user and z its objective function value (OFV). Set S *
= s, z* = z, i = 1 and j = i + 1 = 2
 Step 2 : Consider the exchange between the
positions of facilities i and j in the solution S. If the
exchange results in a solution S’ that has OFV z’ <
z*, set z* = z’ and S* = S’. If j < mn, set j = j + 1;
otherwise, set i = i + 1 and j = i + 1. If i < mn, repeat
step 2; otherwise go to step 3.
2-opt Algorithm
 Step 3 : If S = S*, set S = S*, z = z*, i =1, j =
i+1 = 2 and go to step 2, otherwise, return S *
as the best solution to user. Stop
A Layout of mn Facilities

* * * * * mn
* * * * * *
* * * * * *
* * * * * *
m+1 m+2 * * * *
1 2 * * * m
Sites in which the mn facilities in the
previous are to be placed

* * * * * mn
* * * * * *
* * * * * *
* * * * * *
m+1 m+2 * * * *
1 2 * * * m
Example
 Develop a layout for the LoanBank problem
using 2-opt Algorithm
Office
1 2 3 4
1 - 17 12 11
2 17 - 12 4
Office

3 12 12 - 4
4 11 4 4 -
Distance Matrix
Site
1 2 3 4
1 - 1 1 2
Site

2 1 - 2 1
3 1 2 - 1
4 2 1 1 -
Solution
 Step 1 : Let S be the initial solution in which
the facilities are assigned as show in figure
and z = 83. set S* = s, z* = 83, i = 1 and j = i +
1=2
1 (1) 2 (2)
3 (3) 4 (4)
 Step 2 : Consider exchanging the positions of
facilities 1 and 2. The resulting solution is
shown in figure. The OFV of this solution is
(17)(1) + (12)(2) + (11)(1) + (12)(1) + (4)(2)
_ (4)(1) = 76. Because exchanging the
positions of facilities 1 and 2 results in a
solution with OFV = 76 < 83, set z* = 76 and
store this solution as S*. Since j= 2 < mn=4,
set j to j = i + 1 = 2 + 1 =3 2 (1) 1 (2)
3 (3) 4 (4)
3-Opt Algorithm
BLOCPLAN
 Uses a relationship chart as well as a from-to chart
 Can be used only one at a time
 Objective function: Measures layout “cost” using
 distance based, or
 adjacency-based, or
 REL-DIST
 Number of bands determined by the program
 Usually two or three bands
 Band widths may vary
 Departments contained in only one band
 departments are rectangular
 Uses continuous layout representation
 Can do both construction and improvement
Adjacency score and Rel-Dist score
BLOCPLAN
 The Criterion used is R-score
 R-score=1 – (rel-dist score-LB)/(UB-LB)
 UB: Upper Bound LB: Lower Bound
 R-score =1 means that the solution is optimal
 Hence, BLOCPLAN is trying to develop the
layout with R-score being close to one.
Example
Flow-Between and Relationship Chart
Example

E=0.63
REL-DIST = 2887
Example – Contd.

E=0.63
REL-DIST = 2708

A=10, E=5, I=2, O=1, U=0, X= -10

MICRO-CRAFT (MCRAFT)
 PC version of CRAFT
 Can exchange any two departments whether they are adjacent or not
 Shifts other departments “automatically” if the exchanged
departments are not adjacent and equal sized
 Uses “bands” and assigns grid within band to a department
 User input:
 Length and width of building
 # of bands
 Layout vector or fill sequence
 Computes grid size, number of rows and columns
 Procedure
 Starts from top-left corner of building
 Sweeps bands in a serpentine fashion
MCRAFT - Example
MCRAFT - Facts
 Band widths are equal
 A department may occupy two bands
 Uses a From-To chart for input flow data
 Limitation: fixed department
 Fixed department may move
 MCRAFT’s primary strength is also its primary
weakness
Software for layout modelling

 CORELAP
 CRAFT
 BLOCPLAN
 FactoryCAD
 FactoryPLAN
 FactoryFLOW