Module-5

Plant Location and Plant Layout:

Plant location –need - Factors – comparison –
quantitative methods for evaluation
Plant layout: objectives-principles – factors influencing
– tools and techniques including computer based layout
design – CRAFT, ALDEP, CORELAP. (7 Hours)
http://tancem.com

Plant Layout

https://sail.co.in/rourkela-steel-plant/about-rourkela-steel-plant 3
Introduction
Introduction
What is Plant Layout?
 Physical arrangement of production facilities
 Floor plan of the physical facilities, are used in
which
production

5
Introduction
What is Plant Layout?
 According to Moore
 Plant layoutis a plan of an optimum
arrangement of
facilities including
 personnel,
 operating equipment,
 storage space,
 material handling equipment and
 all other supporting services along with the design
of best structure to contain all these facilities

6
 Objectives of Plant Layout
Primary goal of the plant layout
 To maximize the profit by arrangement of all the plant facilities
to the best advantage of total manufacturing of the product
Plant Layout - Objectives
 Effective utilization of men, equipment and space
 Make effective utilization of existing space
 Minimize materials handling and cost
 Minimize investment in equipment
 Minimize overall production time
 Provide convenience, safety and comfort to employees
 Streamline the flow of materials through the plant
 Facilitate the manufacturing process

8
Plant Layout - Objectives
 Flexibility of manufacturing operations and arrangements
 Maintain flexibility of arrangement and operation
 Facilitate the organizational structure
 Maintain high turnover of in-process inventory

9
Principles of Plant Layout
Plant Layout - Principles

1. Principle of Integration
2. Principle of Minimum Distance
3. Principle of Space Utilization
4. Principle of Materials Flow
5. Principle of Maximum Flexibility
6. Principle of Safety, Security and
Satisfaction
7. Principle of Minimum Handling

11
Plant Layout - Principles
Principle of Integration

Men Machines

Optimum Utilization of
Resources &
Maximum
Effectiveness

Materials Supporting
Services

12
Plant Layout - Principles
Principle of Minimum Distance
 Concerned with the minimum travel/movement of Men
and Materials
 Straight line movement should be preferred
Plant Layout - Principles
Principle of Space Utilization
 All the three dimensions should be utilized optimally
Plant Layout - Principles
Principle of Flow
 Materials to in forward direction towards the final
move product
stage
 No backtracking
Plant Layout - Principles
Principle of Maximum Flexibility
 Future requirements should be taken into account
designing the present layout
while
 Alteration in the present layout done without much cost and
time
Plant Layout - Principles
Principle of Safety, Security and Satisfaction
 Provides safety to the workers
 Workers satisfaction
 Protect the plant and machinery from fire, theft. Etc.,
Plant Layout - Principles
Principle of Minimum Handling
 Reduces the materials handling to the minimum
Factors influencing Plant Layout
Plant Layout - Factors influencing
1. Nature of the
Product
2. Volume of
Production
3. Location of the Plant
4. Type of Machines
5. Climate Conditions
6. Service Facilities
7. Type of
Production
8. Type of Process
9. Management
Policies
Classification of Plant Layout
Plant Layout - Classification
Process/ Functional Layout
Line/ Product Layout

Fixed Position Layout

Combination Layout

Group Layout or Cellular Layout

Plant Layout: Process/ Functional Layout
1. It is for batch production
2. Machines performing similar type
of operations are grouped at one
location
 Flow paths of materials through the facilities vary from product
to product
3. Flow paths are long
 Possibility of backtracking
4. Suitable for variety of products manufactured
Plant Layout: Line/ Product Layout

1. Machines are located as per the processing sequence of the

product
2. Suitable when the production volume of the product is high
3. Minimum material handling cost
4. Breakdown of one in a product line affects the
machine
production
 Lack of flexibility
5. Manufacturing cycle is short
Plant Layout: Combination Layout

1. Combination of process
and product layouts
2. It is suitable when an item is
being
made in different types and sizes
3. Machinery is arranged in a process layout but the process
grouping is then arranged in a sequence to manufacture various
types and sizes of products
4. Sequence of operations remains the same with the variety of
products and sizes
Plant Layout: Fixed Position Layout

 Also called as Project Type

of layout
 Major components remain in a
fixed location and the men,
material and machines are
brought
to the location
 Suitable when one or few pieces of identical heavy products are
to be manufactured
 Assembly consists of large number of heavy products
 Greater flexibility
 Lower layout capital investment
Plant Layout: Group Layout/ Cellular Layout

 It is a combination of Process layout and Product layout

 Combines the advantages of both the layouts
 Process layout - Cost of equipment is minimum
 Product layout - Cost of materials handling is minimum
 Group layout - Both equipment and materials handling cost
are minimum
 Group layout is also called as Multi-Objective layout
Plant Layout: Group Layout/ Cellular Layout

 The basic aim of a group technology layout is to identify families

of components that require similar of satisfying all the
requirements of the machines are grouped into cells
 Each cell is capable of satisfying all the requirements of
the component family assigned to it
 Effective machine operation and productivity
 Drawback: If the product mix is completely dissimilar, then we
may not have meaningful cell formation
 Computer Based
Layout Design - CRAFT

CRAFT - Computerized Relative Allocation of Facilities Technique

Layout Design - CRAFT
Algorithm
 Originally developed by Armour and Buffa
 It is an improvement algorithm
 Starts with an initial layout and the layout by
improves
interchanging departments pairwise  reduction in transport
cost
 The algorithm continues until no further interchanges
possible
are to reduce the cost of transportation
 The result will be good and close to optimum in most of the cases

1 2 3 1 5 6

4 5 6 4 2 3

Initial Layout Final Layout

Layout Design - CRAFT Requirements

 Initial Layout
 Flow Data
 Cost per Unit Distance
 Total Number of Departments
 Number of Interchangeable Departments
 Area of departments
Layout Design - CRAFT Procedure

 Step-1: Input
 Number of departments
 Number of interchangeable departments
 Initial layout
 Cost matrix
 Flow matrix
 Area of departments
Layout Design - CRAFT Procedure

 Step-1: Input
 Number of departments = 4
 Number of interchangeable departments = 4
 Initial layout
 Cost matrix
 Flow matrix
 Area of departments
Layout Design - CRAFT Procedure

 Step-1: Input
 Number of departments = 4
 Number of interchangeable departments = 4
 Initial layout
 Cost matrix From/To 1 2 3 4
1 - 1 1 1
 Flow matrix 2 1 - 1 1
3 1 1 - 1
 Area of departments 4 1 1 1 -
Cost Matrix [Cij]

In Cost Matrix [Cij], the cell values represent costs per unit distance
from department i to department j.
Layout Design - CRAFT Procedure

 Step-1: Input
 Number of departments = 4
 Number of interchangeable departments = 4
 Initial layout
 Cost matrix From/To 1 2 3 4
1 - 5 2 4
 Flow matrix 2 0 - 2 5
3 2 0 - 0
 Area of departments 4 3 0 1 -
Flow Matrix [fij]

In Flow Matrix [fij], the cell values represent the flow in terms of
number of trips in a given period of time from department i to
department j.
Layout Design - CRAFT Procedure

 Step-1: Input
 Number of departments = 4
 Number of interchangeable departments = 4
 Initial layout
 Cost matrix
 Flow matrix
 Area of departments
Department 1 2 3 4
Area (Sq.
Units) 4 4 4 4
Area of Departments
Layout Design - CRAFT Procedure

 Step-2: Calculate the centroids of all the department in

the initial layout
 (X1, Y1 ) = 1, 3
 (X2, Y2 ) = 3, 3
 (X3, Y3 ) = 1, 1
 (X4, Y4 ) = 3, 1
Layout Design - CRAFT Procedure

 Step-3: Calculate the distance matrix [dij]. Distance matrix is the

rectilinear distance between the centroids of two departments
 dij = |Xi - Xj| + |Yi - Yj|
where (Xi , Yi) = centroid of ith department
(Xj , Yj) = centroid of jth
department

From/To 1 2 3 4
1 0 2 2 4
2 2 0 4 2
3 2 4 0 2
4 4 2 2 0
Distance Matrix [dij]
Layout Design - CRAFT Procedure
 Step-4: Calculate the total cost of handling for the
present layout
 Total cost TCij =

From/To 1 2 3 4 From/To 1 2 3 4 From/To 1 2 3 4

1 - 5 2 4 1 0 2 2 4 1 - 1 1 1
2 0 - 2 5 X 2 2 0 4 2 X 2 1 - 1 1
3 2 0 - 0 3 2 4 0 2 3 1 1 - 1
4 3 0 1 - 4 4 2 2 0 4 1 1 1 -
Flow Matrix [fij] Distance Matrix [dij] Cost Matrix [Cij]

From/To 1 2 3 4
1 - 10 4 16
2 0 - 8 10
3 4 0 - 0 Total cost = 66
4 12 0 2 -
Total cost[TCij]
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Rule-1: Departments should have common border
 Rule-2: Departments should have equal area
 Consider only pairwise interchanges
Department
Pairs Remark

1 and 2 Interchange based on common border

1 and 3 Interchange based on common border

1 and 4 Interchange based on common area

2 and 3 Interchange based on common area

2 and 4 Interchange based on common border

3 and 4 Interchange based on common border

Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Pairwise interchange  Interchange of Centroids
 Calculate the distance matrix for each interchange
 Based on that, calculate the total cost

 Interchange between 1 & 2

 Calculate the centroids after
interchange
 (X1, Y1 ) = 3, 3
 (X2, Y2 ) = 1, 3
 (X3, Y3 ) = 1, 1
 (X4, Y4 ) = 3, 1
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Distance matrix after interchange
From/To 1 2 3 4
1 0 2 4 2
2 2 0 2 4
3 4 2 0 2
4 2 4 2 0
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments
(1&2)
 Calculate the total cost after interchange of 1 & 2
 Total cost TCij =
From/To 1 2 3 4 From/To 1 2 3 4 From/To 1 2 3 4
1 - 5 2 4 1 0 2 4 2 1 - 1 1 1
2 0 - 2 5 X 2 2 0 2 4 X 2 1 - 1 1
3 2 0 - 0 3 4 2 0 2 3 1 1 - 1
4 3 0 1 - 4 2 4 2 0 4 1 1 1 -
Flow Matrix [fij] Distance Matrix [dij] Cost Matrix [Cij]
From/To 1 2 3 4
1 - 10 8 8
2 0 - 4 20
3 8 0 - 0 Total cost = 66
4 6 0 2 -
Total cost[TCij]
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Pairwise interchange  Interchange of Centroids
 Calculate the distance matrix for each interchange
 Based on that, calculate the total cost

 Interchange between 1 & 3

 Calculate the centroids after
interchange
 (X1, Y1 ) = 1, 1
 (X2, Y2 ) = 3, 3
 (X3, Y3 ) = 1, 3
 (X4, Y4 ) = 3, 1
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments (1 &
3)
 Distance matrix after interchange
From/To 1 2 3 4
1 0 4 2 2
2 4 0 2 2
3 2 2 0 4
4 2 2 4 0
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments
(1&3)
 Calculate the total cost after interchange of 1 & 3
 Total cost TCij =

From/To 1 2 3 4 From/To 1 2 3 4 From/To 1 2 3 4

1 - 5 2 4 1 0 4 2 2 1 - 1 1 1
2 0 - 2 5 X 2 4 0 2 2 X 2 1 - 1 1
3 2 0 - 0 3 2 2 0 4 3 1 1 - 1
4 3 0 1 - 4 2 2 4 0 4 1 1 1 -
Flow Matrix [fij] Distance Matrix [dij] Cost Matrix [Cij]
From/To 1 2 3 4
1 - 20 4 8
2 0 - 4 10
3 4 0 - 0 Total cost = 60
4 6 0 4 -
Total cost[TCij]
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Pairwise interchange  Interchange of Centroids
 Calculate the distance matrix for each interchange
 Based on that, calculate the total cost

 Interchange between 1 & 4

 Calculate the centroids after
interchange
 (X1, Y1 ) = 3, 1
 (X2, Y2 ) = 3, 3
 (X3, Y3 ) = 1, 1
 (X4, Y4 ) = 1, 3
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments (1 &
4)
 Distance matrix after interchange
From/To 1 2 3 4
1 0 2 2 4
2 2 0 2 4
3 2 4 0 2
4 4 2 2 0
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments
(1&4)
 Calculate the total cost after interchange of 1 & 4
 Total cost TCij =
From/To 1 2 3 4 From/To 1 2 3 4 From/To 1 2 3 4
1 - 5 2 4 1 0 2 2 4 1 - 1 1 1
2 0 - 2 5 X 2 2 0 2 4 X 2 1 - 1 1
3 2 0 - 0 3 2 4 0 2 3 1 1 - 1
4 3 0 1 - 4 4 2 2 0 4 1 1 1 -
Flow Matrix [fij] Distance Matrix [dij] Cost Matrix [Cij]
From/To 1 2 3 4
1 - 10 4 16
2 0 - 4 20
3 4 0 - 0 Total cost = 74
4 12 0 2 -
Total cost[TCij]
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Pairwise interchange  Interchange of Centroids
 Calculate the distance matrix for each interchange
 Based on that, calculate the total cost

 Interchange between 2 & 3

 Calculate the centroids after
interchange
 (X1, Y1 ) = 1, 3
 (X2, Y2 ) = 3, 3
 (X3, Y3 ) = 1, 1
 (X4, Y4 ) = 3, 1
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments (2 &
3)
 Distance matrix after interchange
From/To 1 2 3 4
1 0 2 2 4
2 2 0 4 2
3 2 4 0 2
4 4 2 2 0
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments
(2&3)
 Calculate the total cost after interchange of 2 & 3
 Total cost TCij =
From/To 1 2 3 4 From/To 1 2 3 4 From/To 1 2 3 4
1 - 5 2 4 1 0 2 2 4 1 - 1 1 1
2 0 - 2 5 X 2 2 0 4 2 X 2 1 - 1 1
3 2 0 - 0 3 2 4 0 2 3 1 1 - 1
4 3 0 1 - 4 4 2 2 0 4 1 1 1 -
Flow Matrix [fij] Distance Matrix [dij] Cost Matrix [Cij]
From/To 1 2 3 4
1 - 10 4 16
2 0 - 8 10
3 4 0 - 0 Total cost = 66
4 12 0 2 -
Total cost[TCij]
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Pairwise interchange  Interchange of Centroids
 Calculate the distance matrix for each interchange
 Based on that, calculate the total cost

 Interchange between 2 & 4

 Calculate the centroids after
interchange
 (X1, Y1 ) = 1, 3
 (X2, Y2 ) = 3, 1
 (X3, Y3 ) = 1, 1
 (X4, Y4 ) = 3, 3
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments (2 &
4)
 Distance matrix after interchange
From/To 1 2 3 4
1 0 4 2 2
2 4 0 2 2
3 2 2 0 4
4 2 2 4 0
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments
(2&4)
 Calculate the total cost after interchange of 2 & 4
 Total cost TCij =
From/To 1 2 3 4 From/To 1 2 3 4 From/To 1 2 3 4
1 - 5 2 4 1 0 4 2 2 1 - 1 1 1
2 0 - 2 5 X 2 4 0 2 2 X 2 1 - 1 1
3 2 0 - 0 3 2 2 0 4 3 1 1 - 1
4 3 0 1 - 4 2 2 4 0 4 1 1 1 -
Flow Matrix [fij] Distance Matrix [dij] Cost Matrix [Cij]
From/To 1 2 3 4
1 - 20 4 8
2 0 - 4 10
3 4 0 - 0 Total cost = 60
4 6 0 4 -
Total cost[TCij]
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Pairwise interchange  Interchange of Centroids
 Calculate the distance matrix for each interchange
 Based on that, calculate the total cost

 Interchange between 3 & 4

 Calculate the centroids after
interchange
 (X1, Y1 ) = 1, 3
 (X2, Y2 ) = 3, 3
 (X3, Y3 ) = 3, 1
 (X4, Y4 ) = 1, 1
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments (3 &
4)
 Distance matrix after interchange
From/To 1 2 3 4
1 0 2 4 2
2 2 0 2 4
3 4 2 0 2
4 2 4 2 0
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging departments
(3&4)
 Calculate the total cost after interchange of 3 & 4
 Total cost TCij =
From/To 1 2 3 4 From/To 1 2 3 4 From/To 1 2 3 4
1 - 5 2 4 1 0 2 4 2 1 - 1 1 1
2 0 - 2 5 X 2 2 0 2 4 X 2 1 - 1 1
3 2 0 - 0 3 4 2 0 2 3 1 1 - 1
4 3 0 1 - 4 2 4 2 0 4 1 1 1 -
Flow Matrix [fij] Distance Matrix [dij] Cost Matrix [Cij]
From/To 1 2 3 4
1 - 10 8 8
2 0 - 4 20
3 8 0 - 0 Total cost = 66
4 6 0 2 -
Total cost[TCij]
Layout Design - CRAFT Procedure
 Step-5: Improve the layout by interchanging
departments
 Summary of total cost after interchanging
Pairwise interchange Total cost

1 and 2 66

1 and 3 60

1 and 4 74

2 and 3 66

2 and 4 60

3 and 4 66
Layout Design - CRAFT Procedure
 Step-6: The interchange which has minimum total cost
is considered for actual interchange in the layout
 Interchange between 1 and 3 as well as interchange between
2 and 4 have minimum total cost (=60 in this case)

Pairwise interchange Total cost

1 and 2 66

1 and 3 60

1 and 4 74

2 and 3 66

2 and 4 60

3 and 4 66
Layout Design - CRAFT Procedure
 Step-7: This cost (for 1&3/ 2&4) is compared with the cost of the
present layout (i.e. initial layout). If the cost of the proposed
interchange is less than the present layout cost, the interchange
can be made. If not keep the present layout as the final layout
 Interchange between 1 and 3 as well as interchange between
2 and 4 have minimum total cost (=60 in this case)
 Present layout cost = 66
 Interchange is possible between 1 and 3
Pairwise
or between 2 and 4 because of lower interchang Total cost
e
cost than the present layout cost 1 and 2 66
1 and 3 60
1 and 4 74
2 and 3 66
2 and 4 60
3 and 4 66
Layout Design - CRAFT Procedure
 Step-8: Interchange can be made between 1 and 3. The
layout after interchange is called the new layout

Present layout New layout

Layout Design - CRAFT Procedure
 Step-9: Check for further modifications. If not this new layout
is called as FINAL Layout

Final layout
 Computer Based
Layout Design - ALDEP

ALDEP - Automated Layout Design Program

Layout Design -
ALDEP
 Construction type Algorithm
 Uses basic data on facilities and layout is developed by placing the
layout using information available on relationship between
departments
 Layout score is calculated
 Repeat the algorithm for specified number of iterations and for
each iteration, layout score is calculated
 The best layout is selected based on the maximum score
Layout Design -
ALDEP
Basic Data:
 Total number of departments
 Area of the departments
 Layout dimensions
 Closeness relationships among departments
 Total number of iterations
Layout Design -
ALDEP
Closeness Ratings:

Closeness Notation Stands for Value

A Absolutely Necessary 43 = 64

E Excellent 42 = 16

I Important 41 = 4

O Ordinary 40 = 1

U Unimportant 0
X Not desirable -45 = -1024
Layout Design - ALDEP Procedure
Problem: Consider the following inputs to design a best layout using
ALDEP
 Total number of departments = 4
 Areas of Departments: Dept - 1: 24000 m2 ; Dept-2: 6000 m2;
Dept-3: 12000 m2; Dept-4: 18000 m2
 Closeness Ratings: From
-
1 --
2 A --
3 E O --

4 I E U --
To 1 2 3 4
 Total iterations = 2
Layout Design - ALDEP Procedure
 Step-1: Input
 No. of Departments - 4
 Area

Department Area (m2) No. of Squares

1 24000 40

2 6000 10
Take Area/square = 600 m2
3 12000 20

4 18000 30

Total 60000 100

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒
𝐷𝑒𝑝𝑎𝑟𝑡𝑚𝑒𝑛𝑡
𝐴𝑟𝑒𝑎 𝑝𝑒𝑟 𝑠𝑞𝑢𝑎𝑟𝑒 (ℎ𝑒𝑟𝑒
No. of squares =
Layout Design - ALDEP Procedure
 Step-1: Input
 Length x Width of the layout = 10 x 10 =
100 m2
From  Closeness Ratings From/To 1 2 3 4
-
1 -- 1 -- A E I
2 A -- 2 A -- O E
3 E O -- 3 E O -- U
4 I E U -- 4 I E U --
To 1 2 3 4 To 1 2 3 4

 Total iterations = 2
Layout Design - ALDEP Procedure
 Step-2: Select the first department randomly to add into
the layout. Let us start with Department "1"
 Fill the layout.
 After filling the layout looks like
1 1 1 1 Filling order
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
Layout Design - ALDEP Procedure
 Step-3: Scan the closeness ratings chart for a department with A
and E
 In this case, Department 2 is having A and Department 3 is having
E ratings

From/To 1 2 3 4

1 -- A E I
2 A -- O E
3 E O -- U

4 I E U --
To 1 2 3 4
Layout Design - ALDEP Procedure
 Dept 2 is having more rating. Now we have to fill the layout with
Dept. 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
Layout Design - ALDEP Procedure
 Step-4: Scan the closeness ratings chart for a department with A
and E
 In this case, Department 1 is having A and Department 4 is having
E ratings

From/To 1 2 3 4

1 -- A E I
2 A -- O E
3 E O -- U

4 I E U --
To 1 2 3 4
Layout Design - ALDEP Procedure
 Dept 1 is having more rating. But already it was filled. Therefore
we have to fill the layout with Dept. 4

1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
1 1 1 1 2 4 4 4
Layout Design - ALDEP Procedure
 Step-5: Only leftover department is 3. Fill the layout
with Department 3.

1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
1 1 1 1 2 4 4 4 3 3
Layout Design - ALDEP Procedure
 Step-6: Compute the score of the layout. The score is calculated
based on the sum of the closeness ratings of all the neighbouring
pairs of the departments in the filled layout

Neighbouring
pairs of the Closeness Closeness
department Rating Grade Rating Value

1-2 A 64
2-4 E 16
4-3 U 0
Sum 80
Layout Design - ALDEP Procedure
 Step-7: This is treated as the current best layout. The score is
80
 Step-8: Do the second iteration. Calculate the score for it
 Step-9: Compare the two scores. The layout which is having
more
score will be the best layout
 Computer Based
Layout Design - CORELAP

CORELAP – COmputerized RElationship Layout Planning

Layout Design - CORELAP
 Construction type Algorithm (Graph Based Method)
 Adjacency Based Method (Closeness Values Based Method)
 Closeness Values are
A =6
E =5
I =4
O =3
U =2
X =1
 Selection of the department is based on the Total
Closeness Rating (TCR)
Layout Design - CORELAP
 Total Closeness Rating (TCR) for a department is the sum of the
numerical values assigned to the closeness relationships between
the department and all other departments
Layout Design - CORELAP
 Department Selection
 The first department placed in the layout is the one with the
greatest TCR value. If there is a tie, then choose the one with
more A’s (E’s, etc.).
 If a department has an X relationship with the first one, it is
placed last in the layout and not considered. If a tie exists,
choose the one with the smallest TCR value.
 The second department is the one with an A (or E, I, etc.)
relationship with the first one. If a tie exists, choose the one with
the greatest TCR value.
 The procedure continues until all departments have been placed
 Placement sequence
A = 6; E = 5; I = 4; O = 3; U = 2; X = 1
Layout Design - CORELAP
Department Placement
 Department Neighbors
 Adjacent (in position 1, 3, 5 or 7) with department 0
 Touching (in position 2, 4, 6 or 8) department 0
 Placing rating (PR) is the sum of the weighted closeness ratings
between the department to enter the layout and its neighbors.
Layout Design - CORELAP
Department Placement
 Steps:
 The first department selected is placed in the middle.
 The placement of a department is determined by evaluating
PR for all possible locations around the current layout
 The new department is located based on the
greatest PR value.
Layout Design – CORELAP
Example
 Given the departmental dimensions and the relationship chart,
determine the sequence of the placement of the departments in
the layout based on the CORELAP algorithm. Place the
departments in the layout while evaluating each placement and
also calculate the total score for the layout.
Department Area (Sq.ft) No. of Squares
1 12000 2
2 6000 1
3 6000 1
4 12000 2
5 6000 1
6 12000 2
7 12000 2
Total 66000 11
Layout Design – CORELAP
Example
 Given the departmental dimensions and the relationship chart,
determine the sequence of the placement of the departments in
the layout based on the CORELAP algorithm. Place the
departments in the layout while evaluating each placement and
also calculate the total score for the layout.

1 ---
2 E ---
3 O U ---
4 I E U ---
5 O I U I ---
6 U I O U A ---
7 U U U U I E ---
1 2 3 4 5 6 7
Layout Design – CORELAP
 TCR Calculation and Identifying the 1st Placement Sequence
A = 6; E = 5: I = 4: O = 3; U = 2; X = 1

Department
Relationships Summary
Depart Placement
ment 1 2 3 4 5 6 7 A E I O U X TCR
Sequence

1 --- E O I O U U 0 1 1 2 2 0 19
2 E --- U E I I U 0 2 2 0 2 0 22
3 O U --- U U O U 0 0 0 2 4 0 14
4 I E U --- I U U 0 1 2 0 3 0 19
5 O I U I --- A I 1 0 3 1 1 0 23 1
6 U I O U A --- E 1 1 1 1 2Placement
0 22 order: 5
Layout Design – CORELAP
 The second department is the one with an A relationship with the
first one (or E, I, etc.). If a tie exists, choose the one with the
greatest TCR value. Any X relationships?
Department
Relationships Summary
Depart Placement
ment 1 2 3 4 5 6 7 A E I O U X TCR
Sequence

1 --- E O I O U U 0 1 1 2 2 0 19
2 E --- U E I I U 0 2 2 0 2 0 22
3 O U --- U U O U 0 0 0 2 4 0 14
4 I E U --- I U U 0 1 2 0 3 0 19
5 O I U I --- A I 1 0 3 1 1 0 23 1
Placement order: 5 –
Layout Design – CORELAP
 The next department is the one with an A (E, I, etc.). relationship
with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X?
Department
Relationships Summary
Depart Placement
ment 1 2 3 4 5 6 7 A E I O U X TCR
Sequence

1 --- E O I O U U 0 1 1 2 2 0 19
2 E --- U E I I U 0 2 2 0 2 0 22
3 O U --- U U O U 0 0 0 2 4 0 14
4 I E U --- I U U 0 1 2 0 3 0 19
5 O I U I --- A I 1 0 3 1 1 0 23 1
Placement order: 5 – 6 –
Layout Design – CORELAP
 The next department is the one with an A (E, I, etc.). relationship
with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X?
Department
Relationships Summary
Depart Placement
ment 1 2 3 4 5 6 7 A E I O U X TCR
Sequence

1 --- E O I O U U 0 1 1 2 2 0 19
2 E --- U E I I U 0 2 2 0 2 0 22 4
3 O U --- U U O U 0 0 0 2 4 0 14
4 I E U --- I U U 0 1 2 0 3 0 19
5 O I U I --- A I 1 0 3 1 1 0 23 1
Placement order: 5 – 6 – 7 –
Layout Design – CORELAP
 The next department is the one with an A (E, I, etc.). relationship
with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X?
Department
Relationships Summary
Depart Placement
ment 1 2 3 4 5 6 7 A E I O U X TCR
Sequence

1 --- E O I O U U 0 1 1 2 2 0 19 5
2 E --- U E I I U 0 2 2 0 2 0 22 4
3 O U --- U U O U 0 0 0 2 4 0 14
4 I E U --- I U U 0 1 2 0 3 0 19
5 and Area.
Same TCR O So I select
U I --- A I 1 0 3 1 1 0 23 1
department randomly
Placement order: 5–6–7–2-
Layout Design – CORELAP
 The next department is the one with an A (E, I, etc.). relationship
with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X?
Department
Relationships Summary
Depart Placement
ment 1 2 3 4 5 6 7 A E I O U X TCR
Sequence

1 --- E O I O U U 0 1 1 2 2 0 19 5
2 E --- U E I I U 0 2 2 0 2 0 22 4
3 O U --- U U O U 0 0 0 2 4 0 14
4 I E U --- I U U 0 1 2 0 3 0 19 6
5 O I U I --- A I 1 0 3 1 1 0 23 1
Placement order: 5 – 6 – 7 – 2 – 1 –
6 U I O U A --- E 1 1 1 1 2 0 22 2
Layout Design – CORELAP
 The next department is the one with an A (E, I, etc.). relationship
with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X?
Department
Relationships Summary
Depart Placement
ment 1 2 3 4 5 6 7 A E I O U X TCR
Sequence

1 --- E O I O U U 0 1 1 2 2 0 19 5
2 E --- U E I I U 0 2 2 0 2 0 22 4
3 O U --- U U O U 0 0 0 2 4 0 14 7
4 I E U --- I U U 0 1 2 0 3 0 19 6
5 O I U I --- A I 1 0 3 1 1 0 23 1
6 U I O U A Placement
--- E 1 1 order:
1 1 2 50– 6 22
– 7 – 2 – 12– 4 –
Layout Design – CORELAP
Placement of departments in the layout
 The first department is 5. It is placed in the centre of the 7 x 15
layout

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
4 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

No. Of Squares for department 5 = 1

Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The second department is 6. is placed adjacent to
It Department 5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 0 0 0 0 0 0 6 6 0 0 0 0 0 0 0
4 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
No. Of Squares for department 6 = 2

Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The next department to be placed is 7. The combinations are
given here

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 7 7 0 0 0 0 0 0 0
3 0 0 0 0 0 0 6 6 7 0 0 0 0 0 0
4 0 0 0 0 0 7 7 5 7 0 0 0 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
No. of Squares for department 7 = 2
Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 To select the placement location of 7, calculate PR values
Department
PR = E6-7 = 5 Relationships
Depart
ment 1 2 3 4 5 6 7

1 --- E O I O U U
PR = E6-7 + I5-7 = 5 + 4 = 9 2 E --- U E I I U
3 O U --- U U O U
4 I E U --- I U U
PR = E6-7 + I5-7 = 5 + 4 = 9 5 O I U I --- A I
6 U I O U A --- E
A = 6;7 E = 5:UI = U
4: OU= 3;UU =I 2;EX =---
Select Randomly between these two 1
(since both are equal)
Layout Design – CORELAP
Placement of departments in the layout
 The placement of 7 based on PR is as given below

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 0 0 0 0 0 0 6 6 0 0 0 0 0 0 0
4 0 0 0 0 0 7 7 5 0 0 0 0 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

No. Of Squares for department 5 = 1

Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The next department to be placed is 2. The combinations are
given here

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 0 0 0 0 0 2 6 6 0 0 0 0 0 0 0
4 0 0 0 0 2 7 7 5 2 0 0 0 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

No. Of Squares for department 2 = 1

Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 To select the placement location of 2, calculate PR values
Department
Relationships
High PR – Select this Depart
location ment 1 2 3 4 5 6 7
PR = U7-2+ I6-2 = 6

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
A = 6;
7 E = 5:
U I =U4: OU = 3;
U UI= 2;E X---
=1
PR = I5-7 = 4
PR = U7-2 = 2
Layout Design – CORELAP
Placement of departments in the layout
 The placement of 2 based on PR is as given below

1
1 2 3 4 5 6 7 8 9 0 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 0 0 0 0 0 2 6 6 0 0 0 0 0 0 0
4 0 0 0 0 0 7 7 5 0 0 0 0 0 0 0
5 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
No. of Squares for department 2 = 2
Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The next department to be placed is 1. The combinations are
given here
1
1 2 3 4 5 6 7 8 9 0 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0
3 0 0 0 0 1 2 6 6 1 0 0 0 0 0 0
4 0 0 0 0 1 7 7 5 1 0 0 0 0 0 0
5 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
No. of Squares for department 1 = 2
Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The placement of 1 based on PR is as given below

1
1 2 3 4 5 6 7 8 9 0 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0
3 0 0 0 0 0 2 6 6 0 0 0 0 0 0 0
4 0 0 0 0 0 7 7 5 0 0 0 0 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

No. Of Squares for department 1 = 2

Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The next department to be placed is 4. The combinations are
given here
1
1 2 3 4 5 6 7 8 9 0 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 4 1 1 0 0 0 0 0 0 0 0
3 0 0 0 0 4 2 6 6 4 0 0 0 0 0 0
4 0 0 0 0 4 7 7 5 4 0 0 0 0 0 0
5 0 0 0 0 0 4 4 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

No. of Squares for department 4 = 2

Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The placement of 4 based on PR is as given below

1
1 2 3 4 5 6 7 8 9 0 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 4 1 1 0 0 0 0 0 0 0 0
3 0 0 0 0 4 2 6 6 0 0 0 0 0 0 0
4 0 0 0 0 0 7 7 5 0 0 0 0 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

No. Of Squares for department 4 = 2

Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The next department to be placed is 3. The combinations are
given here
1
1 2 3 4 5 6 7 8 9 0 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 3 4 1 1 3 0 0 0 0 0 0 0
3 0 0 0 0 4 2 6 6 0 0 0 0 0 0 0
4 0 0 0 0 3 7 7 5 0 0 0 0 0 0 0
5 0 0 0 0 0 3 0 3 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

No. Of Squares for department 3 = 1

Placement order:
Layout Design – CORELAP
Placement of departments in the layout
 The placement of 3 based on PR is as given below

1
1 2 3 4 5 6 7 8 9 0 11 12 13 14 15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 4 1 1 3 0 0 0 0 0 0 0
3 0 0 0 0 4 2 6 6 0 0 0 0 0 0 0
4 0 0 0 0 0 7 7 5 0 0 0 0 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

No. Of Squares for department 3 = 1

Placement order:
Layout Design – CORELAP
 Calculation of Total Score
Distance Closeness
Department Department (1) (2) Score
1 2 0 ---- ----
1
1
3
4
0
0
----
----
----
----
Total score for this layout = 46.
1 5 2 3 6
1 6 0 ---- ----
1 7 1 2 2 We can repeat this procedure
2
2
3
4
2
0
2
----
4
----
with different scales and pick
2 5 2 4 8 up the best layout with the
2 6 0 ---- ----
2 7 0 ---- ---- minimum score
3 4 2 2 4
3 5 1 2 2
3 6 0 ---- ----
3 7 2 2 4
4 5 3 4 12
4 6 1 2 2
4 7 1 2 2
5 6 0 ---- ----
5 7 0 ---- ----
6 7 0 ---- ----
Total 46 108
Thank you