4 layout planning models1

7/28/2019 4 Layout Planning Models1

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Layout Planning Models,Layout Planning Models,A gorit ms an computerize

iA gorit ms an computerize

i

1. Tompikins et al., Facility Planning, 3rd edition, John Wiley & Sons Ltd.,

S ngapore, .

2. Richard L.Francis et al., Facility Layout and Location: an analytical

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approc , n e t on, rent ce a o n a t ., .

3. Dr-Ing. Daniel Kitaw, Industrial Management and Engineering Economy


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Introduction

Introduction

The generation of layout alternatives is a critical stepn e ac es p ann ng process, s nce e ayou

selected will serve to establish the physical

relationships between activities.

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CONTD

CONTD

Which comes first, the material handling system or

Centralized versus decentralized storage of work

n process , oo ng, an supp es Fixed path versus variable path handling

The degree of automation used in handling

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,control, and computer control of materials.


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Layout proceduresLayout procedures

A number of different procedures have been developedo a e ac es p anner n es gn ng ayou s.

Improvement type

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Apples plant layout procedureApples plant layout procedure rocure e as c a a

Analyze the basic data Desi n the roductive rocess

Plan service and auxiliaryactivities

Plan the material flow pattern

Consider the general material

Determine space requirements

Allocate activities to total space

an ng p an

Calculate equipment requirement

Plan individual workstations

Construct master layout

Evaluate ad ust and check the

Select specific material handlingequipment

layout with appropriate persons

Obtain approvals

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oor na e grou s o re a eoperations

Design activity interrelationships

Follow up on implementation ofthe layout.


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Reeds plant layout procedureReeds plant layout procedure

Analyze the product or products to be produced

Determine the process required to manufacture the product Prepare layout planning charts

Determine workstations

Ana yze storage area requirements Establish minimum aisle widths

s a s o ce requ remen

Consider personnel facilities and services

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Provide for future expansion


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ContdContd

Layout planning chart is the most important single

phase of the entire layout process, it incorporates theo ow ng:

Flow process, including operations, transportation,

storage an inspection Standard time for each operation

Machine selection and balance

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ContdContd

Layout planningchart

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Systematic Layout Planning(SLP) procedureSystematic Layout Planning(SLP) procedure

Systematic Layout Planning (SLP) methodology was

.

The framework is uses activit relationshi dia ram as

a foundation activity.

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SLP contdSLP contd

Based on the input data and anunderstanding of the roles andre a ons ps e ween ac v es, amaterial flow analysis(from-to-chart )and an activity relationship

performed.

From the anal sis erformed, arelationship diagramis developed.

4 - 10SLP procedure


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ContdContd

The relationship diagram positions

activities spatially.

Proximities are typically used to reflect

e re a ons p e ween pa rs o

activities.

4 - 11Activity relationship chart


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ContdContd

Relationship diagram Space relationship diagram

4 - 12Alternative block layouts


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Algorithmic approachesAlgorithmic approaches

Algorithmic approach is a formal procedure that cane p e ayou ana ys o eve op or mprove a ayou ,

and it provide objective criteria to facilitate the

evaluation of various layout alternatives that emerge

n e process.

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Algorithm classificationAlgorithm classification

os ayou a gor ms can e c ass e accor ng o

the type of input data they requires.

Qualitative flow data(such as relationship chart)

Quantitative flow data(such as flow matrix

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Some al orithms acce ts both relationshi chart

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and from-to-chart


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ContdContd

Layout algorithms can also be classified according totheir objective functions.

Maximizin an ad acenc score

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ContdContd

m = the number of departments

fij = the flow from department i to department j(unitload/unit time)

cij = t e cost o moving a unit oa one istance unitfrom department i to j

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ij = e s ance rom epar men o


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ContdContd

m = the number of departments

fij = the flow from department i to department j(unitload/unit time)

xij = t e a jacent o epartment i an j in t e ayout

The adjacency score is helpful in comparing two or

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more a erna ve ayou s


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Modeling techniques/methodsModeling techniques/methods

methods used in various layout algorithms;a rw se exc ange me o A graph based method

CRAFT BLOCPLAN

MIP

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MULTIPLE


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Graph-based methodGraph-based method

The graph-based method is a construction-

.

.

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its new five de artments of e ual sizes.

9

1

9

0

0

1012

13

720

3

3

5

4

12

10

20 2

138

0

2

4

5

0

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Relationship chart Relationship diagram


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Step 1: from the relationship chart select a department.

9

1

8

0

1012

133

2

0

2

4

5

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Departments 3 and 4 are selected to enter the graph.


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Step 2: Select the third department to enter, the third

weights with respect to departments 3 and 4.

3 4 Total

1 8 10 182

1312

5 0 2 2 3 420

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epartment s c osen w t a va ue o .


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Step 3: Pick the fourth department to enter by

unassigned departments represented by a nodeon a face of the graph 22 3 4 Total

1 9 8 10 27(Best) 13129

3 4

8 10

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Department 1 is chosen with a value of 27.


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Step 4: Determine on which face to insert the last.

1 2 3 4

2

13

12 9

Faces Total 5

1

810

1-2-3 7

1-2-4 9(best)

2

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20- -

2-3-4 9(best)


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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)

Introduced in 1963 by Armour, Buffa, and Vollman.

layout of the facilities.

e ac y s m rove y sw c ng wo or reedepartments to help arrange the facility in an optimal

.

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o From-To Chart,o Cost Matrix,

o Distances determined for a iven la out and an

Initial layout. Cra t is used when the nu ber o de art ents is so

large that the computation by hand would be very

intensive and make the improvement not worth the

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time for many companies.


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o

Attempts to minimize transportation cost,ransportation cost= ow istance unit cost

o CRAFT is a path-oriented method, the final layout is

dependent on the initial layout.o Re uires an assum tion that:

i. Move costs are independent of the equipment

utilization and

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ii. Move costs are linearly related to the length of


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requ remen s:

o Initial layouto Flow data

o Total number of departments

o Fixe epartments an t eir ocation

o Area of departments

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e proce ures a op e or us ng are:

o Determine department centroids.o Calculate rectilinear distance between centroids.

.

o Consider department exchanges of either equal area

boarder.

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o e erm ne ranspor a on cos o eac epar men a

interchange.o Se ect an imp ement t e epartmenta interc ange

that offers the greatest reduction in transportation.

o Repeat the procedure for the new layout until non erc ange s a e o re uce e rans or a oncost.

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a or sa van ages o us ng

o Because the basis is the cost of material handling,on y pro uction epartments are consi ere . Noservice departments are considered.

o

An initial idea of the layout is required. Thereforethe technique is only applies to the modification ofan ex s ng ayou .

o The distances between the departments is taken as

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s ra g nes w ereas n prac ce movemen susually rectangular along ortagonal lines.


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cost matrix. Use Craft algorithm to obtain layout. Theinitial layout and the flow matrix is shown below

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Initial layout Flow matrix


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COmputerized RElationship LAyout Planning (CORELAP)COmputerized RElationship LAyout Planning (CORELAP)

eve ope or ma n rame compu ers

Adjacency

based method, , , ,

values Selection of the de artments to enter the la out is

based on Total Closeness Rating. Total Closeness Rating (TCR) for a department is the

sum o t e numerica va ues assigne to t e c osenessrelationships between the department and all other

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.


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epar men se ec on

1. The first department placed in the layout is the one. ,choose the one with more As (Es, etc.).

2. If a de artment has an X relationshi with the first

one, it is placed last in the layout. If a tie exists,choose the one with the smallest TCR value.3. T e secon epartment is t e one wit an A

relationship with the first one (or E, I, etc.). If a tie

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, .


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. a epar men as an re a ons p w e seconone, it is placed nexttothelast or last in the layout.

,value.

5. The third de artment is the one with most A E I

etc.) relationships with the already placeddepartments. If a tie exists, choose the one with thegreatest TCR va ue.

6. The procedure continues until all departments have

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.


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e p acemen o epar men s s ase on efollowing steps:

1. T e irst epartment se ecte is p ace in t emiddle.

2. The placement of a department is determined byevaluating PR for all possible locations around thecurren ayou n coun erc oc w se or er eg nn ngat the western edge.

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. e new epar men s oca e ase on egreatest PR value.


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ExampleExample

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ALDEP ProcedureoRandomly selects the first departmentoOut o those de art ents which ha e A

relationship with the first one (or E, I, etc. minlevel of importance is determined by the user) itselects randomly the second department.

oIf no such department exists it selects the secondone com e e y ran om y

oThe selection procedure is repeated until all the

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Department placement

Starts from upper left corner and extends it

downward Vertical sweep pattern

Adjacencybased evaluation

,and the scores

Re eats the rocedure max 20 la outs er run

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User evaluation


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4 layout planning models1

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