FMS LAYOUT CONSIDERATIONS

Type of layout used depends on:

type of FMS
main function
part families etc.

4 layout types:

1. Linear single- & double-row machine layout

- machines arranged in straight lines usually along an AGVS path

or

2. Circular machine layout

- based around a handling robot - not an AGVS

robot envelope determines layout size
3. Cluster machine layout

- utilizes gantry robots for part transfer

4. Loop layout

- uses conveyor system - unidirectional part flow

each station has secondary material handling system

Once we have established which machines go into which cell - we can consider
space issues

e.g. machine size & machine clearance & machine sequence

 Layout approach for a straight line of machines

Aim: - to determine non-overlapping optimal sequence of machines such that

total cost of making required movements is minimised

If total cost = Z then minimum Z is given as

where m = number of machines

fij = frequency trips between all pairs of machines (frequency
matrix) for all (i,j), i…j
cij = material-handling cost per unit distance between all pairs of
machines for all (i,j), i…j
li = length of ith machine
dij = clearance between machines i and j
xj = distance of jth machine from the vertical reference line as
shown below

1
This is subject to: xi − x j ≥ (li + l j ) + d ij
2
for all i, i = 1, 2, .....,m - 1,
and j = i + 1, ...., m with xi ≥ 0 for all i = 1, ...,m

This constraint = allows no overlap between machines

For case studies - solved using simple heuristics...

Objective =
sequence a number of machines so that material handling effort is minimised
Data required:
no. of machines (m)

frequency of trips between all pairs of machines

(frequency matrix), fij for all (i, j), i ≠ j

material-handling cost per unit distance between all pairs

of machines, Cij, for all (i, j), i ≠ j

procedure:
1. From the frequency and cost matrices, determine the adjusted flow
matrix as follows:
F = f ij = f ij Cij
2. Determine

f i ' j ' = max  f ij , for all i and j  . Obtain the partial solution
by connecting i’ and j’. Set f i ' j ' = f j 'i ' =∞ .

3. Determine f p 'q ' = max  f i 'k , f j 'l : k =1,2,... , m; l =1, 2, ...., m

4. Connect q’ to p’ and add q’ to the partial solution.

5. Delete row p’ and column p’ from  f ij 

6. If p’ = i’, set i’ = q’: otherwise set j’ = q’.

7. Repeat step 3 until all the machines are included in the solution.

Such processes are rather complex to describe in a series of sentences. It is

much better to illustrate such algorithms with worked examples:
Within a manufacturing cell, there are 5 machines of the following
dimensions:
M1 - 10x10 M2 - 15x15 M3 - 20x30 M4 - 20x20 M5 - 25x15

The cell will be set up as a FMS served by a single AGV, therefore, a

single-row layout is favoured. Due to operational and safety constraints,
there has to be certain minimum clearances between the machines, as
shown below:

M1+M2 = 2, M1+M3 = 1, M1+M4 = 1, M1+M5 = 1, M2+M3 = 1,

M2+M4 = 2, M2+M5 = 2, M3+M4 = 1, M3+M5 = 2, M4+M5 = 1.

Also, to account for intracellular movements and associated materials

handling, the following costs have been formulated for movements
between pairs of machines:

M1+M2 = 2, M1+M3 = 7, M1+M4 = 5, M1+M5 = 3, M2+M3 = 1,

M2+M4 = 4, M2+M5 = 2, M3+M4 = 1, M3+M5 = 2, M4+M5 = 3.

Finally, the number of intracellular moves between machines per part

family have been calculated as follows:

M1+M2 = 20, M1+M3 = 70, M1+M4 = 50, M1+M5 = 30, M2+M3 = 10,
M2+M4 = 40, M2+M5 = 15, M3+M4 = 18, M3+M5 = 21, M4+M5 = 35.

From this information - you have been told to work out what the optimum
machine sequence should be to give the most cost-effective layout.
step 1: - frequency matrix + cost matrix

Adjusted flow matrix = F =  f ij =  f ij Cij 

i.e.
Adjusted flow matrix
1 2 3 4 5
1 0 40 490 250 90
2 40 0 10 160 30
3 490 10 0 18 42
4 250 160 18 0 105
5 90 30 42 105 0

Step 2: link machines 1 and 3 in the solution as this combination has

the largest number ˆ they will stand next to each other

Step 3: next largest number is 250 (M4 + M1) ˆ connect M4 to M1

and delete row and column 1 i.e.
 Adjusted flow matrix
2 3 4 5
2 0 10 160 30
3 10 0 18 42
4 160 18 0 105
5 30 42 105 0
Step 4: the highest number now involves M2 and M4 ˆ link them. M4
now has both neighbours identified - so delete row and
column 4 i.e.

Adjusted flow
matrix
2 3 5
2 0 10 30
3 10 0 42
5 30 42 0
Step 5: add M5 to the solution to complete the sequence. M5 sits next
to M2 rather than M3 (the highest number according to the
matrix above) as it needs to be as close as possible to M4 (the
biggest original number involving M5).

Therefore - the optimal layout is as shown below:

Unfortunately - not drawn to scale!