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Contents
TABLE OF FIGURES............................................................................................................................. 3
INTRODUCTION ................................................................................................................................. 4
A SHORT HISTORY.............................................................................................................................. 5
TYPES OF LAYOUT FORMATS ............................................................................................................. 6
FACILITY SHAPES AND DIMENSIONS .................................................................................................. 8
STATIC VS. DYNAMIC LAYOUT PROBLEMS .......................................................................................... 9
FORMULATION TECHNIQUES ............................................................................................................. 9
RESOLUTION APPROACHES.............................................................................................................. 11
CONCLUSION AND FUTURE SCOPE .................................................................................................. 21
REFERENCES .................................................................................................................................... 22
TABLE OF FIGURES
Figure 1 Tree representation of FLP ................................................................................................... 5
Figure 2 Online store layout............................................................................................................... 7
Figure 3 Heat map tool ...................................................................................................................... 8
Figure 4 Facility shape ....................................................................................................................... 9
Figure 5 Dynamic Layout ................................................................................................................... 9
Figure 6 Layout models from SPIRAL ................................................................................................ 17
Figure 7 Factory Layout Planner Interface ........................................................................................ 18
Figure 8 DES Simulation ................................................................................................................... 19
Figure 9 5D Simulation .................................................................................................................... 19
Figure 10 Collision Simulation
Figure 11 Use of Manikin ................................................................................................................ 20
INTRODUCTION
Determining the physical organization of a production system is defined to be the facility
layout problem. This well-studied combinatorial optimization problem arises in a variety of
production facilities, including service and communications settings. It is concerned with
finding the most efficient arrangement of m indivisible departments with unequal area
requirements within a facility. The objective is to ensure a smooth workflow or a particular
traffic pattern so as to minimize material handling costs and time. Three sets of constraints
present are: (1) department and floor area requirements (2) department location restrictions
and (3) budget restrictions.
The output of the facility layout problem is a block layout, which specifies the relative
location of each department.
A SHORT HISTORY
Numerous articles have been published in this area. Koopmans and Beckmann (1957)
were among the first to consider this class of problems, and they defined the facility layout
problem as a common industrial problem in which the objective is to configure facilities, so
as to minimize the cost of transporting materials between them In order to highlight what
seems to constitute essential features to characterize layout problems a possible rough tree
representation of the different factors taken into account is shown (Amine Drira, 2007). In
fact, the problems addressed in research works differ, depending on such factors as: the
workshop characteristics (e.g., specificities of the manufacturing systems, the facility shapes,
the material handling system, and the layout evolution), what is the problem addressed (e.g.,
problem formulation, objectives and constraints) and the approaches used to solve it
(Resolution approaches).
Types, advantages and limitations, applications and future scope of different
resolution approaches are given emphasize in this project.
energy for deciphering and learning the navigational elements of the store (i.e., it is
perceived as more difficult to use), thereby reducing the mental energy left available
for processing the information contained within the confines of the store; this in turn
hinders goal achievement resulting in lower consumer elaboration and response.
The technology acceptance model (TAM) theorizes that ease of use of a system
interface is one element that has significant behavioural implications (Davis, 1989,
1993; Venkatesh and Davis, 1996, 2000). The TAM argues that as a systems ease of
use (i.e., the perception of the amount of effort necessary to use the system) increases,
a users intentions to use the system increases (as intention to use the system is
derived from the belief that the information system can enhance user performance of
specific tasks while minimizing effort expended). As such, it can be theorized that a
tree structured online retail store layout, because it is perceived to be easier to use by
consumers, may stimulate greater elaboration, and, due to its ability to facilitate
consumer goal achievement by providing easy access to information, generate a more
favourable consumer response both toward the retailer as well as toward the featured
brand. (Griffith, 2005)
To determine the placing of different items in a tree or tunnel layout various analytical
tools can be used which tracks the points at website where most of the consumers
notice. Eye Movement Pattern is one of them. It refers to the complete paths that the
human eye takes when looking at a web page - from the moment visitors enter a page
to the moment they leave it. To get visitors to use your services or purchase your
products important features must be placed at where the eyes go.
Another tool is Heat map. A heat map is a graphical representation of data where the
individual values contained in a matrix are represented as colours. This allows a
visual representation of important areas in a website in terms of colours. The lay out
can be easily rearranged using the information obtained from heat map analysis.
7) Warehouse Layout
Objective is to balance low cost storage with low cost material handling. Hence
tradeoffs between space and material handling are carried out.
FORMULATION TECHNIQUES
1) Quadratic Assignment Problem Approach
Koopmans and Beckman (1957) introduced the quadratic assignment problem (QAP)
to model the problem of locating interacting plants of equal areas. The QAP has been
applied to a wide range of applications, including urban planning, control panel
layout, and wiring design. QAP is a special case of the facility layout problem
assuming that all departments have equal areas. The QAP formulation assigns every
department to one location and at most one department to each location. The cost of
placing a department at a particular location is dependent on the location of the
interacting departments. Such dependency leads to the quadratic objective that
inspires the problems name. The QAP is NP complete, which implies that, in
general, it is a hard problem to solve. Optimal solutions to general cases of the
problem can only be found for problems with less no. of departments.
Applications
RESOLUTION APPROACHES
1) Exact Methods
Branch and Bound Methods
It is used to find an optimum solution of quadratic assignment formulated FLP
because QAP involves only binary variables. Only optimal solutions up to a problem
size of 16 are reported in literature. Beyond n=16 it becomes intractable for a
computer to solve it and, consequently, even a powerful computer cannot handle a
large instance of the problem. (Russell D. Meller, 1996)
Applications
2) Heuristics
Heuristic algorithms can be classified as construction type algorithms where a
solution is constructed from scratch and improvement type algorithms where an initial
solution is improved. Construction based methods are considered to be the simplest
and oldest heuristic approaches to solve the QAP from a conceptual and
implementation point of view, but the quality of solutions produced by the
construction method is generally not satisfactory. Improvement based methods start
with a feasible solution and tries to improve it by interchanges of single assignments.
Improvement methods can easily be combined with construction methods.
Different types of heuristics algorithms can be defined as:
1) Adjacency-Based Algorithms
Adjacency-based algorithms are usually incorporated within a graph based
approach.
Deltahedron Approach
One of the most widely cited adjacency-graph construction approaches is the
Deltahedron Approach (DA). The DA proceeds by determining the sequence
that nodes will enter the graph. At any stage, a node is entered into the centre
of the face (a triangle formed by three nodes) in the graph that will maximize
the adjacency benefits with the other departments in the face. Thus, a planar
graph is always maintained in DA, which allows for an easier transformation
to a block layout. Many heuristics have been developed in an attempt to
improve on DA's performance. The DA has also been modified to consider a
MATCH
MATCH, developed by Montreuil, Ratliff, and Goetschalckx is an interactive
construction type approach that utilizes a discrete representation and integer
programming to solve a b- matching problem. Their algorithm attempts to find
a matching that maximizes the adjacency score while satisfying the lower and
upper bound on the number of matches with each department, and the total
number of times a department must be matched with all other departments.
The algorithm considers the number of adjacent segments when computing
adjacency scores. The departments generated by MATCH are all rectangular
in shape and the approach is iterative, based on user input.
SPIRAL
SPIRAL, created by Goetschalckx, develops an adjacency graph and then a
block layout from the graph. SPIRAL utilizes the concept of "relationship
tuples" to construct an adjacency graph, where tuples quantify the relationship
between one department and other departments. The graph remains planar due
to its hexagonal structure and is used to construct an approximate relative
location diagram by fitting the unequal-area departments into a row-andcolumn structure. SPIRAL compares favourably to layouts generated by other
approaches.
2) Distance-Based Algorithms
The following algorithms employ a distance based objective.
SHAPE
SHAPE, developed by Hassan, Hogg, and Smith, is a construction algorithm
that utilizes a discrete representation and an objective based on rectilinear
3) Metaheuristics
Various meta-heuristics such as SA, GA, and ant colony are currently used to
approximate the solution of very large layout design problems.
Advantages
Better performance
Faster runtime
Suitable for application in large scale DPLP problems
Limits/Disadvantages
Care has to be taken if the surface of the fitness function is relatively flat over
a large area of the site
Determination of layout and the scheduling procedure would need to be
carried out concurrently to demonstrate optimality
Not optimal to solve for problems which have area utilization less than one
May require dummy departments so that the area utilization equals to one.
Consequently, this increases the problem size and results in poorer solution
quality
For discrete representation shapes of the machines are not concerned, so its
difficult to define the real locations of machines.
The continuous representation increases the complexity of problem.
Applications
To solve for:
products vary very fast, new machines and old machines may need
to be added into/removed from the plant in multi-stages
Stochastic layouts
Dynamic layouts.
Stochastic layouts.
Service layouts like hospitals.
Camera: In this mode, the mouse is used to explore the layout: pan,
zoom and rotate function are available for natural navigation in the 3D
scene.
Edit: This is the main mode used to modify the layout. The objects can
be selected, grouped, moved, rotated and their properties viewed and
edited. A snap grid can optionally be enabled to assist the positioning
of the objects.
Connection: When this mode is enabled, the user can connect objects
to create logical relationship useful for the DES simulation. The
available ports are shown and the user can connect then tracing lines
from one port to the other.
Figure 9 5D Simulation
Advantages
Limitations
The resulting quantitative results of algorithmic approach often do not capture all of
the design objectives.
An algorithmic approach is usually less effective in solving a practical design
problem.
Applications
They are applicable for almost any type of layout of manufacturing, construction
service applications.
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