Layout till This Point

„ Coordinating facilities planning with

Chapter 6 other organizational units
„ Facility requirements a product design,
process design, schedule design
Layout Planning Models „ Activity relationships and space
requirements
„ Personnel requirements

Basic Layout Types Layout Procedures

„ Fixed product layouts „ Construction type
„ the workstations are brought to the material „ develop a new layout “from scratch”
Product layouts
„
„ Improvement type
„ based on the processing sequence
„ generate layout alternatives based on an
„ Group layout; Product family layout
existing layout
„ high degree of intradepartmental flow
„ Process layout
„ high degree of interdepartmental flow

3 4

Apple’s Plant Layout Procedure Apple’s Plant Layout Procedure

„ Procure the basic data
„ Analyze the basic data
„ Design the procedure process
„ Plan the material flow pattern
„ Consider the general material handling plan
„ Calculate equipment requirements
„ Plan individual workstations
„ Select specific material handling equipment
„ Coordinate groups of related operations
„ Design activity interrelationships
„ Determine storage requirements
„ Plan service and auxiliary activities
„ Determine space requirements
„ Allocate activities to total space
„ Consider building types
„ Construct master layout
„ Evaluate, adjust, and check the layout with the
appropriate persons
„ Obtain approvals
„ Install the layout
„ Follow up on implementation of the layout

5 6

1
Reed’s Plant Layout Procedure Layout Planning Chart
Analyze the product or products to be produced
„

„ Determine the process required to manufacture the

„ Flow process, including operations,
product transportation, storage, and inspections
Prepare layout planning charts
Standard times for each operation
„
„
„ Determine workstations
„ Analyze storage area requirements „ Machine selection and balance
„ Establish minimum aisle widths
„ Establish office requirements „ Manpower selection and balance
„ Consider personnel facilities and services „ Material handling requirements
„ Survey plant services
„ Provide for future expansion

7 8

Muther’s
Systematic Layout
Planning (SLP)
Procedure

9 10

Space Relationship Diagram

Relationship Diagram

11 12

2
 Alternative Block Layout Algorithmic Approaches
„ The relative placement of departments on the
basis of their “closeness ratings” or “material
flow intensities” is one that can be reduced to
an algorithmic process.
„ Algorithm classification
„ Type of input data
„ qualitative “flow” data (relationship chart)
„ quantitative flow matrix (from-to chart); numerical
values of closing rating ~ mostly used
„ both qualitative and quantitative (BLOCPLAN, used one
at a time)

13 14

Algorithm Classification Algorithm Classification

„ Objective function „ Normalized adjacency score (efficiency rating)
„ “distance-based”: Minimizing the sum of flows times
distances (from-to chart) - QAP

„ Normalized adjacency score for an X

relationship

„ “adjacency-based”: maximizing an adjacency score

(relationship chart)

15 16

Algorithm Classification
„ Layout representation
„ discrete (grid size<->computational
burden)
„ continuous (rectangular building and
department shapes)
„ department cannot be split
„ Any grid assigned to a department must be
“reachable” form any other such grid
„ enclosed void (atrium)

17 18

3

Algorithm Classification
„ Layout improvement
„ start with an initial layout
„ improve through incremental changes
„ Layout construction
„ develop a layout from scratch
„ given dimension (basic assumption in the
book)
„ “green field”: site plan
Relationship Diagramming for
New Layouts
Step 1. Select the first department to enter the layout
- select the department with the greatest # of “A”
Step 2. Select the second department to enter the
layout – have an “A” with the 1st department
Step 3. Select the third department to enter the layout
- AA, AE, AI, A*, EE, EI, E*, II, I*
Step 4. Determine the fourth department to enter the
layout - AAA, AAE, AAI, AA*, AEE, AEI
Step n. Department n is placed according to the rules
described in Steps 3 and 4

19 20

Pairwise Exchange Method for

Layout Improvement Example
„ Minimize the total cost of transporting „ Four departments with equal size
materials among all departments in a „ Material flow matrix
facility
„ Rectilinear distance, from centroid to
centroid
„ Distance matrix

21 22

Pairwise Exchange Method

„ Remark
„ does not guarantee to yield the optimal
solution: local optimality
„ may cycle back to one alternative
„ symmetric layout may occur
„ can be accomplished only if the
department pair considered are of equal
size or if they share a common border

23 24

4
Graph-Based Construction Adjacency graphs for
Method for New Layouts alternative block layouts
„ It is often used with an adjacency-
based objective.
„ 1960s Krejcirik; 1970s Seppanen and
Moore; similar to Muther’s SLP

25 26

Graph-Based Construction
Method for New Layouts
„ The score does not account for distance, nor
does it account for relationships other than
those between adjacent departments
„ Dimensional specifications of departments are
not considered; length of common boundaries
between adjacent departments are not
considered
„ The arcs do not intersect (planarity; 共平面)
„ The score is very sensitive to the assignment
of weights

27 28

Graph-Based Construction
Method for New Layouts
1. Select the department pair with the largest
weight
2. Select the third department that has the
largest sum of the weights with the first two
departments to enter
3. Pick the fourth department to enter on a face
(a bounded region of a graph) of the graph
4. Determine an adjacency graph ->
reconstruct a corresponding block layout

29 30

5
 Computer-Aided Layout
Techniques

31 32

Evaluation and Interchange in

CRAFT Dummy Departments
Interchanges are only possible if
„
„ Depts. are the same size; or
„ May be used to
„ Adjacent (a necessary but not sufficient condition) „ Fill building irregularities
„ Estimate the potential saving for an
interchange „ Represent obstacles or unusable areas in
„ For evaluation only the centroids are swapped the facility (fixed location)
(error?)
„ Select the best among all possible „ Represent extra space in the facility
interchanges
„ Aid in evaluating aisle locations in the final
„ Actually perform the interchange
„ Path-dependent heuristic (locally optimal) layout
„ Try different initial solutions or exchange options
„ the error in estimated cost may go either
direction 33 34

Example 6.1

35 36

6
 37 38

39 40

The Impact of Change Flexibility

„ Plant layout situations
„ Changes in the design of existing product,
the introduction of new products
„ Changes in the processing sequence for
existing products
„ Changes in production quantities and
schedules - the need for capacity changes
„ Changes in production strategies
„ Can be achieved by
„ utilizing modular office equipment,
workstations, and material handling
equipment
„ installing general purpose production
equipment
„ utilizing a grid-based utility and services
system
„ using modular construction

41 42

7
Flexible Layout

43