5.

Design of Cell Layout Algorithms

5.1. Layout By Quantitative Technique

 It is analytical method to assign the appropriate location of facilities.

 Several alternatives are generated by changing between department locations, hence for
( n ) facilities, will be n! alternatives.
 Evaluation of the alternative is done by calculating cost function which is formulated
using ( Load / Move ), ( Distance or Travel ), and ( Cost of Travel ) matrices between
facilities.
 The method require knowing an initial layout, and therefore it is called an Improvement
Method.
 It is used for develop process and group technology layouts.

5.1.1: Data Requires

1. Routing sheet and process charts.

2. Product mix., Volume of production and unit load.
3. Initial layout ( area and coordinates )
4. Handling cost.

5.1.2: Solution Steps:

1. Form move matrix [L] between departments ( From – To ) Matrix.

2. Form transportation cost matrix [ C ] between departments.
3. Form distance matrix [ D ] between departments. I calculated as distance between
department centers using rectilinear ( [X] + [Y] ) or Euclidian ( X2 + Y2 )0.5
4. Calculate the cost function = F = [C][D][L]
5. Calculate layout efficiency = [ F / L ] %
6. Repeat steps 3 – 5 for ( n! ) alternatives to reach the minimum cost where the basic
number of repeated is ( n ( n – 1 ) / 2 ), where, n = number of departments.

This method is called Pair – Wise Exchange Method.

Example -1:

Industrial company produces 10 products according given sequence in table below and moves
with equal unit loads. Assume unit cost backward between departments cost double move
forward. Initial layout is shown. Find optimal layout.

61
Product sequence
1 R,C,B,D,F
2 R,A,E,B,C,F R A B C D E F
3 R,E,A,E,B,F
4 R,A,B,C,D,E,F Raw Finished
5 R,C,A,B,F Materials Goods
6 R,D,C,A,E,F
7 R,E,A,B,F
8 R,A,C,E,A,F . Aisle
9 R,C,B,D,F
10 R,C,A,C,B,C,E,F
To main Building
Solution
Form load matrix [ L ]

R A B C D F F Total

R 3 4 1 2 10

A 3 2 3 1 9
R-A 3 A-B 3 B-C 2 C-D 1 D-E 1 E-F 3
B 3 2 3 8
R-B 0 A-C 2 B-D 2 C-E2 D-F 2
R-C 4 A-D 0 B-E 0 C-F 1
C 3 3 1 2 1 10
R-D 1 A-E 3 B-F 3
R-E 2 A-F 1
D 1 1 2 4
R-F 0
E 3 2 3 8

F 0

Total 0 9 8 10 4 8 10 49

R A B C D E F R A B C D E F

R 1 1 1 1 1 1 R 1 2 3 4 5 6

A 2 1 1 1 1 1 A 1 1 2 3 4 5

[C] B 2 2 1 1 1 1 B 2 1 1 2 3 4
[D]
C 2 2 2 1 1 1 C 3 2 1 1 2 3
Cost Diatance
Matrix D 2 2 2 2 1 1 Matrix D 4 3 2 1 1 2

E 2 2 2 2 2 1 E 5 4 3 2 1 1

F 2 2 2 2 2 2 F 6 5 4 3 2 1

62
 R A B C D E F

R 3 12 4 10 29

A 3 4 12 5 24

B 3 4 12 19
F = [C][D][L]= Efficiency = ( L/F ) = ( 49 / 144 ) = 34 %
C 12 6 1 4 3 26

D 2 1 4 7

E 24 12 3 39

F ---

-- 39 21 21 9 27 27 144

Note that: the matrix axis is important since it shows that moving departments near the axis
reduce cost. Thus when moving department with high moves near the axis better layout could be
obtained. Improve the layout by exchange the pairs B - E

R A B C D E F
Raw Finished
Materials B Goods
E

. Aisle

To main Building

63
 R A B C D E F

R 1 5 3 4 2 6

A 1 4 2 3 1 5

B 5 4 2 1 3 1
[D ]
C 3 2 2 1 1 3
Diatance
Matrix D 4 3 1 1 1 2

E 2 1 3 1 1 1

F 6 5 1 3 2 1

R A B C D E F

R 3 12 4 4 23

A 12 4 3 5 24

B 6 2 3 11
F = [C][D][L]= Efficiency = ( L/F ) = ( 49 / 125 ) = 39 %
C 12 12 1 2 3 30

D 2 1 4 7

E 6 12 12 30

F ---

-- 21 36 24 7 10 27 125

 Improve the last layout by exchanges pairs B - D

R A E C D B F
Raw Finished
Materials B D Goods

. Aisle

To main Building

64
 R A B C D E F

R 1 4 3 5 2 6

A 1 3 2 4 1 5

B 4 3 1 1 2 2
[ D ]
C 3 2 1 2 1 3
Diatance
Matrix D 5 4 1 2 3 1

E 2 1 2 1 3 4

F 6 5 2 3 1 4

R A B C D E F

R 3 12 5 4 24

A 9 4 3 5 21

B 3 2 6 11

C 12 6 2 2 3 25
F = L*D*C= 49
D 4 3 2 9 E= *100 = 42.3%
116
E 6 8 12 26

F --

-- 21 23 23 9 12 28 116

Example 2:

Industrial company produces 9 products according given sequence in table. Also, the table
gives production volume and unit loads moves with equal unit loads. Assume unit cost is
constant and backward move cost is the same as forward move. Initial layout is as shown. Find
optimal layout.

65
 Volume Bulk Factor
( Pcs/Yr ) ( Pcs/Yr ) Sequence
Part No.

1 5000 20 A,B,C,H,I
2 12000 200 A,C,E,G,I I H E
3 600 30 A,B,C,F,G,I
4 2000 500 A,D,E,C,I
D A C
5 5000 100 A,B,H,C,F,I
6 9000 50 A,D,I
7 20000 1000 A,D,G,I G B F
8 2000 100 A,H,F,I
9 1000 250 AB,D,G,I

Solution:
Volume Bulk Factor
( Pcs/Yr ) ( Pcs/Yr ) Loads/Yr Moves/Parts Moves/Yr
Part No.

1 5000 20 250 4 1000

2 12000 200 60 4 240
3 600 30 20 5 100
4 2000 500 4 4 16
5 5000 100 50 5 250
6 9000 50 180 2 360
7 20000 1000 20 3 60
8 2000 100 20 3 60
9 1000 250 4 4 26
2102
A B C D E F G H I

A 324 60 204 20 608

B 270 4 50 324

C 60 70 250 4 384

D 4 24 180 208

Load Matrix E 4 60 64
[L]
F 20 70 90

G 104 104

H 50 20 250 320

I 0

0 324 384 208 64 90 104 320 608 2102

66
 A B C D E F G H I

A 1 1 1 2 2 2 1 2

B 1 2 2 3 1 1 2 2

C 1 2 2 1 1 3 2 3 I H E

D 1 2 2 3 3 1 2 1
D A C
Distance Matrix E 2 3 1 3 2 4 1 2
[D]
G B F
F 2 1 1 3 2 2 3 4

G 2 1 3 1 4 2 3 2

H 1 2 2 2 1 3 3 1

I 2 2 3 1 2 4 2 1

A B C D E F G H I

A 324 60 204 20 608

B 540 8 100 648

C 60 70 500 12 642

D 12 24 180 216

E 4 240 244
F = [ L ][C][D] =
F 40 280 320
Efficiency = 2102 / 3294 = 64 %
G 208 208

H 100 60 250 410

I 0

0 324 704 212 72 130 304 620 930 3294

A-B 4 B-C 2 C-D 0 D-E 1 E-F 0 F-G 1 G-H 0 H-I 1

A-C 1 B-D 1 C-E 1 D-F 0 E-G 1 F-H 0 G-I 4
A-D 2 B-E 0 C-F 2 D-G 2 E-H 0 F-I 1
A-E 0 B-F 0 C-G 0 D-H 0 F-I 0
A-F 0 B-G 0 C-H 1 D-I 1
A-G 0 B-H 1 C-I 0
A-F 1 B-I 0
A-I 0

67
 I H E G F E
Alternative

D A C I H C

G B F D A B

A B C D E F G H I

A 1 2 1 3 2 3 1 2

B 1 1 2 2 3 4 2 3

C 2 1 3 1 2 3 1 2 G F E

D 1 2 3 4 3 2 2 1
I H C
Distance Matrix E 3 2 1 4 1 2 2 3
[D] D A B
F 2 3 2 3 1 1 1 2

G 3 4 3 2 2 1 2 1

H 1 2 1 2 2 1 2 1

I 2 3 2 1 3 2 1 1

A B C D E F G H I Total

A 324 120 204 20 668

B 270 8 100 378

C 60 140 250 8 458

D 16 48 180 244
F = C*D*L =
E 4 120 124

F 20 140 160

G 104 104

H 50 20 250 320

I -----
2456
2102
Efficiency = x100 = 85.8 %
2456

68
5.2. Pair – Wise Exchange Method

The pairwise method is an improvement – type layout algorithm. Although it can be used with
both an adjacency – based and distance – based objective, it is often used with the latter. We will
illustrate the pairwise exchange method below through an example based on equal – area
departments for simplicity. Its implementation with unequal – area departments will be shown
later via CRAFT ( which is the case in practice ).

Example 3

Consider four departments labeled 1, 2, 3, and 4. Each department is represented by a 1x1

square. The following data are given:

1 2 3 4 1 2 3 4

1 10 15 20 1 1 2 3 1 2

2 10 5 2 1 2
3 4
3 5 3 1
Initial layout
4 4

Flow - between matrix Unit cost matrix

List all department pairs that pairwise would consider exchange.

Solution:

Iteration 0:
The Total Cost ( TC ) for the existing layout is computed as follows:

TC1234 = 10*1 + 15*2 + 20*3 + 10*1 + 5*2 + 5*1 = 125

Iteration 1:
The total cost resulting from these exchanges are: Sequence 1 – 2 – 3 – 4

TC2134(1-2) = 10*1 + 15*1 + 20*2 + 10*2 + 5*3 + 5*1 = 105

TC3214(1-3) = 10*1 + 15*2 + 20*1 + 10*1 + 5*2 + 5*3 = 95 minimum cost
TC4231(1-4) = 10*2 + 15*1 + 20*3 + 10*1 + 5*1 + 5*2 = 120
TC1324(2-3) = 10*2 + 15*1 + 20*3 + 10*1 + 5*1 + 5*2 = 120
TC1432(2-4) = 10*3 + 15*2 + 20*1 + 10*1 + 5*1 + 5*2 = 105
TC1243(3-4) = 10*1 + 15*3 + 20*2 + 10*2 + 5*1 + 5*1 = 125

Iteration 2:

69
Consider all feasible exchanges which consist of the same as in iteration 1. The resulting total
costs are: Sequence 3 – 2 – 1 – 4

TC3124(1-2) = 10*1 + 15*2 + 20*1 + 10*1 + 5*2 + 5*3 = 95

TC1234(1-3) = 10*1 + 15*2 + 20*3 + 10*1 + 5*2 + 5*1 = 125
TC3241(1-4) = 10*2 + 15*3 + 20*1 + 10*1 + 5*1 + 5*2 = 110
TC2314(2-3) = 10*2 + 15*1 + 20*1 + 10*1 + 5*3 + 5*2 = 90 minimum cost
TC3412(2-4) = 10*1 + 15*1 + 20*2 + 10*2 + 5*3 + 5*1 = 105
TC4213(3-4) = 10*1 + 15*1 + 20*2 + 10*2 + 5*1 + 5*3 = 105
Iteration 3:

Consider all feasible exchanges which consist of the same as in iteration 2. The resulting total
costs are: Sequence 2 – 3 – 1 – 4

TC1324(1-2) = 10*2 + 15*1 + 20*3 + 10*1 + 5*1 + 5*2 = 120

TC2134(1-3) = 10*1 + 15*1 + 20*2 + 10*2 + 5*3 + 5*1 = 105
TC2341(1-4) = 10*3 + 15*2 + 20*1 + 10*1 + 5*2 + 5*1 = 105
TC3214(2-3) = 10*1 + 15*2 + 20*1 + 10*1 + 5*2 + 5*3 = 95 minimum cost
TC4312(2-4) = 10*1 + 15*1 + 20*2 + 10*2 + 5*3 + 5*1 = 105
TC2413(3-4) = 10*2 + 15*1 + 20*1+ 10*3 + 5*1 + 5*2 = 100

The minimum cost = 95 at this iteration is worse than the total cost at iteration 2 = 90, then stop.
The final layout arrangement is 2 – 3 – 1 – 4.

5.3. Layout By Qualitative Technique

5.3.1 Activity Relationship Diagram ( REL )

The activity relationship diagram, also called an affinity analysis diagram, shows the
relationship of every department, office, or service area with every other department and area as
shown below:

1. Receving
A
2. Punch Press I
A O
3. Press Bending O U
I E U
4. Press Forming X E U
U E I E
5. Riveting U A U
O U E
6. Power Sawing I O
U O
7. Power Draw I
U
8. Welding Robot

70
 Closeness codes are used to reflect the importance of each relationship. As a new person or an
outside consultant, you may need to talk with many people to determine these codes, and once
they are set, your arrangement of departments, offices, and service facilities is nearly determined
for you. The codes are as follows:

Code Definition
A Absolutely necessary that these two department be next each other
E Especially important
I Important
O Ordinary important
U Unimportant
X Closeness undesirable

 A number of factors other than material handling cost might be of primary concern in
layout design.
 Activity relationship chart should be constructed in order to realize the closeness rating
between departments.
 Facilitates consideration of qualitative factors by replacing the numbers in a from-to
chart by a qualitative closeness rating

5.3.1.1. Construction steps of REL chart

1. List all departments or activities to be included

2. Obtain closeness ratings by interviewing or surveying persons
3. Assign a closeness rating to each pair - wise combination of activities
4. Review the REL chart with those providing input in step 2.
5. Reason codes can be used like asterisks.

Closeness code

A
1
Reason code

Proportion for each rating and values

Rating Proportion to the whole Value

relations

A ≤5% 4

71
 E ≤ 10 % 3
I ≤ 15 % 2
O ≤ 20 % 1
U ≥ 50 % 0
X ≤5% -1

5.3.1.2. Worksheet
The worksheet is an interim step between the activity relationship diagram and the
dimensionless block diagram. The worksheet will replace the activity relationship diagram. The
worksheet interprets the activity relationship diagram and becomes the basic data for the
dimensionless block diagram. Steps procedures:
1. List all the activities down the left – hand side of a sheet of paper.
2. Make six columns to the right – hand of activity column and titled these six columns A,
E, I, O, U, and X, relationships.
3. Take one activity ( department, office, or service facility ) at a time, list the activity
number(s) under the proper relationship codes.

Activity A E I O U X

1.Receving 2 8 3 4 5,6,7 ---

1,3 5,6 7 4 8 ----
2.Punch Press

3.Press Bending 2,7 1,6 4 ---- ---- 5

4.Press Forming 1 1,2,8 5,6,7

5.Riveting 2 7 6,8 1,4 3
6.Power Sawing 2,3 8 5 1,4,7

7.Power Draw 3 2,5 1,4,6,8

8.Welding Robot 1,3 6 4,5 2,7

5.3.1.3. Dimensionless Bock Diagram

72
The dimensionless block diagram is the first layout attempt and the result of the activity
relationship chart and the worksheet. Even though this layout is dimensionless, it will be the
basis for the master layout and plot plan. The dimensionless block diagram as follow
For example

A E 1,3 5,6

X = none X = Punch Press

I O 7 4

3 -- -- 2 -- 1,3
.
7 5 8
2,5 -- 7 6,8 6 4,5
2,7 1,6 1,3 5,6 -- 2,3

3 2 6
4 -- 7 4 8 5
2 8 -- --
. 1 4
3 4 1 1,2,8

Example 4:
Develop the worksheet and the dimensionless block diagram for the activity relationship
diagram in the following figure.

73
 1. Receving
A
2. Stores E
A X
3. Press shop X U
A E U
4. Paint Dept. E U X
A I U U
5. Packing U I U U
A U A U O
6. Warehouse I I A I O
A I U A O U
7. Shipping U U U I U U
U U U I X U
8. Maintenance U U I X I
A U O U U
9. Tool crib E O O U
E U O U
10. Production foreman U U U
E U O
11. Time keeper I U
E O
12. Office area U
I
13. R & D

Solution:

No. Activity A E I O U X

1 Receiving 2 3 -- 10,11 5,6,8,9,12 ,13 4,7

2 Stores 3,1 5 10 11 6,7,8,9,12 ,13 4

3 Press shop 2,4,8,9,10 5,1 6,7,11,13 -- -- 12

4 Paint Dept. 3,5 -- 8,11 -- 6,7,9,10,13 1,2,12

5 Packing 4,6 2,3 7,8,11 -- 1,9,10,12 ,13 --

6 Warehouse 5,7 -- 3 11,12 1,8,9,10,13 2,4 --

7 Shipping 6 -- 3,5 11,12 2,4,8,9,10,13 --

8 Maintenance 3,9 10 4,5 13 2,6,7,11,12 --

9 Tool Crib 3,8 10 -- -- 1,2,4,5,6,7,11 --

12,13

10 Prod, 3 8,9,11 2,12 1,13 4,5,6,7 --

Foreman

11 Time keeper -- 10,12 3,4,5 1,2,6,7 8,9,13 --

12 Office area -- 11 10,13 6,7 1,2,5,8,9 3,4

13 R&D -- -- 1,2,3 8,10 1,2,4,5,6,7,9,11 --

74
 5,7 0 4,6 2,3 3,5 0 0 0

6 5 4 13
3 11,12 7,8,11 0 8,11 0 3,12 8,10
6 o 1,3 5 2,4,8, 1,5 3,9 10
9,10
7 2 3 8
3,5 11,12 10 11 6,7,11,13 0 4,5 13
2 3 3 8,9,11 3,8 10

1 10 9
0 10,11 2,12 1,13 0 0
0 11 0 10,12

12 11 1,2
10,13 6,7 3,4,5 6,7

5.3.2: Relationship Diagram Process( RDP)

RDP is a construction algorithm, which adds departments to the layout one by one until all
departments have been placed.
Stage 1: Involves 5 steps to determine the order of placement
Step 1 _ the numerical values are assigned to the closeness rating as: A= 10 000, E= 1000,
I= 100, O= 10, U= 0, X= – 10 000
Step 2 _ TCR (Total Closeness Rating) for each department is computed. TCR refers to the sum
of the absolute values for the relationships with a particular department.
Step 3 _ The department with the greatest TCR is selected as the first placed department in the
sequence of placement.
Step 4 _ Next department in the sequence of placement is determined to satisfy the highest

closeness rating with the placed department(s). With respect to the closeness priorities
A>E>I>O>U
Step 5 _ Departments having X relationship with the placed department(s) are labeled as the last
placed department.

Note: If ties exist during this process, TCR values are utilized to break the ties arbitrarily.
Stage 2: Involves 3 steps to determine the relative locations of the departments:
Step 6 _ Calculate Weighted Placement Value (WPV) of locations to which the next department
in the order will be assigned. WPV refers to the sum of the numerical values for all
pairs of adjacent department(s). When a location is fully adjacent, its weight equals to
1.0, and when it is partially adjacent its weight equals to 0.5.
Step 7 _ Evaluate all possible locations in counter lock-wise order, starting at the western edge of
the partial layout.

75
Step 8 _ Assign the next department to the location with the largest WPV.

Note: If ties exist during this process, first location with the largest WPV is selected.

Department neighbors:
a. Adjacent ( in position 1, 3, 5, or 7 ) with department 0 1 2 3

b- Touching ( in position 2, 4, 6, or 8 ) depatment 0 8 0 4

7 6 5

Example 5:
Given the activity relationship diagram (REL) determine the layout of departments using RDP.

Solution:
Calculate the Total closeness ratings (TCR) with values of A=10,000;
E =1000; I =100; O =10; U=0

Department
Dept.
1 2 3 4 5 6 A E I O U X TCR Order

1 - O E U U U 0 1 0 1 3 0 1010 6
2 O - I I E I 0 1 3 1 0 0 1320 4
3 E I - U U U 0 1 1 0 3 0 1100 5
4 U I U - U A 1 0 1 0 3 0 10100 3
5 U U E U - A 1 1 0 0 3 0 11000 2
6 A A U I U - 2 0 1 0 2 0 20100 1

Placement sequence : 6 – 5 – 4 – 2 – 3 – 1

76
 Entering Department 5
Entering Department 4
5000 10000 500
A = 10000 0 5000 10000 5000
10000 6 10000
0 5 6 10000
5000 10000 5000
0 5000 10000 5000

4 -5: U = 0; 4 - 6: A = 10000

Entering Department 2
Entering Department 3
500 1050 600 50
0 0 0 0
1000 5 6 150
50 5 6 0
500 1150 4 150
100 2 4 0
50 100 50
50 100 50 0
2-4 = 2 - 6 = I = 100 ; 2 - 5 = E = 1000
3-4=3-5=3-6= U = 0 ; 3 - 2 = I = 100

Entering Department 1
Final Layout
0 0 0 0

500 1000 5 6 0 5 6

1000 3 2 4 0 3 2 4

500 1005 510 5 0 1

1-2=O=10; 1-3=E=1000; 1-4=1-5=1-6=U=0

Assignment # 5
Q.1:

Industrial company produces 10 products according given sequence in table and moves with
unit loads. Assume unit cost backward between departments cost triple move forward. Initial
layout is shown.

Product Processing Sequence Load / Period

1 A-B-C-D-E-F 10
77
 2 A-B-C-B-E-D-C-F 12
3 A-B-C-D-E-F- 15
4 A-B-C-E-B-C-F 22
5 A-C-E-F 08
6 A-B-C-D-F 09
7 A-B-D-E-C-B-F 25
8 A-B-D-E-C-B-F 30
9 A-B-C-D-F 19
10 A-B-D-E-F 07

A B C D E F
Raw Finished
material product
Aisle

To main building
a. Compute the efficiency rating.
b. Departments A , D, and F fixed. Compute the efficiency rating by exchange pair
departments B - E.
c. From b compute the efficiency rating by exchange pair departments C – B.

Q.2:
A workshop produces 10 products according the given sequence in table below. Also, the table
gives production volume and unit loads moves with equal unit loads. Assume unit cost is
constant and backward move cost is the same as forward move. Initial layout is as shown. Find
optimal layout.

Part No. Volume Bulk Factor Processing Sequence

( Pcs/Yr ) ( Pcs/Load )
1 6000 30 a-b-c-d-f-l
2 10000 100 a-g-c-i-j-l
3 800 20 a-e-f-d-i-l
4 2400 240 a-c-f-i-l
5 4500 90 a-d-e-h-j-l
6 12000 300 a-c-f-l
7 18000 2000 a-b-c-e-f-l
8 3000 600 a-e-g-i-k-l
9 1000 10 a-k-l
10 1100 50 a-b-d-g-i-l

78
 k j l

i h e
Initial Layout

d a c

g b f

Q.3:
Consider four departments labeled A, B, C, and D. Each department is represented by a 1x1
square. The following data are given:

A B C D A B C D

A 5 0 3 A 2 0 3 A B

B 5 0 B 2 1 0
C D
C 0 C 0 1 0

D D 3 0 0

Flow - between matrix Unit - cost matrix

List all department pairs that pairwise would consider exchange.

Q.4:
Develop the worksheet and the dimensionless block diagram for the activity relationship
diagram in the following figures:
a)

79
 A 2100
A
B 2100 E
E I
C 2100 A O
U O U
D 2800 U U E
E O U
E 1500 I U
E I
F 1500 O
A
G 2900

b)
Receiving 2500
A
Punch Press 5500 I
A O
Press Bending 2500 O U
I E U
Press Forming 2500 X E U
U E I E
Riveting 1500 U A U
O U E
Power Sawing 2500 I O
U O
Power Draw 2000 I
U
welding Robot 1000

Q.5:
Given the relationship chart below, determine the sequence of the placement of the
departments and find the best layout with RDP algorithm assuming that all the departments have
the same size. Use these closeness values: A=125, E = 25, I = 5, O = 1, U = 0, X = -125 and
consider half weight if the departments are only touching by one point.

1. Receiving
A
2. Shipping A
E E
3. Raw material storage A O
E U U
4. Finish good storage A O U
E U U A
5. Manufacturing O U E O
A A E U
6. Work - In - Process stg. A E A
A O U
7. Assembly O A
X O
8. Office A
X
9. Maintenance

80