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VIP-PLANOPT 18
USER’S MANUAL
❖❖❖
CONTENTS
1 INTRODUCTION ............................................................................................................... 7
1.1 MOTIVATION ............................................................................................................... 7
1.2 FILLING THE GAP ........................................................................................................ 8
1.3 UNMATCHED FUNCTIONALITY .................................................................................... 8
OPTIMIZATION ALGORITHM ................................................................................................... 9
2 TERMINOLOGY .............................................................................................................. 11
2.1 MODULE (DEPARTMENT) .......................................................................................... 11
2.2 MODULE ASPECT RATIO ........................................................................................... 12
2.3 MODULE AREA ......................................................................................................... 12
2.4 MODULE TYPE .......................................................................................................... 12
2.5 HARD (RIGID) MODULE ............................................................................................ 12
2.6 SOFT (FLEXIBLE) MODULE........................................................................................ 12
2.7 MODULE MOBILITY .................................................................................................. 12
2.8 FORBIDDEN AREA MODULE (FAM) .......................................................................... 13
2.9 MODULE ORIENTATION............................................................................................. 13
2.10 MODULE PADDING .............................................................................................. 13
2.11 PICK-UP & DROP-OFF POINTS ............................................................................. 14
2.12 BOUNDARY SHAPE .............................................................................................. 14
2.13 ENCLOSURE ........................................................................................................ 15
2.14 FLOW MATRIX .................................................................................................... 15
2.15 UNIT COST MATRIX ............................................................................................ 16
2.16 COST MATRIX ..................................................................................................... 16
3 DISTANCE NORMS......................................................................................................... 17
3.1 RECTILINEAR NORM ................................................................................................. 17
3.2 EUCLIDEAN NORM .................................................................................................... 17
3.3 SQUARED EUCLIDEAN NORM .................................................................................... 17
4 COST FUNCTIONS .......................................................................................................... 18
4.1 COST FUNCTION F1 ................................................................................................... 18
4.2 COST FUNCTION F2 ................................................................................................... 18
4.3 COST FUNCTION F3 ................................................................................................... 19
4.4 COST FUNCTION F4 ................................................................................................... 19
5 PRIMARY INPUT ............................................................................................................ 20
5.1 MAIN MENU .............................................................................................................. 21
5.1.1 Menu Icon: New .......................................................................................... 21
5.1.2 Menu Icon: Open ........................................................................................ 21
5.1.3 Menu Icon: Save.......................................................................................... 21
5.1.4 Menu Icon: Save As..................................................................................... 22
5.1.5 Menu Icon: Import Module Data ................................................................ 22
5.2 MODULE MENU......................................................................................................... 23
5.2.1 Module Preferences .................................................................................... 24
5.2.2 Generate Aspect Ratios ............................................................................... 25
5.3 CONSTRAINTS MENU ................................................................................................ 26
5.4 OPTIMIZATION MENU ............................................................................................... 27
COPYRIGHT
Copyright, 1996-2018, by Engineering Optimization Software.
DISCLAIMER
Considerable expenses, time and effort have gone into the development
of PLANOPT™ and VIP-PLANOPT™ computer programs. In using the
program, however, the user accepts and understands that no warranty
is expressed or implied by the developers or the distributors on the
accuracy or the reliability of the program. The authors and the
distributors hereby disclaim any liability to any party for any loss or
damage resulting from the installation or use of VIP-PLANOPT™ 18.
1 INTRODUCTION
PLANOPT (floor-PLAN layout OPTimization) represents a general-
purpose layout optimization algorithm. VIP-PLANOPT (Visually
Interfaced Package of PLANOPT) is the name of a powerful software
package based on PLANOPT algorithm. It has been developed to
produce high-quality near-optimal or optimal layouts for small,
medium and large-sized problems involving “modules” (departments)
of UNEQUAL-AREA. The term module used in this manual implies a
functional unit like departments, machines, rooms, cells or spaces.
1.1 Motivation
Facility layout has profound effects on the organizational productivity
and profitability. It is estimated that about 20-50% of operating costs in
manufacturing relates to materials handling, a factor highly correlated
to the quality of facility layout design. Superior facility layouts reduce
materials handling costs, help streamline all operations, and reduce
energy bills. It is estimated that billions of dollars are spent annually on
material handling. Consequently, layout design remains an important
issue for industrial facility planners with significant potential for
research and automation.
Optimization Algorithm
PLANOPT optimization algorithm is a research product. It is a robust
hybrid proprietary optimization algorithm. It came into existence in
1995 when two University Professors working together in the areas of
VLSI Layout design and Multi-disciplinary Facility Layout
optimization developed a marvelous technique that could solve the
Unequal Area QAP better than all published algorithms. They realized
that the results were amazing. No researcher in the field could imagine
(at that time) that it is at all possible to solve such a hard optimization
problem better than all GA’s, SA's and the conventional analytical or
heuristic techniques. They decided not to publish the algorithm but to
present the algorithm anonymously in the form of a software package
as a challenge to other researchers. This is how PLANOPT software
package came into existence. Since then, PLANOPT optimization
algorithm has been a challenge to the researchers in the field. It
becomes obvious from the review of published literature that
researchers mostly shied away from comparing their techniques with
PLANOPT using randomly generated benchmarks. In fact, published
optimization algorithms don't even come close to PLANOPT
algorithm.
2 TERMINOLOGY
Since the terminology used for layout optimization differs in various
applications, an effort has been made to adopt a generalized
terminology that could be applicable to most layout optimization
problems. It is briefly described in the following.
Ri = Wi Li (1)
Ai = Wi * Li (2)
2.13 Enclosure
The bounding rectangle enclosing all the modules in the optimized
layout is termed as “enclosure”. Its dimensions along x and y axes are
denoted by LB and WB respectively. Its aspect ratio, given by WB LB,
is denoted by RB and its area, given by WB LB, is denoted by AB.
support that will be used to move materials. PLANOPT allows the flow
matrix to be either symmetric or non-symmetric.
In effect, the cost matrix implies the same as the “activity relationship
matrix” based on the closeness ratings as given in the activity
relationship charts.
3 DISTANCE
NORMS
PLANOPT has the option of the following three norms for the distance
dij between the centroids of any two modules (departments) i and j:
dij = ( xi − x j )2 + ( yi − y j )2 (5)
4 COST
FUNCTIONS
Layout optimization requires minimization of an objective function
usually referred to as “cost” or “cost function”. Its definition may vary
from one application to another. Since PLANOPT is a general-purpose
layout optimization program, a cost function definition has been
adopted that suits most of the applications. Options for symmetric as
well as non-symmetric flow matrices and composite cost functions
have been provided. The cost function definition for a problem of n
modules has four different forms as given below.
n−1 n
F1 = f ij uij dij (6-a)
i =1 j =i +1
or,
n−1 n
F1 = d (6-b)
i =1 j =i +1 ij ij
The function F1 is applicable only when the cost (relationship) matrix
is symmetric.
n n
F2 = ij dij (7-b)
i =1 j =1
The function F2 may be used for both cases: symmetric as well as non-
symmetric cost (relationship) matrix. Non-symmetric cost matrix is
common in facilities/plant layout design.
Note: For symmetric cost matrix F2 = 2*F1
n −1 n
F3 = f ij uij dij + AB (8-a)
i =1 j = i + 1
or,
n −1 n
F3 = ij dij + AB (8-b)
i =1 j = i + 1
Here AB denotes the area of the bounding rectangle and is the user-
specified weight on this area.
n n
F4 = f ij uij dij + AB (9-a)
i =1 j = 1
or,
n n
F4 = ij dij + AB (9-b)
i =1 j = 1
5 PRIMARY INPUT
VIP-PLANOPT has a powerful visual interface with tips guiding the
user as the mouse pointer is moved. Most users learn to use the
program without any manual just by trying VIP-PLANOPT on simple
benchmark problems. Despite the efforts to make VIP-PLANOPT a
self-learning tool supported by this manual, users may have questions
while modeling a real-world problem. Technical support is available
to all users of VIP-PLANOPT. They are encouraged to ask for
assistance whenever they have any such questions.
This menu is shown in Fig. 5.7. The user may access the same
commands using the command buttons in the Optimization Constraints
frame on the right side of the main window.
The windows that open when these items are clicked are described in
the next chapter. The functions of these commands are listed in Table
5.3.
There are four optimization parameters namely the Cost Type, Area
weight, Distance and Optimization Seed, required for optimization,
which are described in the coming sections.
The sixth menu item on this menu is “Analyze”. It opens a window that
displays the optimal layout and lets the user to modify the layout for
comparing the cost with the optimized layout.
The windows that open when these commands are clicked are described
in the next chapter.
5.5.1 Import
Import, when clicked, opens a window called “VIP-PLANOPT Import
Modules” as shown in Fig. 5.10. and lets the user import any data in a
text file with or without serial number.
The data must be in CSV format i.e. the items on each line of input data
are separated by commas, tabs or spaces. VIP-PLANOPT detects if the
module data on a given line is for a hard module or soft module. For
example, if the data lines are numbered with the Module IDs, the input
data file will have data as follows:
1, 8, 8
2, 4, 12
3, 12, 4
8, 8
4, 12
12, 4
In case of soft modules, the data with numbered lines will be as follows:
1, 64, 0.5, 2
2, 48, 0.4, 3
3, 48, 0.2, 2
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VIP-PLANOPT will detect from the above that the modules are soft
and the first term on each line is the module area, and the second and
third terms are the lower and upper bounds on the aspect ratios. In case,
the user chooses the option of Modules not numbered, the data will be
as follows:
64, 0.5, 2
48, 0.4, 3
48, 0.2, 2
The user may mix the hard and soft modules. An example with module
1 and 3 Hard mixed with Module 2 which is Soft is as follows for the
option of Modules numbered on each data line.
1, 8, 8
2, 48, 0.4, 3
3, 12, 4
5.5.2 Export
Export, when clicked, opens a window called “VIP-PLANOPT Data
Export” and lets the user select data for export. The user may export the
module dimensions or the matrices in CSV format. This menu item also
lets the user export the optimal layout to AutoCAD.
Export window, as it appears when the user selects the matrix export
option, is shown in Fig. 5.11. The user may choose the matrix for
export. If the user chooses the AutoCAD Script File option, the user
may get a script file for plotting the layout without the module ID or
with the module ID. A proper text height parameter for AutoCAD is
required.
The third item on this menu is “Authorize”. It lets you install the license
on your system so that optimization is enabled for all problems.
The last item on this menu is “PC Identification”. This will generate a
data file for the profile of your PC which is required for obtaining a
single PC license.
The user may adjust grid/snap size and may zoom in and out. The user
can modify the properties of a Module by typing in the modified data
in the Module Data Table located under the Display Control.
5.8.2 Zoom
“Zoom In” command-button ( ) shows the module magnified. In
cases when a module appears very small, the user might require to
zoom in to edit it graphically.
The “Module Data Table” displays the data related to all modules and
enables the user to modify the properties of any module. The user will
click a cell to select and modify it. Note the following:
4. X-LLC and Y-LLC are the x and y co-ordinates for the Lower Left
Corner of the module in the layout. User will specify them only for
“Anchored” modules using the Anchor input window that opens when
the user clicks the “Anchor” button. For all “Movable” modules, the X-
LLC and Y-LLC are determined by the optimization algorithm of VIP-
PLANOPT.
5. AR-LB is the lower bound on the aspect ratio of a module and AR-
UB is the upper bound. For Hard modules, AR-LB = AR-UB and
cannot be modified by the user. For Soft modules, user may modify the
bounds specified by VIP-PLANOPT.
6. AR-Set is a set ID that the user may specify for Soft modules. The
set will contain discrete values of the aspect ratios as required by the
user. The input window for specifying sets of discrete aspect ratios can
be opened by clicking the “Generate AR” icon in the Module Menu.
Using the above table on the main window of VIP-PLANOPT 18, you
may input the flow from a module to other modules. Move the mouse
pointer to the cell in the above table that you want to modify, double-
click it and then modify the value. You may enter the values for “Flow”
and “Unit Cost”. “Cost of Flow” is calculated by multiplying the Flow
with the Unit Cost.
To view the complete matrix and to use other options like non-
symmetric matrix and import of the matrices from your own data file,
click “To display full matrix, click here…”.
In the context of flow and cost matrices, the current module (the module
on display) will be called the “Source” module. Initially the
“Destination” module ID will be set to be the same as the “Source”
module. In this situation, the user may not enter any values for flow and
the Flow and Cost both are set to zero.
The Distance Norm control gives the user the option to choose any of
the three distance norms; Rectilinear, Euclidean, and Squared
Euclidean.
5.11.4 Optimize
“Optimize” control, when clicked, starts optimization. The data file
must have been saved before starting optimization. Also, all modules
must have flow assigned to them. No user interaction is required during
the optimization and in this sense the optimization is fully automated.
A plot of the optimized layout with important data will be displayed as
soon as the optimization process comes to an end.
A shortcut for this command also exists in the main menu icon bar.
5.11.5 Analyze
“Analyze” control, when clicked, displays the optimal layout in a
separate window and lets the user move around any module by
dragging the mouse pointer to see how the cost varies when a module
is moved from its optimal location.
A shortcut for this command also exists in the main menu icon bar.
6 OTHER INPUT
The Main Input Window of VIP-PLANOPT is supported by several
other input windows. The basic and primary input with no special
properties or constraints may be completed on the Main Input window.
Whenever the user wants to associate special properties to the modules
like anchoring, pick-up and drop-off points, discrete aspect ratio sets,
module padding, boundary shape and other constraints, the input will
be done through of one of these supporting windows. These supporting
data input windows are described in this chapter.
6.1.2 Notes
1) Select type of module that you want as default and then input
the dimensions or area and aspect ratios.
2) You may set the default as “Same as” an existing module.
6.2.2 Notes
3) If you have discrete aspect ratio values at regular intervals,
enter the Minimum Value, Maximum Value and Increment in
the data entry boxes on the right side of the window. Click
“Generate Set x” button.
4) If the aspect ratio set you want to input has values that have no
regular increment, type in the values in the column for the
particular set.
6.3.2 Notes
1) On the right side of this window, a list is displayed. This list
shows all modules that have been tagged as “Anchored”. The
6.4.2 Notes
1) The pick-up point symbol is green color triangle pointing
upward and the drop-off symbol is red color triangle pointing
downward.
6.5.2 Notes
1. Padding of empty space can be applied only to hard
modules.
2. Padding size may be different on all 4 sides of a module.
3. To apply padding to a given module, select it from the drop-
down list in the “Module Selection Control” frame on the
left side of the window. The selected module will be
displayed. Move the mouse pointer towards the boundary
of the module until the mouse pointer changes to a sizing
icon. Click and drag to pad the module.
4. Alternatively, enter the values for padding for one or more
sides in the data entry panel on the right and then click the
button labeled “Apply”.
5. Click the check box “Pad all modules the same way” if the
same padding has to be applied to all modules.
6. Set a grid size to suit the problem. During graphic click and
drag input, the padding snaps to the nearest grid point.
6.6.2 Notes
1) The matrix is displayed is a data grid. Click any cell to modify
the value.
2) By default, “Auto Cell Increment” option is on. With this
option turned on, cell value is incremented each time the user
clicks (left-click) inside a cell. Right-click causes the cell value
to decrement.
3) User may set the increment for “Auto Cell Increment” option.
4) If the data entry involves numbers that cannot be generated by
incrementing, turn the option off. With this option turned off,
click inside a cell to select the cell. Cursor will appear inside
the cell. Select the existing value inside the cell by dragging
the mouse pointer over it and then type in any desired value.
6.7.2 Notes
1) The first thing to do on this window is to select type of shape
from the combo box on the bottom right side of the window.
There are two options: “Rectangular Boundary” and
“Composite Boundary”.
6) Total module area and the area enclosed by the boundary are
displayed in the tool strip at the bottom of the graphics area.
6.8.2 Notes
1) Type in the desired value for the enclosure aspect ratio. Like
all other constraints, VIP-PLANOPT attempts to satisfy the
constraints while minimizing the cost. This constraint is not
necessarily exactly satisfied in all cases.
6.9.2 Notes
1) Upper bounds on distances may be imposed on any pair of
modules. Select Module I from the list of modules that appears
when the down arrow is clicked. Select Module J in a similar
way. Enter the desired value of the upper bound on the distance
between the two modules in the data entry cell under the label
“Upper Bound”. Click “Add/Replace” button.
2) The upper bounds may be modified for any of the constraints
added to the list. To modify a given constraint, select it from
the list. It will appear in blue color and the data will be copied
to the data entry cells above. Modify the values as required and
then click “Add/Replace” button. The constraint will be
updated.
3) To delete a constraint select it from the list then click the
“Delete selected” button.
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6.10.2 Notes
1) This window can only open when the optimized layout file
exists from a previous optimization of the same problem. If
the problem has not been optimized or if the plot data file has
been deleted or modified then this window will not open.
2) The main purpose of this window is to analyze the optimal
layout and compare it with user-modified layouts or other
imported layouts.
3) The user may move any module by clicking inside it and then
by dragging the mouse pointer to any desired location. This
operation results in a modified layout with a modified value of
the cost and other parameters. The user may compare the two
and evaluate the optimality of the layout generated by VIP-
PLANOPT. Any anchored modules may not be moved.
4) After a module is moved by the user from its optimized
location, the button will appear. This button when
clicked will restore the optimized layout.
5) Any user-modified layout must be free from any overlaps
between modules. If the user moves a module and relocates it
at a position that causes overlap then it is returned to its
previous position.
6) The cursor strip above the graphics area displays the
coordinates of the mouse pointer as the user moves it in the
graphics area.
7) A tool bar at the right side of the graphics area has several
other options for the user to control the display.
8) User has option to snap to grid. When this option is chosen, the
module moved by the user will snap according to snap option
selected in the combo box on the left of the tool strip.
7 BENCHMARK
PROBLEMS
Benchmark problems with the number of modules (departments)
ranging from small to large and cost matrices of varying sparseness
and randomness are required for a realistic evaluation of a layout
optimization program. Such a set of completely documented
benchmark problems involving unequal-area modules (departments)
does not exist in the published literature. There are several problems
that have been used as test problems in the published literature but
complete data for their layout is not given so the claimed cost for the
layout cannot be verified. There are some other problems whose
layouts have been shown in the published work but when the cost of
the layout is calculated from the layout shown in the paper, it does not
match the claimed cost obtained for that layout.
The best published result for this problem has a cost of 1264
whereas VIP-PLANOPT produces the optimal layout with a cost
of 1157 only.