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Layout Planning Models,Layout Planning Models,A gorit ms an computerize
iA gorit ms an computerize
i
1. Tompikins et al., Facility Planning, 3rd edition, John Wiley & Sons Ltd.,
S ngapore, .
2. Richard L.Francis et al., Facility Layout and Location: an analytical
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approc , n e t on, rent ce a o n a t ., .
3. Dr-Ing. Daniel Kitaw, Industrial Management and Engineering Economy
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Introduction
Introduction
The generation of layout alternatives is a critical stepn e ac es p ann ng process, s nce e ayou
selected will serve to establish the physical
relationships between activities.
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CONTD
CONTD
Which comes first, the material handling system or
Centralized versus decentralized storage of work
n process , oo ng, an supp es Fixed path versus variable path handling
The degree of automation used in handling
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,control, and computer control of materials.
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Layout proceduresLayout procedures
A number of different procedures have been developedo a e ac es p anner n es gn ng ayou s.
Improvement type
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Apples plant layout procedureApples plant layout procedure rocure e as c a a
Analyze the basic data Desi n the roductive rocess
Plan service and auxiliaryactivities
Plan the material flow pattern
Consider the general material
Determine space requirements
Allocate activities to total space
an ng p an
Calculate equipment requirement
Plan individual workstations
Construct master layout
Evaluate ad ust and check the
Select specific material handlingequipment
layout with appropriate persons
Obtain approvals
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oor na e grou s o re a eoperations
Design activity interrelationships
Follow up on implementation ofthe layout.
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Reeds plant layout procedureReeds plant layout procedure
Analyze the product or products to be produced
Determine the process required to manufacture the product Prepare layout planning charts
Determine workstations
Ana yze storage area requirements Establish minimum aisle widths
s a s o ce requ remen
Consider personnel facilities and services
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Provide for future expansion
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ContdContd
Layout planning chart is the most important single
phase of the entire layout process, it incorporates theo ow ng:
Flow process, including operations, transportation,
storage an inspection Standard time for each operation
Machine selection and balance
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ContdContd
Layout planningchart
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Systematic Layout Planning(SLP) procedureSystematic Layout Planning(SLP) procedure
Systematic Layout Planning (SLP) methodology was
.
The framework is uses activit relationshi dia ram as
a foundation activity.
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SLP contdSLP contd
Based on the input data and anunderstanding of the roles andre a ons ps e ween ac v es, amaterial flow analysis(from-to-chart )and an activity relationship
performed.
From the anal sis erformed, arelationship diagramis developed.
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ContdContd
The relationship diagram positions
activities spatially.
Proximities are typically used to reflect
e re a ons p e ween pa rs o
activities.
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ContdContd
Relationship diagram Space relationship diagram
4 - 12Alternative block layouts
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Algorithmic approachesAlgorithmic approaches
Algorithmic approach is a formal procedure that cane p e ayou ana ys o eve op or mprove a ayou ,
and it provide objective criteria to facilitate the
evaluation of various layout alternatives that emerge
n e process.
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Algorithm classificationAlgorithm classification
os ayou a gor ms can e c ass e accor ng o
the type of input data they requires.
Qualitative flow data(such as relationship chart)
Quantitative flow data(such as flow matrix
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Some al orithms acce ts both relationshi chart
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and from-to-chart
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ContdContd
Layout algorithms can also be classified according totheir objective functions.
Maximizin an ad acenc score
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ContdContd
m = the number of departments
fij = the flow from department i to department j(unitload/unit time)
cij = t e cost o moving a unit oa one istance unitfrom department i to j
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ij = e s ance rom epar men o
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ContdContd
m = the number of departments
fij = the flow from department i to department j(unitload/unit time)
xij = t e a jacent o epartment i an j in t e ayout
The adjacency score is helpful in comparing two or
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more a erna ve ayou s
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Modeling techniques/methodsModeling techniques/methods
methods used in various layout algorithms;a rw se exc ange me o A graph based method
CRAFT BLOCPLAN
MIP
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MULTIPLE
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Graph-based methodGraph-based method
The graph-based method is a construction-
.
.
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Graph-based methodGraph-based method
its new five de artments of e ual sizes.
9
1
9
0
0
1012
13
720
3
3
5
4
12
10
20 2
138
0
2
4
5
0
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Relationship chart Relationship diagram
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Graph-based methodGraph-based method
Step 1: from the relationship chart select a department.
9
1
8
0
1012
133
2
0
2
4
5
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Departments 3 and 4 are selected to enter the graph.
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Graph-based methodGraph-based method
Step 2: Select the third department to enter, the third
weights with respect to departments 3 and 4.
3 4 Total
1 8 10 182
1312
5 0 2 2 3 420
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epartment s c osen w t a va ue o .
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Graph-based methodGraph-based method
Step 3: Pick the fourth department to enter by
unassigned departments represented by a nodeon a face of the graph 22 3 4 Total
1 9 8 10 27(Best) 13129
3 4
8 10
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Department 1 is chosen with a value of 27.
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Graph-based methodGraph-based method
Step 4: Determine on which face to insert the last.
1 2 3 4
2
13
12 9
Faces Total 5
1
810
1-2-3 7
1-2-4 9(best)
2
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2-3-4 9(best)
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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)
Introduced in 1963 by Armour, Buffa, and Vollman.
layout of the facilities.
e ac y s m rove y sw c ng wo or reedepartments to help arrange the facility in an optimal
.
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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)
o From-To Chart,o Cost Matrix,
o Distances determined for a iven la out and an
Initial layout. Cra t is used when the nu ber o de art ents is so
large that the computation by hand would be very
intensive and make the improvement not worth the
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time for many companies.
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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)
o
Attempts to minimize transportation cost,ransportation cost= ow istance unit cost
o CRAFT is a path-oriented method, the final layout is
dependent on the initial layout.o Re uires an assum tion that:
i. Move costs are independent of the equipment
utilization and
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ii. Move costs are linearly related to the length of
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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)
requ remen s:
o Initial layouto Flow data
o Total number of departments
o Fixe epartments an t eir ocation
o Area of departments
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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)
e proce ures a op e or us ng are:
o Determine department centroids.o Calculate rectilinear distance between centroids.
.
o Consider department exchanges of either equal area
boarder.
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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)
o e erm ne ranspor a on cos o eac epar men a
interchange.o Se ect an imp ement t e epartmenta interc ange
that offers the greatest reduction in transportation.
o Repeat the procedure for the new layout until non erc ange s a e o re uce e rans or a oncost.
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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)
a or sa van ages o us ng
o Because the basis is the cost of material handling,on y pro uction epartments are consi ere . Noservice departments are considered.
o
An initial idea of the layout is required. Thereforethe technique is only applies to the modification ofan ex s ng ayou .
o The distances between the departments is taken as
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s ra g nes w ereas n prac ce movemen susually rectangular along ortagonal lines.
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Computerized Relative Allocation of Facility Technique(CRAFT)Computerized Relative Allocation of Facility Technique(CRAFT)
cost matrix. Use Craft algorithm to obtain layout. Theinitial layout and the flow matrix is shown below
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Initial layout Flow matrix
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COmputerized RElationship LAyout Planning (CORELAP)COmputerized RElationship LAyout Planning (CORELAP)
eve ope or ma n rame compu ers
Adjacency
based method, , , ,
values Selection of the de artments to enter the la out is
based on Total Closeness Rating. Total Closeness Rating (TCR) for a department is the
sum o t e numerica va ues assigne to t e c osenessrelationships between the department and all other
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.
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COmputerized RElationship LAyout Planning (CORELAP)COmputerized RElationship LAyout Planning (CORELAP)
epar men se ec on
1. The first department placed in the layout is the one. ,choose the one with more As (Es, etc.).
2. If a de artment has an X relationshi with the first
one, it is placed last in the layout. If a tie exists,choose the one with the smallest TCR value.3. T e secon epartment is t e one wit an A
relationship with the first one (or E, I, etc.). If a tie
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, .
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COmputerized RElationship LAyout Planning (CORELAP)COmputerized RElationship LAyout Planning (CORELAP)
. a epar men as an re a ons p w e seconone, it is placed nexttothelast or last in the layout.
,value.
5. The third de artment is the one with most A E I
etc.) relationships with the already placeddepartments. If a tie exists, choose the one with thegreatest TCR va ue.
6. The procedure continues until all departments have
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.
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COmputerized RElationship LAyout Planning (CORELAP)COmputerized RElationship LAyout Planning (CORELAP)
e p acemen o epar men s s ase on efollowing steps:
1. T e irst epartment se ecte is p ace in t emiddle.
2. The placement of a department is determined byevaluating PR for all possible locations around thecurren ayou n coun erc oc w se or er eg nn ngat the western edge.
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. e new epar men s oca e ase on egreatest PR value.
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ExampleExample
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ALDEP ProcedureoRandomly selects the first departmentoOut o those de art ents which ha e A
relationship with the first one (or E, I, etc. minlevel of importance is determined by the user) itselects randomly the second department.
oIf no such department exists it selects the secondone com e e y ran om y
oThe selection procedure is repeated until all the
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Department placement
Starts from upper left corner and extends it
downward Vertical sweep pattern
Adjacencybased evaluation
,and the scores
Re eats the rocedure max 20 la outs er run
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User evaluation
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