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

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

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

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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

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Muther’s
Systematic Layout
Planning (SLP)
Procedure

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Space Relationship Diagram

Relationship Diagram

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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)

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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)

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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)

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

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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

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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

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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

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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

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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

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5
 Computer-Aided Layout
Techniques

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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

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6
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The Impact of Change Flexibility

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

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7
Flexible Layout

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