Computerised Layout Planning

COMPUTERISED LAYOUT PLANNING
7/9/2012
Computerized Layouts / R K BANSAL
LAYOUT PLANNING PACKAGES

CONSTRUCTION PROGRAMS CORELAP ALDEP PLANET, LSP, LAYOPT, RMA Comp I IMPROVEMENT PROGRAMS CRAFT RUGR (based on graph theory)
7/9/2012 Computerized Layouts / R K BANSAL 2
ALDEP Automated Layout DEsign Program Development within IBM Seehof, J.M and W.O. Evans Automated Layout Design Program:, The Journal of Industrial Engineering, Vol 18, No. 12, 1967, pp 690 - 695.
A E I O U X
ALDEP based on closeness Ratings 43 = 64 43 = 16 41 = 4 40 = 1 0 = 0 -45 = -1,024
Can handle 63 departments on 3 floors

Scoring Pattern of ALDEP

For a Cell (0) the scores of all eight neighbours are added together (as per REL chart)
Then the cell (0) is deleted so that it is not counted again. We then proceed to the next cell till all cells are exhausted. The final cumulative score is the Layout Score
5
2 1 8
3 0 7
4 5 6
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Inputs Requirements for ALDEP

Length, Width and area requirements for each floor. Scale of layout printout (max 30x50) No. of depts. in the layout No. of layouts to be generated Minimum allowable score for an acceptable layout. Minimum dept. preference (A or E) REL chart for the depts. Location and size of restricted area for each floor.
Computerized Layouts / R K BANSAL 6
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Vertical Scanning Pattern for placing depts. in ALDEP
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Mechanism of ALDEP : (a) 1st dept placed randomly. (b) Scan the REL chart for a dept with A,E rating (min dept preference) continue this step till no such dept exists Pick up the next dept. in a random fashion and again proceed by scanning the REL chart [step (b)].
(c)
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An Example of ALDEP
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The Available Space
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10
Placement of 1st Department

B
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11
Placement of 2nd Department

B
D D
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Placement of 3rd Department

B
D D
Placement of 4th Department

C B A C
D
D
Final Layout
C
B
D D
Features of CORELAP
Retain the rectangular shape of each department The layout is built around a central department Placement and choice based on the total and current placement ratio The final layout may end up with irregular boundaries
CRAFT
Computerized
Relative
Allocation of Facilities
Technique
Armour, G.C. and E.S.Buffa, A Heuristic Algorithm and Simulation Approach to Relative Location of Facilities Management Science, Vol 9, No. 1, 1963, pp 294-309 Buffa, E.S, G.C. Armour and T.E. Vollman Allocating Facilities with CRAFT Harvard Business Review, Vol 42, No.2, 1964, pp 136 - 159.
An Example of CRAFT
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Product, Process & Schedule Data

Product Processing sequence 1 2 3 ABCBCD ACBD ACBCBD Daily No of items production in Trolley 100 50 200 5 5 40 Trolley loads/ day 20 10 5
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20
Initial Layout
From /To
A D
A B
--1 2 1
1 --1 2
2 1 --1
1 2 1 ---
C D
Distance Matrix for initial layout (Assuming Rectilinear Distances)

Load Matrix
From/To
A ---
B 20 --45
C 15 45 ---
A B C D
15 20 ---
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Unit Cost Matrix

From/To
A --1 2 1
B 1 --1 1
C 2 1 --1
D 1 1 1 ---
A B C D
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Load x Unit Cost Matrix (Flow Matrix)

From /To
A ---
B 20 --45
C 30 45 --75
D 50 15 20 --35
24
A B C D
60 65 00
00
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Initial Layout (Distance Matrix)

From /To A B A B C D
--1 2 1
1 --1 2
2 1 --1
1 2 1 ---
C D
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Material Handling Effort for Initial Layout

From /To
A ---
B 20 --45
From /To
C 30 45 --A ---
D 15 20 --B 20 --90 C 60 45 ---
From A /To A B C D --1 2 1
A B C D
1 --1 2
2 1 --1
1 2 1 ---
D 80 30 20 --75 110 00 265

26
A B C D
00
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110 105 50
Pair wise Exchanges

Initial Layout A D B C
265 Material Handling Effort
AB B D A C
AC C D B A
AD D A B C
BC A D C B
BD A B D C
CD A C B D
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Alternative 1 (Distance Matrix)

A A B C D ---1 1 2 B 1 ---2 1 C 1 2 ---1 D 2 1 1 ----
B D A C
Material Handling Effort = Flow x Distance Matrix = 220


A A B C D ---1 2 1 B 1 ---1 2 C 2 1 ---1 D 1 2 1 ----
C D B A


A A B C D ---2 1 1 B 2 ---1 1 C 1 1 ---2 D 1 1 2 ----
D A B C


A A B C D ---2 1 1 B 2 ---1 1 C 1 1 ---2 D 1 1 2 ----
A D C B


A A B C D ---1 2 1 B 1 ---1 2 C 2 1 ---1 D 1 2 1 ----
A B D C


A A B C D ---1 1 2 B 1 ---2 1 C 1 2 ---1 D 2 1 1 ----
A C B D

Pair wise Exchanges

Initial Layout A D B C
Material Handling 265 Effort
AB B D A C
220
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AC C D B A
265
AD D A B C
215*
BC A D C B
215*
BD A B D C
265
CD A C B D
220
34
Limitations of CRAFT
CRAFT yields a good heuristic solution that does not guarantee optimality This is because not all (n!) combinations are evaluated, but only (nC2) pair-wise exchange options are considered. In case departments are on unequal size, their centroids are exchanged which can result in irregular shapes of departments
n 1 2 3 4 5 6 7 8 9 10 11 12
8
Factorial Growth n C2 = n! [n(n-1)]/2 0 1 1 2 3 4 6 24 10 120 15 720 21 5040 28 40320 36 362880 45 3628800 55 39916800 66 479001600
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20! = 2.4329 X 1018

30! = 2.65252 X 1032 40! = 8.15915 X 1047
20C = 2
190
30C 2
= 435 = 780
40C 2
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Summary of the CRAFT procedure

This example demonstrates one iteration of the basic CRAFT procedure The best layout so produced is compared with the starting layout. If it is inferior to the starting layout, the starting layout is declared optimal and the search stops Otherwise a new iteration with the discovered layout as the starting node is initiated
Conclusions
Computer packages for layout planning
Construction programs (ALDEP, CORELAP) Improvement programs (CRAFT)
Based on SLP procedure

Activity relationships Material Handling Effort
Good for generation of alternative layouts Limitations of irregular shapes, ignoring realistic constraints

Computerised Layout Planning

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Computerised Layout Planning

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COMPUTERISED LAYOUT PLANNING

Computerized Layouts / R K BANSAL

LAYOUT PLANNING PACKAGES

ALDEP based on closeness Ratings 43 = 64 43 = 16 41 = 4 40 = 1 0 = 0 -45 = -1,024

Can handle 63 departments on 3 floors

Scoring Pattern of ALDEP

Computerized Layouts / R K BANSAL

Inputs Requirements for ALDEP

Vertical Scanning Pattern for placing depts. in ALDEP

Computerized Layouts / R K BANSAL

Computerized Layouts / R K BANSAL

The Available Space

Computerized Layouts / R K BANSAL

Placement of 1st Department

Computerized Layouts / R K BANSAL

Placement of 2nd Department

Computerized Layouts / R K BANSAL

Placement of 3rd Department

Placement of 4th Department

Computerized Layouts / R K BANSAL

Product, Process & Schedule Data

Computerized Layouts / R K BANSAL

Distance Matrix for initial layout (Assuming Rectilinear Distances)

Computerized Layouts / R K BANSAL

Unit Cost Matrix

Computerized Layouts / R K BANSAL

Load x Unit Cost Matrix (Flow Matrix)

Computerized Layouts / R K BANSAL

Initial Layout (Distance Matrix)

Computerized Layouts / R K BANSAL

Material Handling Effort for Initial Layout

D 15 20 --B 20 --90 C 60 45 ---

From A /To A B C D --1 2 1

D 80 30 20 --75 110 00 265

Computerized Layouts / R K BANSAL

Pair wise Exchanges

Computerized Layouts / R K BANSAL

Alternative 1 (Distance Matrix)

Material Handling Effort = Flow x Distance Matrix = 220

Alternative 2 (Distance Matrix)

Material Handling Effort = Flow x Distance Matrix = 265

Alternative 3 (Distance Matrix)

Material Handling Effort = Flow x Distance Matrix = 215

Alternative 4 (Distance Matrix)

Material Handling Effort = Flow x Distance Matrix = 215

Alternative 5 (Distance Matrix)

Material Handling Effort = Flow x Distance Matrix = 265

Alternative 6 (Distance Matrix)

Material Handling Effort = Flow x Distance Matrix = 220

Pair wise Exchanges

Computerized Layouts / R K BANSAL

20! = 2.4329 X 1018

Computerized Layouts / R K BANSAL

Summary of the CRAFT procedure

Based on SLP procedure

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