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IE 368: FACILITY DESIGN AND OPERATIONS MANAGEMENT

Lecture Notes #6
Computerized Methodologies for Facilities Layout
IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Computerized Layout Algorithms

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Objective Understand how different quantitative concepts can be applied to generate layout alternatives
Discrete and continuous departments Different algorithms
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(cont.)
CRAFT Computerized Relative Allocation of
Facilities Technique
Inputs
From-To chart Cost matrix Initial layout
Objective
Distance based
Department representation
Discrete grids No shape restrictions
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(cont.)
CRAFT automatically implements a modified pairwise
interchange method
Many details must be addressed
CRAFT Algorithm
1. Start with an initial layout with all departments made up of individual square grids (Note: each grid represents the same amount of space) 2. Estimate the best two-way department exchange assuming department centroids exchange exactly
Departments i and j exchange New centroid i = centroid j New centroid j = centroid i
Only consider exchanging adjacent departments
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(cont.)
CRAFT Algorithm (contd)

3. Execute the exchange if the estimated cost of the best exchange in (2) is lower than the best cost found so far
The actual result of the exchange is problem-dependent
4. If the estimated cost of the best exchange in (2) is higher than the best cost found so far, stop
Else, go to 1
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Example
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Example (cont.)
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Example (cont.)
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Example (cont.)
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Example (cont.)
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Example (cont.)
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(cont.)
CRAFT Additional notes
Dummy departments
Can be fixed in location Can model irregular shapes, obstacles, extra space, aisles,
CRAFT usually will not (for large layouts) find the global optimal solution
Therefore, run CRAFT with different initial layouts
Today it is not necessary to approximate centroids due to availability of computing power Adjacency does not always mean that departments can be exchanged and leave departments intact
IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT WINTER 2012
In-class Exercises
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Exchange departments 2 and 4 in the layout shown below. All
departments are fixed except 2 & 4.

5 5 5 5 2 1 1 5 5 5 5 2 1 1 5 5 5 5 2 2 2
6 6 6 4 2 3 3
6 6 4 4 2 3 3
If the flow from A to B is 4, A to C is 3, and B to C is 9, and all move
costs are 1, what is the layout cost?

C C C C C C B B B C C B A B C
C B A B C
C B B B C
C C C C C
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In-class Exercises (cont.)

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5 5 5 5 1 1
5 5 5 5 1 1
5 5 5 5
6 6 6
6 6
5 5 5 5 1 1
5 5 5 5 1 1
5 5 5 5
6 6 6
6 6
5 5 5 5 1 1
5 5 5 5 1 1
5 5 5 5
6 6 6
6 6
3 3
3 3
3 3
3 3
3 3
3 3
A B C
A -B C
A B C
A -B --WINTER 2012
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In-class Exercise
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When CRAFT evaluates the exchange of departments, instead of actually exchanging departments, it only exchanges the centroids of departments
a. What is the impact of this method if all departments are the same size? b. Given the data below (each square is 1x1), what does the evaluation of the exchange of depts. B and C indicate and what is the actual result?
To From A B C A x 2 0 B 10 x 0 C 6 7 x
A A A A A A A A A C C C B B B B B B B B B B B B
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In-class Exercise
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(cont.)
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In-class Exercise
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(cont.)
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(cont.)
BLOCPLAN Inputs
Activity relationship chart From-To chart (if desired) Initial layout
Objective
Adjacency based or distance based
Continuous Restricted to horizontal bands across the facility Maximum number of departments = 18 (in the software)
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(cont.)
BLOCPLAN automatically implements a pairwise
interchange method
Can also accommodate manual exchange
BLOCPLAN has a straightforward method of
converting an activity relationship chart to a numerical rating

Default scale: A=10, E=5, I=2, O=1, U=0, X=-10 Can modify the scale if desired
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(cont.)
BLOCPLAN will also convert a from-to chart to an
activity relationship chart

From-To A A B C D X 1 2 5 B 10 X 3 8 C 5 1 X 10 D 4 20 10 X
Flow Between A A B C D X B 11 X C 7 4 X D 9 28 20 X
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(cont.)
BLOCPLAN also computes a
layout, which is:
Rel-Dist value for a
f
i 1 j 1
ij
d ij
The fij in the above equation are the relationship values
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In-class Exercise
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6.32 Suppose the following activity relationship chart
and layout are given (each grid is a unit square)

Compute the efficiency rating Compute the Rel-Dist value
1 1 2 3 4 5 2 A 3 U U 4 E U U 5 U I X A 5 3 4
A=10, E=5, I=2, O=1, U=0, X=-10

In-class Exercise
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(cont.)
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(cont.)
MULTIPLE MULTI-floor Plant Layout Evaluation Inputs

From-To chart (if desired) Cost matrix Initial layout Lift data (if using for a multi-floor layout)
Objective
Distance based
Discrete grid
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(cont.)
MULTIPLE automatically implements a pairwise
interchange/exchange method
simulated annealing
Can also implement a metaheuristic search procedure called
MULTIPLE overcomes inflexibilities existing in other
methods presented
CRAFT Can only exchange adjacent departments BLOCPLAN Departments restricted to bands across the facility
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(cont.)
MULTIPLE also is applicable to multi-floor facility layout It overcomes extensions of other methods to multi-floor layout
CRAFT
Department splitting occurs No consideration of lift locations Independent floor layout
MULTIPLE allows for more departmental shape flexibility than
BLOCPLAN and more department shape control than CRAFT MULTIPLE also can include facility constraints such as walls, fixed department locations, and obstructions in a straightforward manner
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(cont.)
Fundamental basis for the layouts generated by MULTIPLE
A space filling curve or hand generated conforming curve is used

A space filling curve is a mathematical entity with a precise definition
MULTIPLE uses one type of space filling curve called a Hilbert
curve
Intuitively think of a space filling curve as a path traveled when moving from grid to grid in a layout The path will pass through the center of each grid and can only move to adjacent grids All turns in the path must be right-angle turns Used to reconstruct a new layout when any two departments are exchanged

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(cont.)
Example of a
space filling curve
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(cont.)
Example of a hand generated
conforming curve
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(cont.)
How does MULTIPLE use these curves to generate
layouts?
With a curve established for a facility

1. Define a department layout sequence 2. Place the departments in the facility in department sequence along the curve, grid by grid
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(cont.)
Example
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(cont.)
Optimizing MULTIPLE can implement a pairwise exchange/interchange algorithm

All possible exchanges can be examined since the exchanges are exchanges in sequence position Exchanging departments of different sizes and the impact on the rest of the layout is handled by the space filling curve
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Figure 6.32 (a) & (b)

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In-class Exercise
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Controlling Department Shape

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MULTIPLE incorporates a method to control
department shape Let
Pi denote the length of the perimeter of department i Ai denote the area of department i
Overall principle For a fixed department area, as the department shape becomes more irregular, its perimeter gets larger
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Controlling Department Shape (cont.)

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Example MULTIPLE represents departments as
grids.
is more irregular than
P= 20 sides
P= 12 sides
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The minimum perimeter occurs for a department
when it is square in shape
Assumes the department is non-circular, and represented as a grid made up of individual square units
Let Pi* = minimum perimeter occurring when
department i is square
Pi 4 Ai
*
If a square represents the ideal department shape, a
normalized shape measure for a department can be constructed
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Let
i = Normalized shape measure for department i
Pi Pi i * Pi 4 Ai
i 1.50 is recommended for MULTIPLE
A separate upper limit for
be specified
Exchanges resulting in
i for each department can
i upper limit are rejected

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In Class Exercise
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Use layout options 1, 2, and 3 to fill in the information in the
table
1 6
(1)
2 7 3 8 4 9 5 10 8 1 5 9
(2)
2 6 3 7 4 2 3 7 15
(3)
1 4 8 5 9 16 6
11 12 13 14 15 16
10 11 12 15 16
13 14
10 11 12 13 14
i 1 2 3
Pi
Ai
P i Ai
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Multi-Floor Facility Layout

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More common in older cities and buildings (e.g.,
Detroit) and in countries where land is very expensive Less flexibility of use of total facility space
A multi-floor building may have enough total space but may not be able to accommodate departments on different levels without splitting
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Multi-Floor Facility Layout (cont.)

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Additional decisions/constraints The number and location of vertical material handling devices Restriction of certain departments to specific floors
First floor restrictions due to floor loading capacity Ceiling heights Heat/chemical use and/or generation
Departments may have to be kept contiguous
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Modified distance-based objective

H H V V z (cij dij cij dij ) fij i 1 j 1 m m
where,
H cij Cost of moving one unit one horizontal distance unit V cij Cost of moving one unit one vertical distance unit
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Example
Floor r Floor s
Dept. j
Dept. i
Vertical Travel
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Another heuristic approach 1. Assign departments to floors to minimize vertical travel distance. Can also be difficult, but for two or three floor and a small number of departments, this can be completed 2. Treat each floors layout as a single floor layout problem
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Heuristics in Computer-Aided Layout

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The mathematical description or formulation of the
layout problem is a mathematical specification of the optimization (IE 425) problem that a computer-aided layout algorithm (e.g., CRAFT, BLOCPLAN, MULTIPLE) attempts to solve
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Heuristics in Computer-Aided Layout (cont.)

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Example for a simplified problem called the quadratic assignment
problem (QAP)
Deciding what locations to assign to departments (or facilities). All departments can be located at any site
Let, fij Material flow between departments i and j. d hk Distance between sites h and k . cij Cost of moving one unit of material one distance unit between departments i and j. Minimize z cij fij d hk xih xik
i 1 j 1 h 1 k 1 m m m m
Subject to:
x
i 1 m
ih
1 for all h (only one dept. assigned per site). 1 for all i (each dept. assigned to a site).
x
h 1
ih
xih {0,1}

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The optimization problems that CRAFT, BLOCPLAN
and MULTIPLE attempt to solve are more complicated due to department size considerations These problems share one common feature
They are very difficult to solve (find the best or a best solution with respect to the given objective function) Procedures exist but they can become so computationally expensive that all of the worlds computing power cannot solve them
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Example MULTIPLE MULTIPLE simplifies the layout problem by restricting layouts to be constructed in sequence on the space filling curve MULTIPLE searches for the best or optimal sequence Finding this sequence can also be very difficult as the number of departments increases
Example 25 departments. How many sequences?
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Example MULTIPLE There are a lot of possibilities!
There are 25! different schedules The first task has 25 choices, the second has 24 choices. 25! = 15,511,210,043,330,985,984,000,000 25! Pennies would cover the whole State of Texas to a height of over 6,000 miles (Hopp & Spearman 1996)

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MULTIPLE uses pairwise exchange as a method to
find a good sequence
MULTIPLE also uses a search method called simulated annealing
These search methods are called
heuristics
Heuristics are procedures whose objective is to find
an optimal solution, but whose performance cannot be guaranteed CRAFT and BLOCPLAN are also using heuristic search procedures
Example
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Traveling salesman problem
2 1
N
5 Distances from city i to city j are known. Find a minimum distance tour. A tour starts and ends at the same city and visits no city more than once.
3 4
7 6
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Example Traveling Salesman Problem Heuristic

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Nearest neighbor heuristic From the starting city, successively move to the closest city not yet visited The last link completes the tour
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Example Traveling Salesman Problem Heuristic In-Class Exercise

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Starting in City 3, apply the
heuristic. Move to the closest city not yet visited

Distance Matrix City/City 1 2 3 4 5 1
0 132 217 164 58
nearest neighbor
2
132 0 290 201 79
3
217 290 0 113 303
4
164 201 113 0 196
5
58 79 303 196 0
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Example Traveling Salesman Problem Heuristic Improvement

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For each city, apply the
heuristic. Select the best tour.

Distance Matrix City/City 1 2 3 4 5 1
0 132 217 164 58
nearest neighbor
2
132 0 290 201 79
3
217 290 0 113 303
4
164 201 113 0 196
5
58 79 303 196 0
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Traveling Salesman Problem Heuristic

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Personnel Requirements
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General information on: Parking Restrooms Your reading in Chapter 4

Food service Health service
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IE 368: FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Methodologies for Facilities Layout

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

CRAFT Computerized Relative Allocation of

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

CRAFT automatically implements a modified pairwise

Many details must be addressed

Only consider exchanging adjacent departments

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

CRAFT Algorithm (contd)

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

CRAFT Additional notes

Exchange departments 2 and 4 in the layout shown below. All

departments are fixed except 2 & 4.

If the flow from A to B is 4, A to C is 3, and B to C is 9, and all move

costs are 1, what is the layout cost?

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

In-class Exercises (cont.)

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

BLOCPLAN automatically implements a pairwise

Can also accommodate manual exchange

BLOCPLAN has a straightforward method of

converting an activity relationship chart to a numerical rating

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

BLOCPLAN will also convert a from-to chart to an

activity relationship chart

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

BLOCPLAN also computes a

layout, which is:

Rel-Dist value for a

The fij in the above equation are the relationship values

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

6.32 Suppose the following activity relationship chart

and layout are given (each grid is a unit square)

A=10, E=5, I=2, O=1, U=0, X=-10

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

MULTIPLE MULTI-floor Plant Layout Evaluation Inputs

IE 368. FACILITY DESIGN AND OPERATIONS MANAGEMENT

Computerized Layout Algorithms

MULTIPLE automatically implements a pairwise

Can also implement a metaheuristic search procedure called