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Layout Planning
Systematic Layout Planning & Intro to
Mathematical Layout Improvement
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Value-Added
A modification to the product to obtain business
Cross-Docking
Transforming incoming product to outgoing product without
Slotting
Selecting the location of SKUs in the storage zones. Goal is to
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Process Layout
(Job Shop)
Product Layout
(Mass Production Line)
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Schedule Data:
BOM
Routing/Assembly Chrt
Operations Process
Chart
Precedence Diagram
Scrap/Reject Rates
Equipment Fractions
Material Handling
Unit Loads
Storage Systems
Space Data:
Group Technology
From To Chart
Relationship Chart
Dept Footprint & Aisle
Space
Personnel Space
Parking Lot
Restroom/Locker room
Food Prep/Cafeteria
ADA Compliance
Efficiencies
Transportation Systems
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consideration of issues
Can work the process
manually or with computer
aides
Roadmap for the process is
good for communication
Adds the following stages:
Analysis
Search
Evaluation
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volume
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relationship is
shown graphically
Number of lines
similar to rubber
bands holding depts
together
Spring symbol to
push X relations
apart
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Layout Models
Mathematical Objective Functions
Mathematical models can be constructed to measure a design,
The best models are not always the most complex in fact many
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Layout Models
Mathematical Objective Functions
Assume we have these variables defined for n departments:
i is an index to the FROM department in a pair of departments
j is an index to the TO department in a related pair
Thus i and j could be the row/column indices for a From/To Chart
fij is the unit load FLOW from the i
th
to the j th department
th
th
th
to the j th dept
to the j th department
defined to be:
1 if the i th and j th departments share a common edge (border) or
0 if the departments have no common edge or only touch at a point
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Layout Models
Mathematical Objective Functions
Minimize the transportation cost:
n
y fijaij
max
i1 j1
f a
i1 j1
n n
f
i1 j1
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ij ij
ij
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Example
Mathematical Objective Function
Assume the From/To matrix (below)
max
y fijaij
i1 j1
200(1)+250(1)+300(1)+500(1)20(1)+350(0)+10(1)+175(1)+100(0) = 1415
200(1)+250(1)+300(1)+500(1)20(0)+350(0)+10(1)+175(1)+100(0) = 1435
200(1)+250(0)+300(1)+500(1)20(0)+350(1)+10(0)+175(1)+100(1) = 1625
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