Facility Layout 3

Improvement Methods –MULTIPLE

Tompkins Chapter 6.4.8

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The big picture of layout design. 1
Collect
3
Flow and
Generate or Relationship
Improve Data
Layout
2 4

Evaluate
Layout
5

Select
Layout

2
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 Layout Algorithms

Empty Facility, Improves on Initial

Construct from Scratch Solution (Layout)

Examples:
Examples:
QAP
Pairwise Exchange
MIP
CRAFT
SLP
MULTIPLE
Graph-based

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 Improvement methods

Simple Metaheuristics
Heuristics

Pairwise Exchange SABLE

CRAFT Genetic Algorithm
MULTIPLE Ant Colony
… …

Influenced by biological or
natural processes

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MULTIPLE is similar to CRAFT, except that it can exchange
any two departments (using Space Filling Curves)
1 2

4 3

7 8

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MULTIfloor Plant Layout Evaluation (MULTIPLE)

Warehouse
Assembly
Turning
Milling
Stores

Press
Plate
Improvement Algorithm
Stores – 12 6 9 1 4 –
Milling – – – – 7 2 –
Turning – 3 – – 4 – –

Discrete Representation Press

Plate
–
–
–
3
–
1
–
–
3
–
1
4
1
3
Assembly 1 – – – – – 7
Warehouse – – – – – – –

From-To Matrix

Distance-Based Objective

Pairwise Exchange with

steepest descent

Any two-way exchange is considered, even between floors.

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 MULTIPLE (cont.)
Discrete Representation => grids

Space Filling Curves are generated so that

the curve touches each grid in the layout

Check all possible exchanges before making a

swap to the best cost

Stop when no further improvement is found

or other predetermined stopping criteria

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Layout Algorithm Representation
Spacefilling Curve (SFC)
1 1 2 2 4 4

Area Values Layout Vector 1 1 2 2 4 4

ai = (8,6,4,6) 1-2-3-4 1 1 2 2 4 4

1 1 3 3 3 3
Parameter input Variable
Parameter input

2 4
1

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MULTIPLE initialization

1. Divide layout into grids.

2. Generate SFC

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A layout vector determines the order for
adding departments to the layout.
Layout Vector = 1- 2- 3 - …

Dept. Areas: ai = (12, 4, 6)

1 = 12 grids
2 = 4 grids
3 = 6 grids

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To exchange Layout Vector = 1- 2- 3 -…
departments, the
positions of the
departments in the
layout vector are
exchanged.
Layout Vector = 2- 3 – 1 - …

Dept. Areas: ai = (12, 4, 6)

1 = 12 grids
2 = 4 grids
3 = 6 grids

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 Horizontal Vertical
Multi-Floor Objective Function cost & distance cost & distance

 f (d )
Indices:
i, j departments
m floors
MIN ij c +d c
H H
ij ij
V V
ij ij
l lifts i j

Flow

𝑉
𝐻
𝑑𝑖𝑗 if 𝑑𝑖𝑗 =0 Binary for
where: 𝑑𝑖𝑗 = 𝑉 vertical distance
min𝑙 𝑑𝑖𝑙 + 𝑑𝑙𝑗 if 𝑑𝑖𝑗 >0

Area Constraint: a i  Am Am = area of floor m

im ai = area of dept i

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Example - MULTIPLE Each grid 10 ft by 10 ft.
6 departments.
Each dept requires 1 grid.
All cij = $0.1/ft.
F 1 2 3 4 5 6
1 - 100 10 5 Space Filling Curve =
2 - 25 A- D-E- B- C- F
3 - 25
4 - 10
5 - 100 Initial Layout Vector = 6-2-3-4-5-1
6 -
Dist A B C D E F 2 3 1
A - 10 20 10 20 30
B - 10 20 10 10 6 4 5
C - 30 20 10
D - 10 20
E - 10
F -

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 Example – Initial layout cost
F 1 2 3 4 5 6 Initial Layout Vector = 6-2-3-4-5-1
1 - 100 10 5
2 - 25
3 - 25
2 3 1
4 - 10 6
Layout 6-2-3-4-5-1
4 5
5 - 100
6 -
Pair Flow Cost Dist Total
Cost = 100*20*0.1
1-2 100 0.1 20 200
+ 10*10*0.1 1-3 10 0.1 10 10
1-5 5 0.1 10 5
+ 5*10*0.1
2-6 25 0.1 10 25
+ 25*10*0.1 3-4 25 0.1 10 25
4-5 10 0.1 10 10
+ 25*10*0.1 5-6 100 0.1 20 200
+ 10*10*0.1
Total 475
+ 100*20*0.1
Same D-based score,
= 475 different format

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 Example – Exchange 1 and 2
Each grid 10 ft by 10 ft.
F 1 2 3 4 5 6 New Layout Vector = 6-1-3-4-5-2
1 - 100 10 5
2 - 25
3 - 25 1 3 2
4 - 10
5 - 100 6 4 5
6 -

Pair Flow Cost Dist Total

1-2 100 0.1 20 200
1-3 10 0.1 10 10
1-5 5 0.1 30 15
2-6 25 0.1 30 75
3-4 25 0.1 10 25
4-5 10 0.1 10 10
5-6 100 0.1 20 200

Total 535

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 Example – First iteration Initial Layout, $475

2 3 1
6 4 5
$535 $435 $475
1 3 2 3 2 1 2 5 1
6 4 5 6 4 5 6 4 3
$405 $495 $495
2 1 3 4 3 1 2 6 1
6 4 5 6 2 5 3 4 5
$475 $315 $405
2 3 4 5 3 1 2 3 1
6 1 5 6 4 2 6 5 4
$695 $675 $435
2 3 5 6 3 1 2 3 1
6 4 1 2 4 5 4 6 5

$315 Selected $495 $535

2 3 6 2 4 1 2 3 1
1 4 5 6 3 5 5 4 6

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Example – Second iteration Current Layout, $315

123456 2 3 6
1 4 5

$335 $405 $315

213456 Exchange 1-2 Exchange 2-3 Exchange 3-5

$315 $335 $425

321456 Exchange 1-3 Exchange 2-4 Exchange 3-6

$435 $495 $435

Exchange 1-4 Exchange 2-5 Exchange 4-5

$715 $715 $315

Exchange 1-5 Exchange 2-6 Exchange 4-6

$475 $315 $355

Exchange 1-6 Exchange 3-4 Exchange 5-6

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No more exchanges ! Final Layout. Is it optimal?
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Exchanges in MULTIPLE are accomplished by changing the layout
vector and reassigning grids via the SFC

Initial Layout Vector = 6-2-3-4-5-1

Exchange 2 and 5 2 3 1
6 4 5

New Layout Vector = 6-5-3-4-2-1 5 3 1

6 4 2

Note: The spacefilling curve is set at the beginning and remains the same
throughout the algorithm execution.

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 ICE #8 MULTIPLE
Question: What is the final cost (i.e., score) to at the end of iteration 1?

Score = 94

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MULTIPLE improvements over CRAFT
Multi-floor Accurate cost
capabilities savings

Exchange any Considers

two exchanges
departments across floors

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To incorporate a constraint on irregular shaped
departments, departments are measured for closeness
to rectangular
Smallest enclosing
SER
rectangle

SER ratio SER length/ SER width

Normalized Shape Factor

Omega
(also called Omega)

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Measure 1: SER (Smallest Enclosed Rectangle)
Enclosed Rectangle Area / Department Area

5 5*2 + 2*3 = 16
Department Area = 16
2
5 25 16 = 1.5625
2

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Measure 2: SER Ratio = SER length/ SER width
Enclosed Rectangle Length / Enclosed Rectangle Width
5

5 5 5 =1

Shape factor of 1 may

Department Area = 16 not be optimal

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Measure 3: Omega Shape Factor
Ω = Department Perimeter / Ideal Department Perimeter

What is the ideal

8
department perimeter?
2
Square => Ω = 1

Ω = 20/16 = 1.25

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