Chapter Four

Solving Layout Problems

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 4.1 Introduction to Solving of Layout
Problems
Different types of facility layout procedures have been suggested by
different authors and scholars. Among the main facility layout
procedures the following are well known.
i. Immer’s Basic Steps (1950)
ii. Naddler’s Ideal System Approach (1961)
iii. Reed’s Plant Layout Procedure (1961)
iv. Muther’s Systematic Layout Planning (SLP)
(1961)
v. Apple’s Plant Layout Procedure (1977)

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 Immer’s Basic Steps

Immer described the analysis of a layout problem as follows:

“This analysis should be composed of three simple steps, which
can be applied to any type of layout problem. These steps are:
1. Put the problem on the paper.
2. Show lines of flow.
3. Convert flow lines to machine lines.”

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 Naddler’s Ideal System Approach
The ideal system approach is based on the “theoretical
ideal system.” the following hierarchical approach
toward design:
1. Aim for “theoretical ideal system.”
2. Conceptualize the “ultimate ideal
system.”
3. Design the “technologically workable ideal
system.”
4. Install the “recommended system.”
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SLP is a step-by-step planning procedure allowing users to identify,
visualize, and rate the various activities, relationships, and alternatives
involved in a layout project
The first and the most important thing in systematic layout planning
procedure, is to gather the vital information or inputs about the essential
elements (PQRST) of the layout and these in inputs can be generalized as
the product data, the process data and the scheduled data.
The three fundamental areas of the technique are relationships, space and
adjustment
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Relationship area are : Space area are:
collection of input data, space requirements,
flow of materials, space available and
activity of relationships space relationship diagrams
and relationship diagrams.

Adjustment area are:

modifying considerations
 practical limitations and
 evaluation and final selection.

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 4.2.Algorithmic approaches
Algorithmic approach is a formal procedure that can help the layout
analyst to develop or improve a layout and it provide objective criteria to
facilitate the evaluation of various layout alternatives that emerge in the
process.
Most layout algorithm can be classified according to the type of input data
they require, those require qualitative flow data uses REL chart while
those require quantitative flow data use from-to –chart. But there are
others that use both.
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Layout algorithm can also be classified according to
their objective functions.
i. Minimizing: the sum of flows times distances
ii. Maximizing an adjacency score

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According to the primary functions layout algorithms
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-can be classified as :
i. Improvement type : start with an initial layout and seek to improve the objective
function through incremental change.
ii. Construction type: Develop layout from scratch
the overall modeling techniques and /or methods used in various algorithm classified as
follow.

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 1. Pair wise exchange

The pairwise exchange method is an improvement –type layout algorithm.

Though it can be used with both adjacency based and distance based objective
it is often used with the latter. Most of the time it is utilized for equal area
department but possible to use it for unequal department with incorporation
of CRAFT,MULTIPLE and other.
The pairwise exchange method simply states that for each iteration all feasible
exchange in the location of department pairs are evaluated one at a time and
the pair that resulted in the largest reduction in total cost is selected.
Moving the direction of largest cost reduction is also known as “steepest
descent” in optimization.
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Evaluating each exchange one at time means when department i and j are exchanged and the
layout cost is computed, department i and j are placed back in their current positions in the
layout before the next pair of department is exchanged.
Each department can be either fixed or variable, when one department is assigned as fixed no
exchange is made on it.
Let have the following existing layout with a material flow and distance matrix as given in
table 4.1 and 4.2 respectively
From to 1 2 3 4
1 - 10 15 20
2 10 5
3 5
4

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 Distance Matrix Based on Existing Layout
From to 1 2 3 4
1 - 1 2 3
2 1 2
3 1
4

the existing layout cost(T1234) is as follow

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Using steepest descent we select pair 1-3 and exchange the location of
departments 1 and 3 in the layout. For the next iteration, we consider
all feasible exchanges that consists of the same set as in iteration 1.The
resulting layout costs are as follows:

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The pair 2-3 is selected with a total of layout cost of 90.If we proceed to the
next iteration (third iteration) the minimum layout cost, which is 95 occurs at
the layout 3-2-1-4 and is equivalent with the first iteration.
Iteration Layout Cost
0 1-2-3-4 125
1 3-2-1-4 95
2 2-3-1-4 90
3 3-2-1-4 95
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 2. Graph Based Method

Graph based method is a construction type layout algorithm, it

has a roots in graph theory and works based on adjacency
based objective.
The adjacency score does not account for distance, nor does it
account for relationships other than those between adjacent
department.
Dimensional specifications of departments are not considered.
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i.e. the length of common boundaries between adjacent department
are also not considered. While drawing the graph one should keep
planarity property of the graph, i.e. the arc do not intersect.
The score is very sensitive to the assignment of numerical weights in
the relationship chart.
Example: consider a company that want to develop layout for its new
five department of equal size. The numbers both in the REL chart
and diagram are weights.

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 Procedures
Step 1: from the relationship chart select a department pair with the
largest weight.
Departments 3 and 4 (weight =20) are selected to enter the graph.
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Step 2: Select the third department to enter, the third dep’t is selected based on the sum
of the weights with respect to depar ment 3 and 4.
t

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Step 3: pick the fourth dep’t to enter by evaluating the value of adding
on of the unassigned dep’t represented by a node on a face of the graph.

Department 1 is chosen with a value of 27.

Step 4: determine on which face to insert the last department.
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• Step 5: construct a corresponding block layout

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 3. RDP( Relationship Diagram Process) algorithm
 Is a construction algorithm,
 Adds departments to the layout one by one until all departments have been placed.
 This algorithm utilized based on two stages.
 In the first stage determine the order of placement by using five steps while in the
 second stage, which involves three steps used to determine the relative location of the
departments.
Stage I (involves 5 steps to determine the order of placement)
Step 1:assigning numerical values to the closeness rating as

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A= 10 000, E= 1000, I= 100, O= 10, U= 0, X= – 10 000.
Step 2 : Computing TCR ( Total Closenes Rating).
TCR is calculated for each department. TCR refers to the sum of the absolute
values for the relationships with a particular department.
Step 3: The department with the greatest TCR is selected as the first placed
department in the sequence of placement.
Step 4: Next department in the sequence of placement is determined to satisfy
the highest closeness rating with the placed department(s). With respect to
the closeness priorities A>E>I>O>U
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Step 5: Departments having X relationship with the placed department(s) are
labeled as the last placed department.
Note: If ties exist during this process, TCR values are utilized to break the ties
arbitrarily.
Stage II: (Involves 3 steps to determine the relative locations of the departments)
Step 6:Calculate Weighted Placement Value (WPV) of locations to which the next
department in the order will be assigned. WPV refers to the sum of the
numerical values for all pairs of adjacent department(s). When a location is fully
adjacent, its weight equals to 1.0, and when it is partially adjacent its weight
equals to 0.5.
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Step 7:Evaluate all possible locations in counter clock-wise order, starting at the
western edge of the partial layout.

Step 8: Assign the next department to the location with the largest WPV.

Note: If ties exist during this process, first location with the largest WPV is selected.
Example: Given the activity relationship diagram (REL) as follow and determine the
layout of departments using RDP.

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4.ALDEP – Automated Layout Design Program
ALDEP is a construction algorithm and the input requirements for it are as
follows:
 Relationship chart
 Department areas
 Sweep width
Arbitrarily selects first department and allows fixed departments.
The basic idea behind ALDEP was that it is based on the activity relationship
chart.
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These activity relationships are called A for absolutely essential, E for essential, I for
important, O for ordinary closeness is okay, U for unimportant and X undesirable.
These are numerical values given to these numbers commonly it is 4 to the power
0(O),4 to the power 1(I), 4 to the power 2 (E), 4 to the power 3 (A) and U=0.The X
which is highly undesirable requirement between two departments is given in
negative score of –4 raise to power 5 in that sense. So these are the numerical
ratings that come. Essentially this is rated in a logarithmic scale in that sensibility.
ALDEP has a capability of handling 63 departments on three floors, when the
package is operated and produce many layouts.
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 Steps in ALDEP

First department selected randomly

Next department selected based on relationship with placed departments
 If more than one with same relationship, choice is random
 If no departments with minimally acceptable relationship exist, choice is
random
Place first department in the upper left corner and extend downward
Additional departments begin where the previous one ended
Sweep width < area of smallest department
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The typical stopping criteria for ALDEP, the minimum department
preference can be either A or E generally. What it means is that if
department is already placed in the layout, the next department which you
pick up for placing adjacent to that department should have a high activity
relationship with that particular layout. It can be specified as A or E, you
need the REL chart for the departments.
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 ALDEP example

Use ALDEP procedure to determine the layout vector, construct and evaluate
the layout for the facility based on the relationship chart and the departmental
dimensions given below. The dimensions of the facility are 10x18. Use the
sweep width of 2 and the minimum acceptable level of importance “E”. The
closeness values: A=64, E=16, I=4, O=1, U=0, X=-1024
Solution
One unit of template( commonly known as grids) has 400 unit of area and
hence we will have different number of templates (grids) for each dep’t as
follow.
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 5. CORELAP -Computerized Relationship Layout Planning

CORELAP is a construction type algorithm which developed for main

frame computers. It works based on adjacency based method and uses
A=4, E=3, I=2, O=1, U=0 and X=-1 values.
It has the following features:
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
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• Selection of the departments to enter the layout is based on Total
Closeness Rating (TCR). Once again the total closeness rating is
the sum of numerical values assigned to the closeness
relationships between the department and all other
departments ..

Procedure (similar to one of the procedures for relationship

diagramming).
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 Department selection procedures
1.The first department placed in the layout is the one with the greatest TCR
value. If there is a tie , then choose the one with more A’s (E’s, etc.).
(strong relation)

2. If a department has an X relationship with the first one, it is placed last in

the layout and not considered. If a tie exists, choose the one with the smallest
TCR value.
3. The second department is the one with an A (or E, I, etc.) relationship with
the first one. If a tie exists, choose the one with the greatest TCR value.

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4. If a department has an X relationship with the second one, it is
placed next-to-the-last or last in the layout. If a tie exists, choose the
one with the smallest TCR value.
5. The next department is the one with an A (E, I, etc.) relationship
with the already placed departments. If a tie exists, choose the one
with the greatest TCR value.
6. The procedure continues until all departments have been placed.
“Placement sequence”
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 Department placement

Once the department selected department placement is based on

both adjacent and touching condition of neighbor departments
with the selected department. This is then generally done by
placing rating (PR) which is the sum of the weighted closeness
rating between the department to enter the layout and its
neighbors.

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The placement of departments is based on the following steps:
1. The first department selected is placed in the middle.
2. The placement of a department is determined by evaluating PR for all possible
locations around the current layout in counterclockwise order beginning at the “western
edge”.
3. The new department is located based on the greatest PR value.
Example: Given the relationship chart and the departmental dimensions below determine
the sequence of the placement of the departments in the layout based on the CORELAP
algorithm. Place the departments in the layout while evaluating each placement. Number
of grid is obtained by dividing each dep’t area to the smallest dep’t. (dep’t 8)
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A=4, E=3, I=2, O=1, U=0, X=-1

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 The placement sequence: 5-6
Based on this the final table of TCR Values with the placement sequence 5-6-7-9-3-8-1-2-4.

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60
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 The final layout is the following
  free space
8  
 
 

3
9
5
1 7
2 6

4 Free space

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 How we can evaluate the layout
We can evaluate the layout we design by calculating the efficiency using
scores of the layout and the relationship diagram closeness rating. The
score of the layout is as follow and we must double it as it is obtained
only from the upper triangle of the matrix.
1 2 3 4 5 6 7 8 9 score
1   2 2 0 - - 0 - - 4
2
    1 0 - - - - - 1
3
    - 2 - 1 3 0 6
4     - 1 1 - - 2
5     4 4 1 - 9
6     2 - 3 5
7     - - 0
8     0 0
9                   27 64
As it is given in the REL diagram the total closeness value is 2*39 which is 78.
Department relationship summary
 
scor
Dep't 1 2 3 4 5 6 7 8 9
A E I O U X
e 

  I I U O U U U U 0 0 2 1 5 0 5
1

    O U O U U U O 0 0 0 3 4 0 3
2

0 1 1 2 2 0 7
3       U I O O E U

        O O O O O 0 0 0 5 0 0 5
4

          A A O O 2 0 0 2 0 0 10
5

            I O E 0 1 1 1 0 0 6
6

              U O 0 0 0 1 1 0 1
7

0 0 1 0 0 0 2
8                 I

                              0
9

39
Total

Hence the efficiency of the layout is 2*27/78 = 69.23%

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Let use WPV which is based on the fully adjacency and touching based
algorithm by taking a half weight of touching and one weight of fully
adjacent. Once again from the TCR result the sequence is 5-6-7-9-3-8-1-2-4.
Let as put at the center and we will have eight adjacent for the first
department as follow. The numbering from 1-8 is labeled counter-clockwise
starting at the left west corner and the best placement is the smallest
number with greatest WPV.
8 7 6

1
5 5

2 3 4

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Therefore the final layout is as follow. The table below the layout is the relationship
among departments and the value on the right end column is the score of each
department. The value is based on the upper triangle matrix and as we are working
based on symetericity and doubling the value is must.

Improved layout
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Hence the efficiency of the improved layout is (2*31)/(2*39) or
possibly 31/39 which is 79.48 %.
You can contine until no improvement is made. The final layouts are
evaluted by the distance –based layout score. CORELAP uses the
shortest rectilinear path between the departments. Reconvening
/dispatching areas are assumed to be on the side of the department
nearest its neighbor.
The layouts often result in irregular building shapes.
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