Chapter 5: Algorithms for layout

design and appliation

Lê Đức Đạo, Phd

Industrial System Enginerring Department
Faculty of Mechanical Engineering
Ho Chi Minh City University Of Science and Technology
Phone: 0937286746
Email: [email protected]
Layout generation
Distance calculation
Pairwise exchange method
Aldep
CRAFT
Methods for layout design
Layout evaluation
◦ Distance-based scoring
◦ Adjacency-based scoring
Layout generation
◦ Construction algorithms
 Building a block layout by iteratively adding
departments
◦ Improvement algorithms
 Incrementally improving an initial block
layout
Calculate based distance
Calculate based relationship
 Calculate based Relationship
Assign the score to evaluate the relationship
- Definition of relationship
+ share as least one borders
+ The centroids are within a certain distance
Give the punishment to the X relationship
Construction algorithms
 SELECT an activity to be placed
 PLACE the selected activity in the layout

 Selection rules
◦ Choose the departments based on the importance
scores (first place all A, then all E, all I, etc.)
◦ Choose the departments having the largest number
of A (E, I, etc.) relationships with the departments
already in the layout.
◦ Consider costs and user specified placement
priorities.
Construction algorithms
Placement rules
◦ Contiguity Rule
 If an activity is represented by more than
one unit area square, every unit area
square representing the activity must share
at least one edge with at least one other
unit area square representing the activity.
◦ Connectedness Rule
 The perimeter of an activity must be a
single closed loop that is always in contact
with some edge of some unit area square
representing the activity.
 Construction algorithms
Placement
Rules
◦ Enclosed Voids Rule
 No activity shape
shall contain an
enclosed void.
◦ Shape Ratio Rule
 The ratio of a feasible shape’s greatest
length to its greatest width shall be
constrained to lie between specified
limits.
◦ Corner Count Rule
 The number of corners for a feasible
 Algorithm classification
Construction algorithms Improvement algorithms
Graph-based method Pairwise exchange method
ALDEP CRAFT
CORELAP MCCRAFT
PLANET MULTIPLE

BLOCPLAN
LOGIC
Mixed integer programming
Distance Calculations
Centroid is a center of
mass
 Distance Calculations
 If (xi,yi) and (xj,yj) represent the coordinates of two
locations i and j then the distance model measures can be:

◦Rectilinear: B

 distance between i and j is

A
D = |xi-xj| + |yi-yj|

B
◦Euclidean:
 distance between i and j is
A
D x  x
i j
2
 yi  y j
2
Distance Calculations

 Rectilinear distance from  Euclidean distance from

centroid to centroid centroid to centroid
y y

y2 y2

y1 y1

x1 x2 x x2 x
x1
Distance Calculations

Rectilinear distance from A to B:

D (AB) = 2.5
Exercises tính khoảng
cách theo 2 cách

tính khoảng cách C-B, C-A, C-E, F-A

Pairwise exchange method
For layout improvement
Distance-based objective
The objective is to minimize the total
cost of transporting materials among all
departments in a facility
◦ Based on rectilinear distance from centroid to
centroid
Since the final outcome is based on the initial
layout, we might not converge to the optimal
solution
Pairwise exchange method
Procedure
Calculate total cost for the existing layout
For each iteration evaluate all feasible
exchanges in the locations of department
pairs
Select the pair that results in the
largest reduction in total cost
Recompute the distance matrix each time
an exchange is performed
If the lowest total cost for your next
iteration is worse than the total cost for the
previous iteration, the procedure is
terminated
Pairwise exchange method
Example Initial layout
 Four departments with equal sizes
 From-To Chart

 Distance matrix (based on existing layout)

Determine final layout

 Pairwise exchange method
From-To Chart

Example
m m

Total cost for the existing layout: z   f ijc ijd ij

Distance matrix - initial layout i1 j
TC1234=10*1 + 15*2 + 20*3 + 10*1 + 5 *2 + 5*1
1 = 125

Evaluate all feasible pairwise exchanges:

Switch departments 1-2, 1-3, 1-4, 2-3, 2-4, and 3-4
2 1 3 4
Switching: 1-2
3 2 1 4
1-3
1-4 4 2 3 1

2-3 1 3 2 4

2-4 1 4 3 2

3-4 1 2 4 3

The lowest cost => next iteration

Pairwise exchange method
Example

Repeat the switching between

departments 1-2, 1-3, 1-4, 2-3, 2-4, and 3-4.
◦ Sequence 2314 with total score of 90 is the best
option
TC2314=10*2 + 15*1 + 20*1 + 10*1 + 5 *3 + 5*2 = 90

The process is repeated until the lowest

total score cannot be reduced anymore.
In this particular case the best option
is 2314.
Pairwise exchange method- exercises
 ALDEP
 Department selection
 Randomly selects the first department
 Locate those departments which have “A” relationship with the first one (or
“E”,”I” etc.-min level of importance is determined by the user MACR ).
 If no such department exist, it selects the second one completely randomly
 The selection procedure is repeated until all the departments are selected
(always search for departments having relationships with the last one placed in
the layout-not all)
 Department placement
 Stars from upper left corner and extends it downward
 Vertical sweep pattern
 Sweep width is determined by user
ALDEP

 Choose randomly 4
 Choose 3 since the A
relationship with 4
 Choose 2 or 1 (choose 2) (has E
relationship with 3)
 Choose 1
 Remaining 5
ALDEP
 Layout size 300
 Square size 100100
 Arrange layout follow sweep
route

 If sweep width is
changed the layout
will be adjusted
ALDEP

Arrange layout with Sweep width=2 and MACR=E

ALDEP

Order: 4-2-1-6-5-7-3
ALDEP

Order: 4-2-1-6-5-7-3
ALDEP
Exercises
Arrange 5 department with MACR=E and sweep width =1 and 2
Layout size: 40x20 (x=40, y=20)
Square size: 50 m2 (5*10)
MARCE= E

Depart Area 1 2 3 4 5
ment
1 200 I I A A
2 100 U E I
3 200 I U I I
4 150 A E I U
5 50 A I I U
Relax
Inside google headquaters
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Inside Microsoft’s Massive Headquarter

https://www.youtube.com/watch?
v=lOTmYcxCxjU&t=131s
Corelap

Computerized Relationship Layout Planning:

Method based on the departmental relationship
A=4,E=3,I=2.U=0.X=-1
Using the total closeness rating (TCR) to allocate the department.

TCR is the total relationship ranged by numbers of allocated

department with the others
 Corelap
Rule
• Allocate the department has the largest TCR. If we the same largest TCR
is obsevered within some department, allocate the department havingmore
A, then E and so on
• Once the department has the X relationship with re-arraganged
department, It will be establised in the the final step. If we have a lot X
department, re-arragnged it by decsent of TCR
• The next department will be allocated based on the close- relationship with
the first one (A,E,I). Using TCR if we have more than one possible
outcome.
• Make the loop of process until all deparments has been arranged
Corelap –
Ex1 Given a relational schema and space requirements as
below. Arranged it using corelap

Department Area Square

33
Corelap algorithm
Strong relationsip 1-3-5-7
Medium relationship 2-4-6-8

Placement ratio (PR - placing rating) is the

sum of weighted adjacency ratios between
the part to be arranged and its neighbors.

Using PR to chose the arrangment oders

The first selected part is placed in the middle
The second will be place based on the raltionship with previous allocated
department (begin with the west corner )
 Corelap –
EX 1

TCR table

Order:
35
5-6-7-9-3-8-1-2-4
Corelap –
EX 1
Cả hai vị trí có
cùng PR
PR=A[5-7]+I[6-7]
=4 + 2=6

Nếu bố trí 7 như

trên hình bên thì PR
sẽ là:
PR = A[5-7] = 4

Thứ tự bố trí: 36

5-6-7-9-3-8-1-2-4
Corelap –
EX 1

Thứ tự bố trí: 37

5-6-7-9-3-8-1-2-4
Corelap –
EX 1

38

Thứ tự bố trí: 5-6-7-9-3-8-1-2-4

Corelap –
Ví dụ 1

Tiếp tục??

39

Thứ tự bố trí: 5-6-7-9-3-8-1-2-4

 Cho biểu đồ quan hệ bên cạnh và thứ tự

CORELAP –
bố trí các bô phận là 7-5-9-3-1-4-2-6-8, tìm
mặt bằng tốt nhất với CORELAP. Giả sử
rằng tất cả các bộ phận có cùng kích

EX2 thước. Sử dụng giá trị gần kề: A=125,

E=25, I=5, O=1, U=0, X=-125. Nếu các bộ
phận chỉ tiếp xúc nhau qua 1 điểm, giá trị
gần kề sẽ là ½ giá trị gốc.

40
CORELAP – A=125, E=25, I=5, O=1, U=0, X=-125
Thứ tự bố trí: 7-5-9-3-1-4-2-6-8

EX2

41
CORELAP – A=125, E=25, I=5, O=1, U=0, X=-125
Thứ tự bố trí: 7-5-9-3-1-4-2-6-8

EX2

42
CORELAP – A=125, E=25, I=5, O=1, U=0, X=-125
Thứ tự bố trí: 7-5-9-3-1-4-2-6-8

EX2

43
Exercises Corelap
 CRAFT
Computerized Relative Allocation of Facilities Technique
 For improvement of an existing facility
 Attempts to minimize transportation cost, where
Transportation cost = flow * unit cost * distance
m m
Mi z  f ij cij
n dij
 Assumptions
◦ Moving costs are not dependent
i1 on j1
the equipment utilization.
◦ Moving costs are linearly related to the length of the move.

 Distance metric used is the rectilinear distance between

department centroids.

• Input is FT Chart (From-To chart)

• Department shapes are not restricted to the
rectangular ones
 CRAFT
Procedure
1. Determine department centroids.
2. Calculate rectilinear distance between centroids.
3. Calculate transportation cost for the layout.
4. Consider department exchanges of either equal area
departments or departments sharing a common
border.
5. Determine the estimated change in transportation
cost of each possible exchange.
6. Select and implement the departmental exchange
that offers the greatest reduction in transportation
cost.
7. Repeat the procedure for the new layout until no
interchange is able to reduce the transportation cost.
Exchange centroid
CRAFT
Example
• A facility with 7 departments
• Cost of carrying any material cij = 1 for all i and j pairs.
• Each grid size is 20 X 20, total 72,000 m2 is available
• Total requirement is 70,000 m2
• Location of receiving (A) and shipping (G) departments are fixed
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 A A A A A A A A A G G G G G G G
A G AG G
2 A Receiving D. A G G G Shipping D.
3 A A A BA BA A A A C G C C
A C C E E E E
4 B B B E G E
G GE GE GE
5 B G BD C D E
F F F E
6 B D D F C E E
F F
7 B E F E F F
8 D DD D B
D D C D C
D C
D CD
H CF E
H H EH E
H F F F F
9 D D
B B B B F
 Improve the layout 10 D Dummy
Department
F
F F

F F
F
• Total available space > total required space:
therefore we use a dummy department (H) with the size of 2,000 m2
 CRAFT Example
1. Determine department centroids.
2. Calculate rectilinear distance
between centroids.
3. Calculate transportation cost
for
the layout.

Distance between A and B is 6 units

(illustrated by the red line above)

m m
z 
i1 j
f ij c ij d ij
1
CRAFT Example
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 A A A A A A A A A A G G G G G G G
G
G Shipping
Which
2 A Receiving D. A
3 A A A A A A A A A A G D.
GG G
G
GG G G G G departments
4 B B B B B C C C C C E E EE E E E E E E
5 B B C C E E E E E E E to exchange?
6 B B D C C C C CD E D D F F F F F
7 B B B B B F F E E F F
8 D D D F F F F
9 D D D D H H FH H H F F F F
10 D F
D
Dummy Department
D 1. Bringing the departments E and D closer
might help to reduce total material flow
D
2. Bringing the departments F and G closer
might help to reduce total material flow
D

FD Exchange E and F
F Departments E and F can be reorganized
D only if they have the same areas OR
D
D they have common border
D
 CRAFT
Selection Criterion for Exchange
Estimated change in the transportation cost:
◦ Consider two departments i and j:

 Let the centroids of each location be Li and Lj

 Assume that after the exchange, the new centroid of i
becomes Lj and the centroid of j becomes Li.
 Compute the change in the total transportation cost by
using the new estimated centroids
 Centroids of the two departments are temporarily swapped
 The actual size of cost reduction can be overestimated or
underestimated
 CRAFT
Swapping the centroids
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 A A A A A A A A AA G G G G G G G G
2 A Receiving D. A G
3 A A A A A A A A AA G G G Shipping G
G
4 B B B B B C C C C C E EG D. G G G G G
5 B B C C E E E E E E E
E Centroid of E
6 B B C C C CF C F E F E F E F E F E EE E E
E F F F Centroid of F
7 B B B B B D D D D F
8 D D D D DD D DD H HF H H F F F F
9 D D D H F F F FF F
10 D D D D D Dummy Department
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
To calculate the
17 18 A G G G G G G G G estimated change
1 A A Receiving
A A A A AD. A A A G in cost after the
2 A A A A A A A A A G G G Shipping G exchange:
G
3 A A G D.G G G G G
4 B B B B B C C C C C E E
5 B B C C E E E E E E E Centroid of F
E F F F F F F E E
6 B B C C C C FC E E E E E E FE F
E
Centroid of E
F
7 B B B B B DD D D D HD H H H F F F F
8 D D D D D DD D H F F
 CRAFT Example
Trial distance matrix
 Estimation of the
change in
transportation cost

Trial cost matrix

Initial cost matrix
CRAFT
Exchanging two departments
 If the areas of the two departments are of equal sizes one
department takes the shape of the other.

 If the areas are not identical:

◦ Draw a box enclosing the two departments (this enclosed
shaped includes the grids of the two departments only)

◦ Count the number of grids of the smaller department. Let this

count be k

◦ Count k grids from the non-adjacent side of the larger

department. These grids now become the new location of the
smaller department. The space emptied by the smaller
department now becomes part of the larger department’s new
territory
CRAFT
Exchanging two departments
 CRAFT Example – exchanging E and F
1 2 3 4 5 6
9 7 8 10 11 12 13 14 15 16
17 18 A G G G G G G G G
1 A A A A A A AD.
Receiving A A A G
2 A A A A A A A A A G G G Shipping G
G
3 A A E E G D.
G G G G G
4 B B B B B C C C C C E E E E E E E E E
5 B B C C E E E E E E E E
6 B B C C C C C F F F F E E
7 B B B B B D D D D F F F F F
8 D D D D D D D F F
9 D D F
D D D H H HF HF HF FF F F F
10 D D D D D F
Department E needs less space
than department F. Then:
Dummy Department
Starting from the non-adjacent
1 2 3 4 5 6 9 7 8 10 11 12 13 14 15 16 side of department F, locate all the
17 18 A G G G G G G G G cells for department E
1 A A A Receiving
A A A A D. A A A G G
Shipping
2 A A A A A A A A G G G G
D.
3 A A A G G G G G G
4 B B B B B C C C C C FF FF F F F F F
5 B B C C F New Layout – after
6 B B DC DC DC D
C EC F F
E F F F FF exchanging E and F
7 B DB B DB DB D D F E F
8 D E EE E E F
9D D D D D D D D D H H H HE H E E F
10 ED F
F
 CRAFT Example

Final Layout – after exchanging B and C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18 A A A G
1 A A A A A A A G G
2
3 A Receiving D.
A A A A G G
Shipping D.
A A G G
A G G
4 C C C B B B B B B BF F F FGFA GF GF GGF GF GF G
5 C C C B B F F F F F F
6 C C CC C B B BD BD B BF E E F
7 C B
D DD D D E E F
8 D DD E EE GE E F
9 D D D D A
D HA HA E
G
H FHD H E EE F F
10 D DD G
DF

E F
D E
E F
CRAFT Example
Manual Adjustment on CRAFT output
CRAFT Insufficiency of Adjacency for Exchange
If 2 departments are not equal in
area, then adjacency is a necessary
but not sufficient condition for an
exchange

CRAFT is unable to exchange

departments 2 and 4 without
splitting the department 2 or
shifting other departments
 CRAFT - Pros
 CRAFT is flexible with respect to department shapes.
 In theory, CRAFT is applicable only to rectangular facilities, yet using dummy
extensions, we can still apply CRAFT algorithm to non-rectangular shapes.
 Dummy departments
• Have no flows or interaction with other departments
• Require certain area
• Can be fixed
• Used for:
 Non-rectangular facilities
 Fixed areas in the layout (obstacles, unusable areas, etc.)
 Aisle locations
 Extra space
 Building irregularities
 CRAFT captures the initial layout with reasonable accuracy
 CRAFT - Cons
 Locally optimal solution only
◦ CRAFT is a path-oriented method so the final layout is dependent on
the initial layout. Therefore, a number of different initial layouts should
be used as input to the CRAFT procedure.
 CRAFT may lead to irregular shapes both for individual
departments and the facility itself.
◦ Most of the time, a manual “finishing” must be done before presenting
the CRAFT output.
 It is not always possible to exchange two unequal size, adjacent
departments without splitting the larger one.
Initial layout
Flow matrix
(Industrial robot )
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Industrial robot
https://www.youtube.com/watch?v=9mG1bgs_ND0

Smart factory

https://www.youtube.com/watch?v=MHQR_Kdl4tU
Exercise
Departme 1 2 3 4 6
nt
Area 16 16 24 16 8
(sq.Units)

4 2 4
4 1 5 4
4 2 3
4 6
 Exercise
Distance

Flow

Total cost
 Exercises
Department Can be Value
exchanged
4 4 2
1 and 2
1 and 3 4 1 4 5

1 and 4 4 2 3
1 and 5 4 6
2 and 3
2 and 4 The centroid will be approximately
2 and 5 interchanged when the departments
3 and 4 exchanged
3 and 5
4 and 5
Exercises 4
1
2
5
4
4
4
4 2 3
4 6
Department Can be exchange Value
1 and 2 205
1 and 3
1 and 4 193
1 and 5 208 Complete iteration 2
2 and 3 197
2 and 4 201
2 and 5
3 and 4 178
3 and 5 183
4 and 5 163