Tata Letak Fasilitas Manufaktur

D0394 Perancangan Sistem

Manufaktur
Kuliah Ke XXI - XXII

QAP Formulation
Define,
rij = rate of item movement between departments i and j
drs = distance between locations r and s
xir = 1, if department i is assigned to location r; 0,
otherwise
d =0
11

1 du

1 du

d12 = 1
d13 = 2
d14 = 1
d15 = 2
d16 = 3

QAP Formulation
Define,
rij = rate of item movement between departments i and j
drs = distance between locations r and s
n
n
n
xir = 1, ifn department
i is assigned
to
location
r; 0,items move

z
=
total
distance
min z rij d rs xir x js
otherwise
i 1 j 1 r 1 s 1
objective has quadratic form
n

st:

xir 1
r 1
n

xir 1
i 1

xir 0,1

, i 1, , n
, r 1, , n
i , r

constraints are assignment

contraints
every dept. to one location
every location one dept.

Quadratic Assignment Problem

Solution Representation
Represent a solution to the facility layout problem
as a permutation vector a
a = (a(1), a(2), , a(n))

Element a(i) represents the location to which

department i is assigned
a(3) = 5 implies that department 3 is assigned to
location 5

Solution Representation
Represent a solution as a permutation vector a
Element a(i) represents the location to which
department i is assigned
a = (2, 4, 5, 3, 1, 6)
Example:
1

location sites

layout design

Solution Representation
Represent a solution as a permutation vector a
Element a(i) represents the location to which
department i is assigned
a = (2, 4, 5, 3, 1, 6)
Example:
1

location sites

layout design

Solution Evaluation
Assume that the direction of flow is unimportant
So weight between departments i and j is wij = rij + rji

Assume distance matrix is symmetric

Total flow cost is
n 1

C a

w d a i , a j

i 1 j i 1

ij

Solution Evaluation
Assume that the direction of flow is unimportant
So weight between departments i and j is wij = rij + rji
Assume distance matrix is symmetric
Total flow cost is n 1 n
C a

w d a i , a j

i 1 j i 1

ij

a = (2, 4, 5, 3, 1, 6); C(a) = 114

Flow matrix (rij)

From/To
1
2
3
4
5
6

1
0
1
4
0
3
2

2
3
0
1
1
2
3

3
2
3
0
1
0
4

4
2
1
1
0
2
1

5
1
0
2
4
0
5

6
2
5
2
1
5
0

Solution Evaluation
Given a, the total cost for department k is given by
pk a wik d a i , a k wkj d a k , a j
1i k

k j n

pk a wkj d a k , a j

with wkk 0

j 1

What is the cost if the locations of departments u and v are exchanged?

(a represents the new layout)

Cuv a C a C a
n 1

Cuv a

n 1

wij d a i , a j wij d a i , a j

i 1 j i 1

i 1 j i 1

Pairwise Exchange
n
n

Cuv a wiu d a i , a u wiv d a i , a v wuv d a u , a v

i 1

i 1
n
n

wiu d a i , a u wiv d a i , a v wuv d a u , a v

i 1

i 1
n
n

Cuv a wiu d a i , a u wiv d a i , a v wuv d a u , a v

i 1

i 1

wiu d a i , a v wiv d a i , a u wuv d a u , a v

i v

i u
n

Cuv a wiu wiv d a i , a u d a i , a v 2 wuv d a u , a v

i 1

Pairwise Exchange
Exchange departments 2 and 4
a = (2, 3, 5, 4, 1, 6)

a = (2, 4, 5, 3, 1, 6)

C(a) = 114

C24(a) = 10

C(a) = 104

Pairwise Exchange
If a least total cost assignment, a*, is found,
then if any two departments are exchanged
Cuv(a*) 0.
Necessary condition for a least total cost
assignment
Not sufficient, in general, since k-way
interchanges (k > 2) may improve the solution

Solution Generation
Construction Heuristics
Begin with the basic problem data and build up a solution in
an iterative manner

General Procedure
Let, a(i) = 0 if department i has not been assigned to a location
Let, a(F) be the set of locations assigned to departments in set F
0. While F< n
1. select i F
A specification implementation requires
2. select r a(F)
particular rules for performing these steps
3. a(i) r
4. F F {i}
5. End

Construction Heuristics
Many reasonable rules are possible for steps 1 and
2. Consider,
Random department selection in step 1
Minimize additional total cost for partial solution in
step 2
Partial solution is (F, a(F)) with cost C(a(F))
If we augment the partial solution by assigning department k to
location r, we obtain an increase in cost as follows

pk a F r

wkj d r , a j
j F

Construction Heuristics
Specific Procedure
1. Randomly select i {1,2,,n}
2. a(i) 1
3. While F< n
4. Randomly select i F
5. pi(a(F) k}) = min {pi(a(F) r}) r a(F)}
6. a(i) k
7. F F {i}
8. End

Could repeat several times and pick best solution

Many variations on this basic procedure

Construction Heuristics
Example

From/To
1
Randomly select department 3 2
3
Assign to location 1; a(3) = 1 4
5
6

1
0
1
4
0
3
2

2
3
0
1
1
2
3

3
2
3
0
1
0
4

4
2
1
1
0
2
1

5
1
0
2
4
0
5

6
2
5
2
1
5
0

Construction Heuristics
Example

From/To
1
Randomly select department 3 2
3
Assign to location 1; a(3) = 1 4
5
Randomly select department 4 6

1
0
1
4
0
3
2

2
3
0
1
1
2
3

3
2
3
0
1
0
4

4
2
1
1
0
2
1

5
1
0
2
4
0
5

6
2
5
2
1
5
0

Construction Heuristics
Example

From/To
1
Randomly select department 3 2
3
Assign to location 1; a(3) = 1
4
Randomly select department 4 5
6

w43d21 = (2)(1) = 2
w43d31 = (2)(2) = 4
w43d41 = (2)(1) = 2
w43d51 = (2)(2) = 4
w43d61 = (2)(3) = 6

Assign to location 2; a(4) = 2

1
0
1
4
0
3
2

2
3
0
1
1
2
3

3
2
3
0
1
0
4

4
2
1
1
0
2
1

5
1
0
2
4
0
5

6
2
5
2
1
5
0

Construction Heuristics
Example

From/To
1
Assign 3 to location 1; a(3) = 1 2
Assign 4 to location 2; a(4) = 2 34
Randomly select department 2 5
6

w42d32 + w32d31 = 2+8 = 10

w42d42 + w32d41 = 4+4 = 8
w42d52 + w32d51 = 2+8 = 10
w42d62 + w32d61 = 4+12 = 14

1
0
1
4
0
3
2

2
3
0
1
1
2
3

Assign to location 4; a(2) = 4

3
2
3
0
1
0
4

4
2
1
1
0
2
1

5
1
0
2
4
0
5

6
2
5
2
1
5
0

Construction Heuristics
Example

Assign 3 to location 1; a(3) = 1

Assign 4 to location 2; a(4) = 2
Assign 2 to location 4; a(2) = 4
Randomly select department 5
w25d34 + w45d32 + w35d31 = 16
w25d54 + w45d52 + w35d51 = 12
w25d64 + w45d62 + w35d61 = 22

From/To
1
2
3
4
5
6

1
0
1
4
0
3
2

2
3
0
1
1
2
3

3
2
3
0
1
0
4

Assign to location 5; a(5) = 5

4
2
1
1
0
2
1

5
1
0
2
4
0
5

6
2
5
2
1
5
0

Construction Heuristics
Example

From/To
1
=1 2
3
=2 4
= 4 56

Assign 3 to location 1; a(3)

Assign 4 to location 2; a(4)
Assign 2 to location 4; a(2)
Assign 5 to location 5; a(5) = 5
Randomly select department 1

1
0
1
4
0
3
2

2
3
0
1
1
2
3

3
2
3
0
1
0
4

w51d35 + w21d34 + w41d32 + w31d31 = 34

w51d65 + w21d64 + w41d62 + w31d61 = 34

Assign to location 3; a(1) = 3

4
2
1
1
0
2
1

5
1
0
2
4
0
5

6
2
5
2
1
5
0

Construction Heuristics
Example

From/To
1
= 2
3
4
= 5
6

Assign 3 to location 1; a(3)

1
Assign 4 to location 2; a(4)
2
Assign 2 to location 4; a(2) =
4
Assign 5 to location 5; a(5) =
5
Assign 1 to location 3; a(1) =
3
Assign 6 to location 6; a(6) =
6

1
0
1
4
0
3
2

2
3
0
1
1
2
3

3
2
3
0
1
0
4

4
2
1
1
0
2
1

5
1
0
2
4
0
5

6
2
5
2
1
5
0

Construction Heuristics
Observations
Many different variations of the construction procedure
Clearly the initial location has an effect as does the
department sequence
Intuitively, you want large weights near the center and
small weights near the outside
Difficult to formalize as a general algorithm
Example
5 & 6 largest weights; 2 & 3 close to
6; 1 close to 3
a = (3, 4, 6, 1, 2, 5)
C(a) = 92

Solution Quality
How good is the solution?
Lower Bound
Order location pairs by increasing distance, d
Preferred locations

Order weights by decreasing flow volume, w

Highest activities

Assign largest weights to preferred locations

LB = d w
d = (1, 1, 1, 1, 1, 1, 1, 2, 2, 2, 2, 2, 2, 3, 3)
w = (10, 8, 6, 6, 6, 4, 4, 4, 4, 2, 2, 2, 2, 2, 2)
LB = 10(1) + 8(1) + 6(1) + + 2(3) + 2(3) = 88

Improvement Heuristics
Modify a given solution so that the total cost is
reduced
Pairwise interchange
Select two departments and interchange their locations
General Procedure
0. a a0
1. Select a pair of facilities (u, v)
2. Evaluate Cuv(a)
3. Decide whether or not to make the interchange
4. Decide whether or not to continue
A specific implementation requires rules for performing
each of the steps

Improvement Heuristics
Many reasonable rules exist for these steps.
Consider,
Enumeration of all pairs in step 1 and 4
Make exchange if Cuv(a) > 0
Alternatively, make exchange between u and v
such that Cuv(a) is the largest value for a given
u.

Steepest Descent Pairwise

Interchange
a a0
done false
While (not.done)
done true
max 0
For i = 1 to n-1
For j = i+1 to n
If (Cij(a) > max) then
max Cij(a)
ui
vj
done false
Endif
Endfor
Endfor

If (max > 0) then

temp a(u)
a(u) a(v)
a(v)
temp
Endif
Endwhile

Improvement Heuristics
Pairwise Interchange has several difficulties
May be trapped in bad solution
Departments 5 and 6 have a large flow between
them so if they get trapped on the outside, any
exchange that moves one and not the other will have
a negative Cuv(a) so it is never made
5

SDPI
initial solution

good solution

VNZ Heuristic
TFCi wij d a i , a j
j i

Order departments by TFCi : TFC[1] TFC[2]

TFC[n]
Phase 1
Set m = M1 = [1] and M2 = [2]
Order list of departments i by non-increasing Cim(a).
Proceed through list making each switch provided Cis(a) > 0
(where a is updated assignment vector as switches are made)
Repeat for m = M2

Phase 2
Evaluate Cij(a) for each dept. pair 1 and 2, 1 and 3, , M-1
and M. Exchange i and j if cost is reduced.
Continue until every pair has been examined without making a
change or each pair has been examined twice.

Improvement Heuristics
Initial (starting) solution is important -- try
several!
Could consider k-wise interchanges
Computational burden increases greatly

Good starting solution not necessary

In general, more effort should be expended in the
improvement phase
Quickly, generate a large variety of starting solutions
and then try to improve them