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LOCATION
Outline
The Problem
Objective of Facility Layout
Basic Types of Layout
Product versus Process Layout
Cellular Layouts
Proximity
Assignment Problem
The Problem
Facilitate
organization structure
communication and interaction between workers
manufacturing process
visual control
Minimize
manufacturing cycle time or customer flow time
investment
Provide
convenience, safety and comfort of the employees
flexibility to adapt to changing conditions
Basic Types of Layouts
Process Layout
Used in a job shop for a low volume, customized
products
Product Layout
Used in a flow shop for a high volume, standard
products
Basic Types of Layouts
Inventory
A product layout has a low work-in-process
inventory and high finished goods inventory because
production is initiated by demand forecast.
On the other hand, a process layout has a high
work-in-process inventory and low finished goods
inventory.
Material handling
A product layout can use automatic guided vehicles
which travels in a fixed path. But, variable path
forklifts are suitable for a process layout.
Product vs. Process Layouts
Scheduling/line balancing
In case of a process layout, jobs arrive throughout
the planning period. A process layout requires
dynamic scheduling where a new scheduling
decisions is made whenever a new job arrives.
In case of a product layout, sequencing and timing
of product flow are standard and set when the line is
designed. With a change in demand, a product
layout may need a new line balancing decision.
Cellular Layouts
Machines
Enter
Worker 2
Worker
Worker 1 3
Exit
Assembly
4 6 7 9
5 8
2 10 12
1 3 11
A B C Raw materials
Cellular Layouts Example
Machines
Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
Cellular Layouts Example
Machines
Parts 1 2 4 3 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
Cellular Layouts Example
Machines
Parts 1 2 4 3 5 6 7 8 9 10 11 12
A x x x x x
D x x x x x
B x x x x
C x x x
E x x x
F x x x
G x x x x
H x x x
Cellular Layouts Example
Machines
Parts 1 2 4 8 3 5 6 7 9 10 11 12
A x x x x x
D x x x x x
B x x x x
C x x x
E x x x
F x x x
G x x x x
H x x x
Cellular Layouts Example
Machines
Parts 1 2 4 8 3 5 6 7 9 10 11 12
A x x x x x
D x x x x x
F x x x
B x x x x
C x x x
E x x x
G x x x x
H x x x
Cellular Layouts Example
Machines
Parts 1 2 4 8 10 3 5 6 7 9 11 12
A x x x x x
D x x x x x
F x x x
B x x x x
C x x x
E x x x
G x x x x
H x x x
Cellular Layouts Example
Machines
Parts 1 2 4 8 10 3 6 9 5 7 11 12
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x x
E x x x
H x x x
Cellular Layouts Example
Assembly
8 10 9 12
11
4 Cell1 Cell 2 6 Cell 3
7
2 1 3 5
Raw materials A C B
Each of A, B, C now visits only one area, minimizing jumping.
Advantages of Cellular Layouts
Punch
Saws Milling Press Drills
Saws 18 40 30
Milling 18 38 75
Punch Press 40 38 22
Drills 30 75 22
Assignment Method
Many methods can be used to solve the facility layout
problem. Here we discuss assignment method to minimize
material handling costs.
Suppose that some machines 1, 2, 3, 4 are required to be
located in A, B, C, D. The cost of locating machines to
locations are known and shown below. For example, if
Machine 2 is located to location C, the cost is 7 (say,
hundred dollars per month).
Location
Machine A B C D
1 10 7 6 11
2 6 4 7 9
3 8 6 5 6
4 9 5 3 12
Assignment Method
The problem is to locate the machines to minimize total
material handling costs.
One solution can be (not necessarily and optimal solution)
to assign 1, 2, 3, 4 to respectively C, B, A, D. In such a
case total cost is 6+4+8+12=30 hundred dollars per
month.
Location
Machine A B C D
1 10 7 6 11
2 6 4 7 9
3 8 6 5 6
4 9 5 3 12
Assignment Method
Notice in this solution that every machine is assigned to
one location and every location is assigned to one
machine. So, there is a single box in each row and each
column. Every solution will must this property.
If there are more locations than machines, dummy
machines must be added with the same cost for all
locations. Assignment method finds an optimal solution.
Location
Machine A B C D
1 10 7 6 11
2 6 4 7 9
3 8 6 5 6
4 9 5 3 12
Assignment Method
1. Perform row reductions
Subtract minimum value in each row from all other row
values
2. Perform column reductions
Subtract minimum value in each column from all other
column values
3. Line Test
Cross out all zeros in matrix using minimum number of
horizontal & vertical lines. If number of lines equals
number of rows in matrix, optimum solution has been
found, stop.
4. Matrix Modification
Subtract minimum uncrossed value from all uncrossed
values & add it to all cells where two lines intersect. Go
to Step 3.
Assignment Example
Location
Machine A B C D
1 10 7 6 11
2 6 4 7 9
3 8 6 5 6
4 9 5 3 12
Row reduction Column reduction Line Test
4 1 0 5 2 1 0 4 2 1 0 4
2 0 3 5 0 0 3 4 0 0 3 4
3 1 0 1 1 1 0 0 1 1 0 0
6 2 0 9 4 2 0 8 4 2 0 8
See the matrix under line test on Slide 34. The minimum
uncovered number is 1. There are three types of
numbers and these numbers are modified in three
different ways:
uncovered numbers: subtract minimum uncovered
number 1 from all uncovered numbers.
numbers covered by one line: do nothing
numbers covered by two lines: add minimum
uncovered number 1 to all numbers covered by two
lines.
The modified matrix is shown next.
Assignment Example
Modify matrix Line Test
1 0 0 4 1 0 0 4
0 0 4 5 0 0 4 5 # lines = # rows
0 0 0 0 0 0 0 0 so at optimal solution
3 1 0 8 3 1 0 8
Location Location
Machines A B C D
1 1 0 0 4 Machines A B C D
2 0 0 4 5 1 10 7 6 11
3 0 0 0 0 2 6 4 7 9
4 3 1 0 8 3 8 6 5 6
4 9 5 3 12
Total material handling costs = 22
Assignment Example
Reading:
Section 10.1-10.4 pp. 557-573 (4th Ed.), pp. 535-552
(5th Ed.)
Exercises:
10.1 p. 568, 10.7, p. 573 (4th ED.)
10.1 p. 547, 10.7, p. 552 (5th ED.)
LESSON 21: LOCATING A SINGLE FACILITY
THE RECTILINEAR DISTANCE PROBLEM
Outline
Notations:
X-coordinate of user location i = ai
Y-coordinate of user location i = bi
Weight assigned to user location i = wi
Location of the proposed facility = (x,y)
For the picture shown on the previous slide, there is
only one user location. So, index i can be omitted.
We have,
a=2, b=1, x=5, y=5
Locating New Facilities
Rectilinear distance
= distance along the x-axis +distance along the y-axis
= |x-a|+|y-b|
=
L(5,5) Rectilinear
5 distance
4
Euclidean distance 3 Euclidean
x a 2 y b2 A(2,1) distance
Locating New Facilities
Census Cumulative
Tract (ai,bi) Weight, wi Weight
A (2.5,4.5)
B (3.0,2.5)
D (5.0,2.0)
C (5.5,4.0)
E (8.0,5.0)
Example: Minimize Weighted Sum of
Rectilinear Distances
Census Cumulative
Tract (ai,bi) Weight, wi Weight
D (5.0,2.0)
B (3.0,2.5)
C (5.5,4.0)
A (2.5,4.5)
E (8.0,5.0)
Example: Minimize Weighted Sum of
Rectilinear Distances
c1 min (ai bi )
1i n
c2 max (ai bi )
1i n
c3 min (ai bi )
1i n
c4 max (ai bi )
1i n
c5 max( c2 c1 , c4 c3 )
Minimize Maximum
Rectilinear Distance
Define:
x1 (c1 c3 ) / 2, y1 (c1 c3 c5 ) / 2
x2 (c2 c4 ) / 2, y2 (c2 c4 c5 ) / 2
x1 (c1 c3 ) / 2
y1 (c1 c3 c5 ) / 2
x2 (c2 c4 ) / 2
y2 (c2 c4 c5 ) / 2
Reading:
Section 10.8-10.9 pp. 598-606 (4th Ed.), pp. 575-584
(5th Ed.)
Exercises:
10.25 p. 600, 10.32, 10.38, pp. 608-609 (4th Ed.)
10.25 p. 578, 10.32, 10.38, p. 585 (5th Ed.)
LESSON 22: LOCATING A SINGLE FACILITY
THE EUCLIDEAN DISTANCE PROBLEM
Outline
Notations:
X-coordinate of existing facility i = ai
Y-coordinate of existing facility i = bi
Weight assigned to user location i = wi
Location of the proposed facility = (x,y)
Euclidean distance = ( x ai ) 2 ( y bi ) 2
Example
The Euclidean Distance Problem
wi ai wi bi
x* i 1n y * i 1n
wi wi
i 1
i 1
Example: Gravity Problem
Census Weight
Tract (i) (ai,bi) wi wiai wibi
1 (2.5,4.5) 2
2 (3.0,2.5) 5
4 (5.5,4.0) 10
3 (5.0,2.0) 7
5 (8.0,5.0) 12
Example: Gravity Problem
n n
wa i i wb i i
x* i 1
n
y* i 1
n
w
i 1
i w
i 1
i
Euclidean distance = ( x ai ) 2 ( y bi ) 2
Square of the Euclidean distance = ( x ai ) 2 ( y bi ) 2
Weighted sum of the squares of the
Euclidean distances from optimal location
(5.72,3.76 ) to 5 locations
5
wi 5.72 ai 3.76 bi
2 2
i 1
a g i i b g i i
x i 1
n
y i 1
n
g
i 1
i g
i 1
i
w2 w2
g2
x a2 y b2
2 2
5.72 a2 2 3.76 b2 2
n n
a g i i b g i i
x i 1
n = y i 1
n =
g
i 1
i g
i 1
i
Example: Minimize Weighted Sum of the
Euclidean Distances
Repeat the process with (x,y) = (5.59, 3.88). The
result is (x,y) = (5.54, 3.94).
Repeat the process with (x,y) = (5.54, 3.94). The
result is (x,y) = (5.52, 3.97).
Repeat the process with (x,y) = (5.52, 3.97). The
result is (x,y) = (5.51, 3.98).
Repeat the process with (x,y) = (5.51, 3.98). The
result is (x,y) = (5.51, 3.99).
Repeat the process with (x,y) = (5.51, 3.99). The
result is (x,y) = (5.50, 3.99).
Repeat the process with (x,y) = (5.50, 3.99). The
result is (x,y) = (5.50, 3.99).
Stop.
Example: Minimize Weighted Sum of the
Euclidean Distances
Euclidean distance = ( x ai ) 2 ( y bi ) 2
Weighted sum of the Euclidean distances
from location (5.50,3.99 ) to 5 locations
5
wi 5.50 ai 2 3.99 bi 2
i 1
Reading:
Section 10.10 pp. 609-612 (4th Ed.), pp. 586-588 (5th
Ed.)
Exercises:
10.41 p. 612 (4th Ed.) p. 589 (5th Ed.)
LESSON 23/24:
COMPUTERIZED LAYOUT TECHNIQUE
Outline
10 20 30 40 50 60 70 80 90 100
Following are A D
some
examples of
questions
addressed by C
CRAFT:
B
Is this a good
layout?
If not, can it be
improved?
10 20 30 40 50 60 70 80 90 100
CRAFT: Distance Between Two Departments
Let
Centroid of Department A = xA , yA
Centroid of Department B = xB , yB
Then, the distance between departments A and B,
Dist(A,B)
xA xB y A yB
10 20 30 40 50 60 70 80 90 100
Centroid of A A D
=
(80,85)
C
Centroid of C
=
B
10 20 30 40 50 60 70 80 90 100
CRAFT: Total Distance Traveled
10 20 30 40 50 60 70 80 90 100
result in a peculiar shape of a D A
department; a shape that is
composed of some rectangular
pieces C
Let
50 60 70 80 90 100
A1 Area A1 A A1
A2 Area A2
x1 , y1
Centroid of A1 A2
x2 , y2
10 20 30 40 50 60 70 80 90 100
Centroid of A1
X-coordinate Multiply
Rectangle Area of centroid (2) and (3)
(1) (2) (3) (4)
A1
A2
Total
A1 x1 A2 x2
X-coordinate of the centroid of A
A1 A2
Y-coordinate Multiply
Rectangle Area of centroid (2) and (3)
(1) (2) (3) (4)
A1
A2
Total
A1 y1 A2 y2
Y-coordinate of the centroid of A
A1 A2
50 60 70 80 90 100
A A1
A2
10 20 30 40 50 60 70 80 90 100
Given
Size of the facility
The departments
Size of the departments
Proximity relationships (activity relationship chart) and
A sweep width (defined later)
ALDEP constructs a layout.
ALDEP
The size of the facility and the size of the departments are
expressed in terms of blocks.
The procedure will be explained with an example. Suppose
that the facility is 8 blocks (horizontal) 6 block (vertical).
The departments and the required number of blocks are:
Production area 14 blocks
Office rooms 10
Storage area 8
Dock area 8
Locker room 4
Tool room 4
ALDEP
A: absolutely necessary
E: especially important
I: important
O: ordinarily important
U: unimportant
X: undesirable Production area
O
Office rooms A
U I
Storage O E
A X A
Dock area U U
U O
Locker room O
U
Tool room
ALDEP
See carefully that the allocation started from the upper left
corner and started to move downward with an width of 2
(=sweep width) blocks.
After the down wall is hit, the allocation continues on the
adjacent 2 (=sweep width) columns on the right side and
starts moving up.
This zig-zag pattern will continue.
D D
Next time, when the top wall will
D D
be hit, the allocation will continue
D D
on the adjacent 2 (=sweep width)
D D
columns on the right side and
starts moving down. S S S S
S S S S
ALDEP
Exercises:
10.13, 10.15, 10.19, pp. 586-587 (4th Ed.), pp. 564-
567 (5th Ed.)