FACILITY LAYOUT

Lecture-04

OUTLINE
Facility layout: [Using Quantitative

Measures]
Facility layout: [Using Quantitative and
Qualitative Measures]

FLOW PROCESSES

Layout Evaluation Criteria

The most commonly used quantitative
criterion for evaluating layout:
M M

TC TC MF TC tran f ij hij d ij
i 1 j 1

TCMF :Total Cost of Material Flow per time period

TCtran: Total Cost of Material Transport per time

period
TC : Total Cost of Material Movement per time
period

Total Cost of Material Movement

M: number of activities (facilities)
fij : flow volume between activities i and j,
measured per time period
dij: distance between activities i and j,
measured per time period
hij: cost per move between activities i and
j per unit distance

FACILITY LAYOUT

FACILITY LOCATION

FACILITY LAYOUT
Machine Layout
Department Layout

Machine Layout
Relationship between activities:
Quantitative measures (Flow of materials)

Other quantitative and qualitative measures are

possible (e.g. adjacency)

Flow Requirements
Unit load (batch) sizes
Equivalence Factors

Machine Layout Criterion

Total weighted distance
Total cost
Combination of Quantitative and Qualitative Criteria.

FLOW WITHIN DEPARTMENTS

Depends on the type of machine layout
Fixed Product Layout
Product Layout
Most flow is between adjacent machines.
Depends on whether or not operators are
shared between machines (end-to-end, frontto-front, U-shaped flow pattern, etc.)

Group Layout

Little flow between groups

FLOW WITHIN DEPARTMENTS

Process Layout
Variable-path material handling
Most flow is between machines
Flow pattern depends on machine-aisle
arrangement (Two-way aisles; One-way aisles)

QAP Model of Machine Layout

Machine layout can be modelled as a

Quadratic Assignment Problem (QAP)

QAP

Example:[4 Sites & 4 Facilities]

QAP
The layout models are NP-complete
Optimal algorithms: Branch and bound,

Decomposition, Cutting plane algorithms

These algorithms can produce optimal solutions
for only small sized problem (M<=20)
Since it is computationally infeasible to find an
optimal solution when M>20.
Heuristic (non-optimal) procedures are typically
used to solve QAPs
Steepest Descent Pairwise Interchange (SDPI)
Heuristic

Steepest Descent

SLP

Qualitative Relationships
Material Flow
Personnel Flow
Same resource
Same personnel
Communication
Safety
Noise
Structural

Systematic Layout Planning

RELATIONSHIP DIAGRAMMING FOR NEW

LAYOUTS
Step-1: Select the first department to enter the

layout (The Dept with the greatest number of

A)
Step-2:Select the second department to enter
the layout (The Dept selected should have an A
relationship with the first Dept.)
Step-3:Select the third department to enter the
layout (The third Dept selected should have the
highest combined relationship with the two
Depts)

RELATIONSHIP DIAGRAMMING FOR NEW

LAYOUTS
Step-4:Select the fourth department to enter the

layout (The same logic as in Step-3)

Step-n:Department n is placed according to the
rules described in Steps 3 and 4.

Systematic Layout Planning

Systematic Layout Planning

Systematic Layout Planning

Department Layout
Manufacturing Departments
A group of machines and/or workstations

Non-Manufacturing Departments

Shipping/Receiving areas, Storage areas,

Offices, Cafeterias, etc.

Flow Pattern between Departments

U-shaped, S-Shaped, W-Shaped.

Block Layout Representations

Block Layout Representations

Non-Manufacturing Departments
Offices offices for administrative, support, and

engineering staff; meeting/conference rooms;

etc.
Storage/Warehousing dedicated areas outsides
of each manufacturing department for the
storage of raw materials, in-process inventories,
and finished goods.
Shipping/Receiving dockboard area, manuvering
area for MHE used for loading/unloading,
buffer/staging areas, container and trash storage,
offices and truckers lounge.
Restrooms located within 200 feet of every
permanent workstation.

Non-Manufacturing Departments
Food Services
Health Services, looker rooms, and wash

rooms.
Plant Services HVAC, pump, generators,
etc.
Emergency exits an exit must be within
150 ft of any point in the building.

Total Facility

Total Site