Facility Layout 3

Non-computerized Block Layouts:

Graph Based Construction, SLP/DEO, and
Pairwise Exchange
Graph-based construction method (p.317)

construction => new layout

Steps:
1. Build a graph that represents adjacency
2. Convert to block layout
3. Evaluate block layout (usually A-based)
Step 1: Construct the graph.

1. Select the two departments with the largest

weights, break ties arbitrarily.
2. Select the third department based on the sum of
the weights relative to the two departments already
selected.
3. Select the fourth department based on maximizing
the value to the first three departments in the
graph.
4. Add departments maximizing value to a face until
all departments have been added to the graph.
We begin with a relationship chart with weights, instead of
letter ratings.

REL 1 2 3 4 5
1 - 9 8 10 0
2 - - 12 13 7 Select the two
departments with the
3 - - - 20 0 largest weights.
4 - - - - 2
5 - - - - -
(A direct link between two
departments means that
they will be adjacent)
Form graph with departments 3 & 4

3 20 4
Select the 3rd department to enter the graph.

REL 1 2 3 4 5
1 - 9 8 10 0
2 - - 12 13 7 Select the next
3 - - - 20 0 department with the
4 - - - - 2 largest sum of
5 - - - - - weights with 3 & 4.

12 13

Add department 2
to graph
3 20 4
Select the 4th department to enter the graph.

REL 1 2 3 4 5
1 - 9 8 10 0 Select the next
2 - - 12 13 7 department with the
largest sum of
3 - - - 20 0
weights with 2, 3 & 4.
4 - - - - 2
5 - - - - -

9
12 13

Add department 1 1
to graph 8 10

3 20 4
Select the 5th department to enter the graph.
REL 1 2 3 4 5
1 - 9 8 10 0
Assign the next
2 - - 12 13 7
department with the
3 - - - 20 0 largest sum of weights
4 - - - - 2 to a face.
5 - - - - -

2
2 7
13
Add 5
9 12 9
12 13 department 5 0

1 to face 1-2-4 1 2
8 10 8 10

3 20 4 3 20 4
Construct Block Layout from graph

2
7 Total
Weight =
13
9 5
12 (9+8+10+0) +
0 (12+13+7) +
20 + 2 = 81
1 2
8 10

3
20
4
SLP Construction Approach

1. Determine Department Entry Order (DEO)

from REL chart
2. Add blocks to layout based on DEO
3. Maximize Adjacency score
Transform REL Chart
REL 1 2 3 4 5
1 - I I E U
2 - - E A I
3 - - - A U
4 - - - - O
5 - - - - -
Generate DEO
Create Block Layout from DEO and Relationships

REL 1 2 3 4 5
1 - I I E U
2 - - E A I
3 - - - A U
4 - - - - O
5 - - - - -

A = 64
3 E = 16 Adjacency Score = 168
4 2 I =4
Efficiency = 168/173 = 97%
O=1
1 5
U=0
Pairwise Exchange – Improvement Method
Material Flow Matrix
To/ 1 2 3 4
From Objective: Minimize
1 - 10 15 20 Distance-based score
2 - - 10 5
3 - - - 5 Layout 1: (equal-sized departments)
4 - - - - 1 2 3 4

Total Cost = 10(1) + 15(2) + 20(3) + 10(1) + 5(2) + 5(1) = 125

(1,2) (1,3) (1,4) (2,3) (2,4) (3,4)

Pairwise Exchange - Greedy Algorithm
Layout 1
Material Flow Matrix
To/ 1 2 3 4 1 2 3 4
From
1 - 10 15 20 TC (1-2) = {2,1,3,4}
2 - - 10 5 10(1) + 15(1) + 20(2) + 10(2) + 5(3) + 5(1) = 105
3 - - - 5 TC (1-3) = {3,2,1,4}
4 - - - - 10(1) + 15(2) + 20(1) + 10(1) + 5(2) + 5(3) = 95

TC (1-4) = {4,2,3,1} = 120

TC (2-3) = {1,3,2,4} = 120
TC (2-4) = {1,4,3,2} = 105
TC (3-4) = {1,2,4,3} = 125

Select “Best” Exchange Exchange 1 & 3

Pairwise Exchange - Greedy Algorithm
Layout 2, TC = 95
Material Flow Matrix
To/ 1 2 3 4 3 2 1 4
From
1 - 10 15 20
2 - - 10 5 TC (1-2) = {3,1,2,4} = 95
3 - - - 5 TC (1-3) = {1,2,3,4} = 125
TC (1-4) = {3,2,4,1} = 110
4 - - - -
TC (2-3) = {2,3,1,4} = 90
TC (2-4) = {3,4,1,2} = 105
TC (3-4) = {4,2,1,3} = 105

Select “Best” Exchange Exchange 2 & 3

Pairwise Exchange - Greedy Algorithm
Layout 3, TC = 90
Material Flow Matrix
2 3 1 4
To/ 1 2 3 4
From
1 - 10 15 20
2 - - 10 5 TC (1-2) = 95
3 - - - 5 TC (1-3) = 120
TC (1-4) = 125
4 - - - -
TC (2-3) = 105
TC (2-4) = 100
TC (3-4) = 95

No improvement possible Finished at “BEST”

layout with TC = 90