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Facility layout
1. Production Plant Layout (1)Production Plant Layout (1)
• Facility Layout Problem: design problemFacility Layout Problem: design problem
– locations of activitieslocations of activities
– dimensionsdimensions
– configurationsconfigurations
• No overall algorithm existsNo overall algorithm exists
2. Design problem
Greenfield Location of one
new machine
Production Plant Layout (2)Production Plant Layout (2)
• Reasons:Reasons:
– new productsnew products
– changes in demandchanges in demand
– changes in product designchanges in product design
– new machinesnew machines
– bottlenecksbottlenecks
– too large bufferstoo large buffers
– too long transfer timestoo long transfer times
Production Plant Layout (2)Production Plant Layout (2)
4. Production Plant Layout (3)Production Plant Layout (3)
• Goals (examples):Goals (examples):
– minimal material handling costsminimal material handling costs
– minimal investmentsminimal investments
– minimal throughput timeminimal throughput time
– flexibilityflexibility
– efficient use of spaceefficient use of space
5. Production Plant Layout (4)Production Plant Layout (4)
• Restrictions:Restrictions:
– legislation on employees workinglegislation on employees working
conditionsconditions
– present building (columns/waterworks)present building (columns/waterworks)
• Methods:Methods:
– Immer: The right equipment at the rightImmer: The right equipment at the right
place to permit effective processingplace to permit effective processing
– Apple: Short distances and short timesApple: Short distances and short times
6. Goals Production Plant LayoutGoals Production Plant Layout
• Plan for the preferred situation in thePlan for the preferred situation in the futurefuture
• Layout must support objectives of the facilityLayout must support objectives of the facility
• No accurate dataNo accurate data layout must be flexiblelayout must be flexible
7. Selection
Search
Analysis
Systematic Layout PlanningSystematic Layout Planning
Muther (1961)Muther (1961)
0 Data gathering
10 Evaluation
4 Space
requirements
5 Space
available
6 Space relationship
diagram
1 Flow 2 Activities
3 Relationship
diagram
7 Reasons to
modify
8 Restrictions
9 Layout alternatives
8. 0 - Data gathering (1)0 - Data gathering (1)
• Source: product designSource: product design
– BOMBOM
– drawingsdrawings
– ““gozinto” (assembly) chart, see fig 2.10gozinto” (assembly) chart, see fig 2.10
– redesign, standardizationredesign, standardization simplificationssimplifications
machines
product design
sequence of assembly operations
layout (assembly) line
9. 0 - Data gathering (2)0 - Data gathering (2)
• Source: Process designSource: Process design
– make/buymake/buy
– equipment usedequipment used
– process timesprocess times
operations process chartoperations process chart (fig 2.12)(fig 2.12)
assembly chartassembly chart
operationsoperations
precedence diagramprecedence diagram
(fig 2.13)(fig 2.13)
10. 0 - Data gathering (3)0 - Data gathering (3)
• Source: Production schedule designSource: Production schedule design
– logistics: where to produce, how muchlogistics: where to produce, how much
product mixproduct mix
– marketing: demand forecastmarketing: demand forecast
production rateproduction rate
– types and number of machinestypes and number of machines
– continuous/intermittentcontinuous/intermittent
– layoutlayout scheduleschedule
11. 1/2 - Flow and Activity Analysis1/2 - Flow and Activity Analysis
• Flow analysis:Flow analysis:
– Types of flow patternsTypes of flow patterns
– Types of layoutTypes of layout
flow analysis approachesflow analysis approaches
• Activity relationship analysisActivity relationship analysis
12. 1/2 - Flow analysis and activity1/2 - Flow analysis and activity
analysisanalysis
Flow analysisFlow analysis
• quantitative measure of movementsquantitative measure of movements
between departments:between departments:
material handling costsmaterial handling costs
Activity analysisActivity analysis
• qualitative factorsqualitative factors
13. Flow analysisFlow analysis
• Flow of materials, equipment andFlow of materials, equipment and
personnelpersonnel
Raw material Finished product
layout facilitates this flowlayout facilitates this flow
14. Types of flow patternsTypes of flow patterns
P = receivingP = receiving
S = shippingS = shipping
R S
R S
R
S
long line
• Horizontal transportHorizontal transport
15. LayoutLayout
volumes of productionvolumes of production
variety of productsvariety of products
• volumes: what is the right measure ofvolumes: what is the right measure of
volume from a layout perspective?volume from a layout perspective?
• varietyvariety high/low commonalityhigh/low commonality
layout typelayout type
16. Types of layoutTypes of layout
• Fixed product layoutFixed product layout
• Product layoutProduct layout
• Group layoutGroup layout
• Process layoutProcess layout
18. Product layout (flow shop)Product layout (flow shop)
• Production line according to theProduction line according to the
processing sequence of the productprocessing sequence of the product
• High volume productionHigh volume production
• Short distancesShort distances
19. Process layout (Job shop)Process layout (Job shop)
• All machines performing a particularAll machines performing a particular
process are grouped together in aprocess are grouped together in a
processing departmentprocessing department
• Low production volumesLow production volumes
• Rapid changes in the product mixRapid changes in the product mix
• High interdepartmental flowHigh interdepartmental flow
20. Group layoutGroup layout
• Compromise between product layoutCompromise between product layout
and process layoutand process layout
• Product layouts for product familiesProduct layouts for product families
cells (cellular layout)cells (cellular layout)
• Group technologyGroup technology
21. Production volume and product varietyProduction volume and product variety
determines type of layoutdetermines type of layout
group layout process layout
product variety
production
volume
product
layout
22. Layout determinesLayout determines
• material handlingmaterial handling
• utilization of space, equipment andutilization of space, equipment and
personnel (table 2.2)personnel (table 2.2)
Flow analysis techniquesFlow analysis techniques
• Flow process chartsFlow process charts product layoutproduct layout
• From-to-chartFrom-to-chart process layoutsprocess layouts
23. Activity relationship analysisActivity relationship analysis
• Relationship chart (figure 2.24)Relationship chart (figure 2.24)
• Qualitative factors (Qualitative factors (subjective!subjective!))
• Closeness rating (A, E, I, O, U or X)Closeness rating (A, E, I, O, U or X)
24. 3 - Relationship diagrams3 - Relationship diagrams
• Construction of relationships diagrams:Construction of relationships diagrams:
diagrammingdiagramming
• Methods, amongst others: CORELAPMethods, amongst others: CORELAP
25. Relationship diagram (1)Relationship diagram (1)
• Spatial picture of the relationshipsSpatial picture of the relationships
between departmentsbetween departments
• Constructing a relation diagram oftenConstructing a relation diagram often
requires compromises.requires compromises.
What is closeness? 10 or 50 meters?What is closeness? 10 or 50 meters?
• See figure 2.25See figure 2.25
26. Relationship diagram (2)Relationship diagram (2)
PremisePremise:: geographicgeographic proximityproximity reflects thereflects the
relationshipsrelationships
Sometimes other solutions:Sometimes other solutions:
– e.g. X-rating because of noisee.g. X-rating because of noise
acoustical panels instead of distanceacoustical panels instead of distance
separationseparation
– e.g. A rating because of communicatione.g. A rating because of communication
requirementrequirement
computer network instead of proximitycomputer network instead of proximity
27. Graph theory based approachGraph theory based approach
• closeclose adjacentadjacent
• department-nodedepartment-node
• adjacent-edgeadjacent-edge
• requirement: graph is planarrequirement: graph is planar
(no intersections)(no intersections)
• region-faceregion-face
• adjacent faces: share a common edgeadjacent faces: share a common edge
graphgraph
28. Primal graphPrimal graph dual graphdual graph
• Place a node in each facePlace a node in each face
• Two faces which share an edge – joinTwo faces which share an edge – join
the dual nodes by an edgethe dual nodes by an edge
• Faces dual graph correspond to theFaces dual graph correspond to the
departments in primal graphdepartments in primal graph
block layout (plan) e.g. figure 2.39block layout (plan) e.g. figure 2.39
29. Graph theoryGraph theory
• Primal graph planarPrimal graph planar dual graphdual graph
planarplanar
• Limitations to the use of graph theory:Limitations to the use of graph theory:
it may be an aid to the layout designerit may be an aid to the layout designer
30. CORELAPCORELAP
• Construction “algorithm”Construction “algorithm”
• Adjacency!Adjacency!
• Total closeness rating = sum ofTotal closeness rating = sum of
absolute values for the relationshipsabsolute values for the relationships
with a particular department.with a particular department.
∑=
j
iji rTCR
31. CORELAP - stepsCORELAP - steps
1.1. sequence of placements ofsequence of placements of
departmentsdepartments
2.2. location of departmentslocation of departments
32. CORELAP – step 1CORELAP – step 1
• First department:First department:
• Second department:Second department:
– X-relationX-relation “last placed department”“last placed department”
– A-relation with first. If noneA-relation with first. If none E-relationE-relation
with first, etceterawith first, etcetera
i
i
TCRmax
34. 4 - Space requirements4 - Space requirements
• Building geometry or building siteBuilding geometry or building site
space availablespace available
• Desired production rate, distinguish:Desired production rate, distinguish:
– Engineer to order (ETO)Engineer to order (ETO)
– Production to order (PTO)Production to order (PTO)
– Production to stock (PTS)Production to stock (PTS)
marketing forecastmarketing forecast productions quantitiesproductions quantities
35. 4 - Space requirements4 - Space requirements
Equipment requirements:Equipment requirements:
• Production rateProduction rate number of machinesnumber of machines
requiredrequired
• Employee requirementsEmployee requirements
rate
machine operators
machines employees
assembly
37. 4 - Space determination (1)4 - Space determination (1)
1. Production center1. Production center
• for manufacturing areasfor manufacturing areas
• machinemachinespace requirementsspace requirements
2. Converting2. Converting
• e.g. for storage arease.g. for storage areas
• present space requirementpresent space requirement spacespace
requirementsrequirements
• non-linear function of production quantitiynon-linear function of production quantitiy
# machines per operator
# assembly operators
Space requirements
38. 4 - Space determination (2)4 - Space determination (2)
4.4. Space standardsSpace standards
– standardsstandards
4.4. Ratio trend and projectionRatio trend and projection
– e.g. direct labour hour, unit producede.g. direct labour hour, unit produced
– Not accurate!Not accurate!
– Include space for:Include space for:
packaging, storage, maintenance, offices, aisles,packaging, storage, maintenance, offices, aisles,
inspection, receiving and shipping, canteen, toolinspection, receiving and shipping, canteen, tool
rooms, lavatories, offices, parkingrooms, lavatories, offices, parking
factor
space
39. Deterministic approach (1)Deterministic approach (1)
• n’ = # machines per operator (non-integer)n’ = # machines per operator (non-integer)
• a = concurrent activity timea = concurrent activity time
• t = machine activity timet = machine activity time
• b= operatorb= operator
ba
ta
n
+
+
='
40. Deterministic approach (2)Deterministic approach (2)
( )
+
+
=
bam
ta
Tc
• TTcc = cycle time= cycle time
• a = concurrent activity timea = concurrent activity time
• t = machine activity timet = machine activity time
• b = operator activity timeb = operator activity time
• m = # machines per operatorm = # machines per operator
41. Deterministic approach (3)Deterministic approach (3)
( )
m
T
mCCmTC c
21)( +=
• TC(m) = cost per unit produced as a function of mTC(m) = cost per unit produced as a function of m
• CC11 = cost per operator-hour= cost per operator-hour
• CC22 = cost per machine-hour= cost per machine-hour
• Compare TC(n) and TC(n+1) for n < n’ < n+1Compare TC(n) and TC(n+1) for n < n’ < n+1
42. Designing the layout (1)Designing the layout (1)
• Search phaseSearch phase
• Alternative layoutsAlternative layouts
• Design process includesDesign process includes
– Space relationship diagramSpace relationship diagram
– Block planBlock plan
– Detailed layoutDetailed layout
– Flexible layoutsFlexible layouts
– Material handling systemMaterial handling system
– PresentationPresentation
43. Designing the layout (2)Designing the layout (2)
• Relationship diagram + spaceRelationship diagram + space
space relationship diagramspace relationship diagram
(see fig 2.56)(see fig 2.56)
• Different shapesDifferent shapes
44. 9 – Layout alternatives9 – Layout alternatives
• Alternative layouts by shifting theAlternative layouts by shifting the
departments to other locationsdepartments to other locations
block plan, also shows e.g. columnsblock plan, also shows e.g. columns
and positions of machinesand positions of machines
(see fig 2.57)(see fig 2.57)
selection
detailed design
detailed design
selection
or
45. Flexible layoutsFlexible layouts
• FutureFuture
• Anticipate changesAnticipate changes
• 2 types of expansion:2 types of expansion:
1.1. sizessizes
2.2. number of activitiesnumber of activities
46. Material handling systemMaterial handling system
• Design in parallel with layoutDesign in parallel with layout
• PresentationPresentation
– CAD templates 2 or 3 dimensionalCAD templates 2 or 3 dimensional
– simulationssimulations
– ““selling” the layout (+ evaluation)selling” the layout (+ evaluation)
47. 10 Evalution (1)10 Evalution (1)
Selection and implementationSelection and implementation
• best layoutbest layout
– cost of installation + operating costcost of installation + operating cost
– comparecompare futurefuture costs for both the new and the oldcosts for both the new and the old
layoutlayout
• other considerationsother considerations
– selling the layoutselling the layout
– assess and reduce resistanceassess and reduce resistance
• anticipate amount of resistance for each alternativeanticipate amount of resistance for each alternative
48. 10 Evalution (2)10 Evalution (2)
• Causes of resistance:Causes of resistance:
– inertiainertia
– uncertaintyuncertainty
– loss of job contentloss of job content
– ……
• Minimize resistance byMinimize resistance by
– participationparticipation
– stagesstages
50. Systematic Layout PlanningSystematic Layout Planning
0 Data gathering
10 Evaluation
Analysis
Search
Selection
4 Space
requirements
5 Space
available
6 Space relationship
diagram
1 Flow 2 Activities
3 Relationship
diagram
7 Reasons to
modify
8 Restrictions
9 Layout alternatives
51. Systematic Layout PlanningSystematic Layout Planning
0 Data gathering
10 Evaluation
Analysis
Search
Selection
4 Space
requirements
5 Space
available
6a Space relationship
diagram
1 Flow 2 Activities
3 Relationship
diagram
7 Reasons to
modify
8 Restrictions
9 Layout alternatives
6b Analytical analyses
52. Automatic Guided Vehicles (AGV’s)Automatic Guided Vehicles (AGV’s)
• Unmanned vehicle for in-plant transportation onUnmanned vehicle for in-plant transportation on
manufacturing and assembly areasmanufacturing and assembly areas
• Two types of guidanceTwo types of guidance
– free rangingfree ranging
• dead reckoning + lasers or transpondersdead reckoning + lasers or transponders
– path restrictedpath restricted
• induction wires in the floorinduction wires in the floor
• AGVAGV fork lift truck with RF-communicationfork lift truck with RF-communication
53. Design and operational control of anDesign and operational control of an
AGV systemAGV system
• AGV systemAGV system
– track layouttrack layout
– number of AGVsnumber of AGVs
– operational controloperational control
• Traffic control: zonesTraffic control: zones
max. throughputmax. throughput
capacitycapacity
54. Track layoutTrack layout
• infrastructureinfrastructure
• location of pick-up and drop-off stationslocation of pick-up and drop-off stations
• buffer sizesbuffer sizes
– congestion/blockingcongestion/blocking
• tandem configurationtandem configuration
55. Determination of number of AGVsDetermination of number of AGVs
h
timetravelemptytotaltv
AGVs
i j
ijij∑∑ +
=
)min(
#
5 x
6 x
4 x LP-problem
(i.e. a classical TP)
56. Operational transportation controlOperational transportation control
Job controlJob control
(routing and scheduling of transportation tasks)(routing and scheduling of transportation tasks)
Traffic controlTraffic control
Traffic rulesTraffic rules
• Goal: minimize empty travel + waiting timeGoal: minimize empty travel + waiting time
• Single load:Single load: Performance indicators:Performance indicators:
- Throughput- Throughput
- Throughput times- Throughput times
57. Operational controlOperational control
• production controlproduction control transportation controltransportation control
– flow shopflow shop
– job shopjob shop
• centralized controlcentralized control
– all tasks are concurrently consideredall tasks are concurrently considered
• or decentralized controlor decentralized control
– FEFS: AGV looks for work (suited for tandem configuration)FEFS: AGV looks for work (suited for tandem configuration)
• think-aheadthink-ahead
– combine tasks to routescombine tasks to routes
• or no think-aheador no think-ahead
59. Combination 1Combination 1
Separated/no think-aheadSeparated/no think-ahead
• centralized controlcentralized control
• on-line priority rules:on-line priority rules:
1.1. transportation task assignmenttransportation task assignment
tasks wait, ortasks wait, or
2.2. idle vehicle assignmentidle vehicle assignment
idle vehicles waitidle vehicles wait
Ad 1: push/pull (JIT), e.g. FCFS, MOQRSAd 1: push/pull (JIT), e.g. FCFS, MOQRS
PushPush sometimes “shop locking”sometimes “shop locking”
Ad 2: NV, LIVAd 2: NV, LIV
60. Combination 3Combination 3
Separated/think-ahead (1)Separated/think-ahead (1)
• Centralized controlCentralized control
a. without time windowsa. without time windows
– Only routingOnly routing
– Minimize empty travel time by simulatedMinimize empty travel time by simulated
annealing:annealing:
– 2 options:2 options:
• determine optimal route each time a new taskdetermine optimal route each time a new task
arrivesarrives
problem: a task may stay at the end of the routeproblem: a task may stay at the end of the route
• Periodic controlPeriodic control
time horizon (length?)time horizon (length?)
61. Combination 3Combination 3
Separated/think-ahead (2)Separated/think-ahead (2)
• Centralized controlCentralized control
b. with time horizonsb. with time horizons
– Simulated annealingSimulated annealing
machine 1
machine 2
machine 3
machine 1
machine 2
machine 3
machine 1
machine 2
machine 3
loaded trip
empty trip
loaded trip
empty trip
loaded trip
empty trip
