1. Facility Layout 2 Basic Data and Layout Evaluation

2. The objective is to design a block layout. 4b 1 23 4 5 Block Layout Show the general placement, dimensions and relative position of departments

3. Next, how do we evaluate the block layout. Flow Patterns – qualitatively Qualitatively generated reward matrix –REL chart –Maximize A-based measure Quantitatively generated reward matrix –Flow x Distance x Cost –Minimize this D-based objective 1 2 43 100 200 100

4. Flow patterns – qualitative measure

5. Interaction Data REL chart Flow chart From-to Flow between Rewardmatrix Qualitative DataQuantitative Data Chart adapted from Meller- ISE3214/5244 Rewardmatrix Develop Layouts Objective Function Select Layout Where does the data come from?

6. An example ABC Widgets Inc. is trying to create a layout for a new facility. The lot of terrain available is a square, 300 ft. by 300 ft. The company is organized in four departments, with the following dimensions: Dept 1:100’ x 300’ Dept 2:100’ x 200’ Dept 3:100’ x 200’ Dept 4: 100’ x 200’ First, try to build a couple of feasible layouts in the next page

7. 300 x 300 Let’s play with layouts 1 2 4 3 3 4 1 2

8. Now, let’s explore the relationships between the departments It is absolutely necessary that depts. 1 and 2 are close, and it is especially important that 1 and 4 are close. It is also important that 3 and 4 are somehow close and it’s OK if departments 2 and 4 are close to each other. Other than that, all other relationships are unimportant. REL1234 1-AUE 2--UO 3---I 4---- RatingDefinition A Absolutely Necessary E Especially Important I Important O Ordinary Closeness OK U Unimportant X Undesirable

9. 1 2 43 1 2 4 3 Layout 1Layout 2 100 200100 200 100 REL1234 1-AUE 2--UO 3---I 4---- In this example, we will calculate an Adjacency Based and a Distance Based Score for two layouts

10. Step 1: Convert REL data to a Reward Matrix REL1234 1-AUE 2--UO 3---I 4---- A = 8 E = 4 I = 2 O = 1 U = 0 (X = -8) REL1234 1-804 2--01 3---2 4---- Scores are usually powers of a base number f ij

11. Step 2: Find the Adjacency-Based score x ij = 1 if the departments are adjacent = 0 if the departments are not adjacent Adjacency means that they share a border, not corners Layouts with same adjacency score may have different travel distances

12. 1 2 43 Layout 1 100 200 100 1 2 4 3 Layout 2 100200 100 Here is the data we need REL1234 1-804 2--01 3---2 4---- f ij ABS 1 = 11 ABS 2 = 15

13. Step 3: Find the Relative Efficiency for both layouts ABS 1 Rel. Efficiency 1 = = 73% ABS 2 Rel. Efficiency 2 = = 100%

14. Back to the company Now we will obtain some data related to the production processes that take place on ABC Widgets 1 42 3 200 units a day 50 25 1 Size of the unit load 100 200 Flow1234 1-804 2--01 3---2 4---- f ij

15. Step 1: Find the flow data In this example, we will use the number of daily trips between departments f flow between dept i and j c cost of moving the load (independent of MHE) d distance from dept i to j (Centroid-to-Centroid and Rectilinear) Flow1234 1-804 2--01 3---2 4---- f ij

16. How do we calculate Rectilinear Distances? Rectilinear Distance means that we move horizontally and vertically, not diagonally Does this make sense? When or where? y1y1 y2y2 x1x1 x2x2 dxdx dydy Rect. Dist. = d x + d y Rect. Dist. = |x 1 -x 2 | + |y 1 -y 2 |

17. Step 2: Let’s find the the distances between departments 1 2 43 100 200 100 1 2 4 3 200 100 1234 x 50200150250 y 150250100 1234 x 50200 y 15025050150 Centroids Rectilinear Distances d 1234 1 -250150250 2 --200 3 ---100 4 ---- d 1234 1 -250 150 2 --200100 3 --- 4 ----

18. Step 3: Find the Distance Based score d 1234 1 -250150250 2 --200 3 ---100 4 ---- d 1234 1 -250 150 2 --200100 3 --- 4 ---- Flow1234 1-804 2--01 3---2 4---- f ij DBS 1 = 3400 DBS 2 = 2900

19. Next few classes will we discuss FLP algorithms. Methods to generate layouts from scratch or just generating improvements to layouts. Once we have a layout, we use our D-based and A- based measures to compare the layouts and select the best alternative. 4b 1 23 4 5