2. GROUP MEMBERS Ahsen Ali 11-IE-06 Mohsin Tariq 11-IE-22
Shahbaz Farid 11-IE-35

3. Layout Planning Models and Design Algorithms
Chapter#06
Layout Planning Models and Design Algorithms

4. Facility Layout
Facility layout is simply the way a facility is arranged in order to maximize processes that are not only efficient but effective towards the overall organizational goal.
It consists of two levels:
Block layout
Detailed layout

5. Block Layout
Block layout shows the location, shape, and size of each planning department.
Block layout is concerned primarily with macro flows in the facility.

6. Detailed Layout
Detailed layout shows the exact location of all the equipment, work benches and storage areas within each department.
Detailed layout is concerned with micro flows in the facility.

7. Which layout comes first!
First, we must obtain the basic requirement of each department (such as space requirement, shape constraints, etc) and then develop a set of alternative block layouts.
Once the desirable block layout is identified, the analyst can then develop a detailed layout of each department.

8. Layout Procedures Many procedures are available Broadly classified:
Construction layout method
It involves developing a new layout “from scratch”
Improvement layout method
Generating layout alternatives by doing improvements in an existing layout

9. Apple’s Plant Layout Procedure

10. Apple’s Plant Layout Procedure

11. Reed’s Plant Layout Procedure

12. Reed’s Plant Layout Procedure
Most important
Prepare layout planning chart
Layout planning chart incorporates the following:
Flow process, including operations, transportation, storage and inspections
Standard times for each operations
Machine selection and balance
Manpower selection and balance
Material handling requirements

13. Layout Planning Chart

14. Systematic Layout Planning
A well known procedural solution approach for the layout problem is the Systematic Layout Planning (SLP), which is developed in the early 1970s by Muther
It consists of four phases:
determining the location of the area where facilities will be laid out
establishing general overall layout
establishing detailed layout plans
installing the selected layout

16. Activity Relationship Chart

17. Relationship Diagram
Relationship diagram position the activities spatially.
Proximities are typically used to reflect the relationship between pair of activities
Relationship diagram are usually two-dimensional

18. Relationship Diagram

19. Space Requirement Diagram
It involves the determination of the amount of space to be assigned to each activity
Once the space assignments have been made, space templates are developed for each planning department, and space is “hung on the relationship diagram” to obtain the space relationship diagram

20. Space Requirement Diagram

21. Alternative Block Layout

22. Algorithmic Approaches
It helps the analyst to develop and improve the layout.
It provides the objective criteria to facilitate the evaluation of various layout alternatives that emerge in the process.

23. Algorithm Classification
Layout algorithm can be classified on the type of input data.
Qualitative data (Relationship Chart)
Quantitative data (To and From Chart)
It can be classified w.r.t Objective Function.
Distance based objective
Adjacency based objective

24. Distance Based Objective

25. Adjacency Based Objective

26. Modeling Techniques for Algorithm
There are many method/techniques which are used in various layout Algorithms.
Here we will discuss only two:
Pairwise Exchange Method
Graph Based Method

34. Department Shapes and Main Aisles
Attaining good department shapes is an important consideration in finalizing block layout
Irregular department shapes leads to irregular main aisles
For efficient material handling, safety and evacuation in emergency

35. Main aisle should connect all the departments in a facility with
Minimum travel
Minimum number of turns
Minimum jog overs
Controlling department shapes is straight forward for rectangular departments obtained with BLOCPLAN and MIP
It is straight-forward to define and measure shape of rectangle
It is ratio of longer side to its shorter side

36. Non rectangular shapes those obtained with CRAFT and MULTIPLE
Shape measurement and control is not straight forward for given two alternatives but “similar shape” for the same department
One alternative may be regarded as acceptable while other regarded as poor

37. First measure obtained by dividing the area of the smallest enclosing rectangle (SER) by area of department
The second measure is obtained by dividing the longer side of SER by its shortest side
Third measure based on observation, given an object with fixed area the perimeter of the object generally increases as its shape become more irregular

38. Measure the shape of a department by dividing its perimeter by its area
It is difficult to predict reasonable value for it
Above ratio is normalized as follow
If ideal shape for a department is square, then ideal shape factor
S*=(P/A)*=4√A/A=4/√A

39. Normalized Shape Factor F is equal to
F=S/S*=P/A/4/√A=P/4√A
If a department is square shape then we obtain
F=1.0 otherwise F>1.0
Reasonable shapes are obtained if
1≤F ≤1.4

41. First measure Second measure
For figure a,b,c,d
= a) = 4
25/16= b) =1
= c) =1
= d) =1
Third measure perimeter
a) = a) =20
b)= b) =20
c) c) =24
d) d) =26