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Presentation 13
Presentation 13
Presentation 13
CORELAP:
CORELAP Computerized Relationship Layout Planning
Layout design IV. y Developed for main frame computers
Ch
Chapter 6
6 y Adjacency‐based method
◦ CORELAP uses A=4, E=3, I=2, O=1, U=0 and X=‐1
Layout generation values
l
CORELAP y Selection of the departments to enter the
ALDEP layout is based on Total Closeness Rating
layout is based on Total Closeness Rating
MULTIPLE ◦ Total Closeness Rating (TCR) for a department is
the sum of the numerical values assigned to the
MIP closeness relationships between the department
and all other departments.
m
TCR = ∑w
j =1,i ≠ j
ij
CORELAP CORELAP
Department selection Department placement
1. The first department placed in the layout is the one with the
1 The first department placed in the layout is the one with the • Department neighbors
Department neighbors 8 7 6
greatest TCR value. If there is a tie, then choose the one with o Fully adjacent (in position 1, 3, 5 or 7) with department 0 1 0 5
more A’s (E’s, etc.). o Touching (in position 2, 4, 6 or 8) department 0 2 3 4
2. If a department has an X relationship with the first one, it is
placed last in the layout. If a tie exists, choose the one with
l d l t i th l t If ti it h th ith
the smallest TCR value. • Placing rating (PR) is the sum of the weighted closeness ratings between the
3. The second department is the one with an A relationship with department to enter the layout and its neighbors.
( )
the first one (or E, I, etc.). If a tie exists, choose the one with PR = ∑ wikk where k = {departments already placed}
the greatest TCR value. k
4. If a department has an X relationship with the second one, it is • The placement of departments is based on the following steps:
placed next‐to‐the‐last or last in the layout. If a tie exists,
choose the one with the smallest TCR value
choose the one with the smallest TCR value. 1. The first department selected is placed in the middle.
p p
5. The third department is the one with most A (E, I, etc.) 2. The placement of a department is determined by evaluating PR for all possible
relationships with the already placed departments. If a tie
locations around the current layout in counterclockwise order beginning at the
exists, choose the one with the greatest TCR value.
6. The procedure continues until all departments have been “
“western edge”.
t d ”
placed. 3. The new department is located based on the greatest PR value.
CORELAP – Example 1 CORELAP – Example 1
¾Given the relationship chart and the departmental dimensions
Given the relationship chart and the departmental dimensions A=4 E=3 I=2 O=1 U=0 X= 1
A=4, E=3, I=2, O=1, U=0, X=‐1
below determine the sequence of the placement of the
departments in the layout based on the CORELAP algorithm. Place
the departments in the layout while evaluating each placement.
the departments in the layout while evaluating each placement.
Table of TCR Values
PR = E[6,9] = 3
Both options gives the
p g
same PR Score
PR = A[5,7]+I[6,7]
= 4 + 2 = 6
4+2 6
If the location for the
p
department 7 is chosen as PR = E[6,9]+O[5,9] = 3 + 1= 4
shown, the PR would be
PR = A [5,7] =4
The placement sequence: 5‐6‐7‐9‐3‐8‐1‐2‐4 The placement sequence: 5‐6‐7‐9‐3‐8‐1‐2‐4
CORELAP – Example 1 CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=‐1 A=4, E=3, I=2, O=1, U=0, X=‐1
PR = I[1,3]
[1 3] + U (1,7) = 2 +
( , ) 0 = 2
PR I[3,5] + O
PR = I O[3,7] + U (3,9) = 2 + 1 + 0 = 3
U (3 9) 2 1 0 3
Continue with Department 4.
The placement sequence: 5‐6‐7‐9‐3‐8‐1‐2‐4 The placement sequence: 5‐6‐7‐9‐3‐8‐1‐2‐4
¾ Given the relationship chart below and the sequence of the
Given the relationship chart below and the sequence of the CORELAP – Example 2
Example 2
placement of the departments 7‐5‐9‐3‐1‐4‐2‐6‐8, find the best layout
The placement sequence: 7‐5‐9‐3‐1‐4‐2‐6‐8
with CORELAP algorithm assuming that all the departments have the
same size. Use these closeness values: A=125, E=25, I=5, O=1, U=0, X=‐
125 and consider half weight if the departments are only touching by 62.5 125 62.5 62.5 187.5 187.5 62.5
one point.
1. Receiving
g
125 7 125 125 5 7 125
A
2. Shipping A 62.5 125 62.5 62.5 187.5 187.5 62.5
E E
3. Raw Materials Storage A O
E U U
4. Finished Goods Storage A O U 62.5 125 62.5 0 62.5 125.5 63.5 0.5 0
E U U A
5. Manufacturing O U E O
A A E U 187 5
187.5 5 7 0 125 3 5 7 0
6. Work-In-Process Storage A E A
A O U 187.5 9 187.5 0 62.5 126.5 9 1.5 0
7. Assembly O A
X O 62 5 125
62.5 62 5
62.5 05
0.5 1 05
0.5
8. Offices A
X
9. Maintenance
A=125, E=25, I=5, O=1, U=0, X=‐125 A=125, E=25, I=5, O=1, U=0, X=‐125
CORELAP – Example 2
Example 2 CORELAP – Example 2
Example 2
The placement sequence: 7‐5‐9‐3‐1‐4‐2‐6‐8 The placement sequence: 7‐5‐9‐3‐1‐4‐2‐6‐8
1 2 1 9 4 63.5
CORELAP ‐
CORELAP Comments ALDEP – Automated Layout Design Program
ALDEP Automated Layout Design Program
y The final layouts are evaluated by the y Similar to CORELAP (objectives,
distance‐based layout score requirements)
◦ CORELAP uses the shortest rectilinear path
p y The main differences:
between the departments (not always ◦ Randomness
realistic)
◦ Multi
Multi‐floor
floor capability
capability
y The layouts often result in irregular ◦ CORELAP attempts to produce the best
building shapes layout, ALDEP produces many layouts
y , p y y
ALDEP
ALDEP ‐ Procedure
ALDEP
y Department selection
y Vertical sweep pattern
◦ Randomly
Randomly selects the first department
selects the first department
◦ Out of those departments which have “A” relationship with the first one
(or “E”, “I”, etc. – min level of importance is determined by the user) it
selects randomly the second department y Sweep width
◦ If no such department exists it selects the second one completely
If no such department exists it selects the second one completely Dept size = 14 grids
Dept. size = 14 grids Dept size = 8 grids
Dept. size = 8 grids
randomly
◦ The selection procedure is repeated until all the departments are x 1 grid
selected
y D
Department placement
t t l t
◦ Starts from upper left corner and extends it downward Dept. size = 14 grids
◦ Vertical sweep pattern
◦ Sweep width is determined by the user
Sweep width is determined by the user x 2 grids
2 grids
y Adjacency‐based evaluation
◦ If minimum requirements met, it prints out the layout and the scores Dept. size = 8 grids
y Repeats the procedure (max 20 layouts per run)
Repeats the procedure (max 20 layouts per run)
y User evaluation x 3 grids
ALDEP Example
ALDEP ALDEP Example
ALDEP
¾ Use ALDEP procedure to determine the layout y Department selection
vector, construct and evaluate the layout for the
vector construct and evaluate the layout for the
facility based on the relationship chart and the Step Department selected Reason for selection
departmental dimensions given below. Use the 1 4 random
sweep width of 2 and the minimum acceptable
sweep width of 2 and the minimum acceptable 2 2 “E” i h 4
“E” with 4
level of importance “E”. The closeness values: 3 1 “E” with 2
A=64, E=16, I=4, O=1, U=0, X=‐1024 4 6 random
5 5 “A” with 6
6 7 random
Dept. Area # of unit area templates
7 3 remaining
1 12,000 30
2 8000 20
3
4
6000
12,000
15
30
y Layout vector
5 8000 20 ◦ 4‐2‐1‐6‐5‐7‐3
6 12 000
12,000 30
7 12,000 30
Dept. # of unit area
ALDEP Example 1
2
templates
30
20 ALDEP Example
ALDEP
y Layout construction 3
4
15
30
◦ Layout vector: 4‐2‐1‐6‐5‐7‐3 5 20
◦ Sweep width: 2
6 30
S id h 2 7 30
y Adjacency score A=64, E=16, I=4, O=1, U=0, X=‐1024
• Final layout
MULTIPLE – Multi
MULTIPLE Multi‐floor
floor Plant Layout Evaluation
Plant Layout Evaluation MULTIPLE ‐ Spacefilling Curves (SFC)
MULTIPLE Curves (SFC)
y Construction and improvement algorithm y Spacefilling curve connects all the grids in a layout
◦ Each grid is visited exactly once
E h id i i it d tl
y Distance‐based algorithm ◦ Next grid visited is always adjacent
to the current grid (only horizontal or
y Similar to CRAFT (departments not
Similar to CRAFT (departments not vertical moves)
vertical moves)
y SFC is generated by the computer
restricted to rectangular shapes, discrete y SFC allows MULTIPLE to
representation two‐way
representation, two way exchanges)
exchanges) Map a layout vector into a
Map a layout vector into a
y But MULTIPLE can exchange non‐adjacent two‐dimensional layout
y Procedure:
departments ◦ The departments are placed based on the layout vector
(similar as MCRAFT)
y Uses spacefilling curves to reconstruct a
◦ The SFC is followed until the required number of grid for
new layout after each iteration
l t ft h it ti each department is reached
hd h d
MULTIPLE ‐ Example
MULTIPLE MULTIPLE ‐ Example
MULTIPLE
Dep. Area
y Create a MULTIPLE layout for the y Layout vector 1‐2‐3‐4‐5‐6 1 16
2 8
d
departments below based on the layout
b l b d h l 3 4
vector 1‐2‐3‐4‐5‐6. Then build a new layout 4 16
by exchanging the departments 1 and 5 The
by exchanging the departments 1 and 5. The 2 3 4 5 8
6 12
facility and SFC are given below.
Department Area (m^2)
1 16
5
2 8 1
3 4
4 16 6
5 8
6 12
MULTIPLE ‐ Example
MULTIPLE MULTIPLE ‐ Example
MULTIPLE
Dep. Area
y Layout vector 1‐2‐3‐4‐5‐6 1 16 y Exchange 1 and 5 ‐ Layout vector 5‐2‐3‐4‐1‐6
2 8
3 4
4 16
2 3 4 5 8
6 12
5
1
6
MULTIPLE ‐ Example
MULTIPLE MULTIPLE ‐ Example
MULTIPLE
Dep. Area
y Layout vector 5‐2‐3‐4‐1‐6 y Initial layout
1 16
2 8
3 4
4 16
4 1 5 8
6 12
3 y LLayout after
t ft
the exchange
2
5 6
MULTIPLE ‐ Conforming Curves
MULTIPLE Conforming Curves MULTIPLE ‐ Conforming Curves
MULTIPLE Conforming Curves
y Conforming curves are hand‐generated curves
y They are used:
◦ If the building shape is irregular
◦ If we want to capture the initial layout exactly
If we want to capture the initial layout exactly
◦ If there are numerous obstacles (walls)
◦ If there are fixed departments
y Procedure:
◦ May start and end at any grid
◦ The curve visits all the grids assigned to a particular
department before visiting other department
◦ The fixed departments and obstacles are not visited
p
MULTIPLE MULTIPLE
y Final MULTIPLE layout for the CRAFT y Final MULTIPLE layout for the CRAFT
example
example may also need massaging to
smooth the department borders
y The cost is lower than for the final layout
f
found by CRAFT!
db !
◦ MULTIPLE is very likely to obtain lower‐cost
so ut o s t a C
solutions than CRAFT, since it considers a larger
, s ce t co s de s a a ge
set of possible solutions at each iteration
y Optimal layout vector:
MULTIPLE ‐ Construction algorithm
MULTIPLE Construction algorithm D B H C F E
D‐B‐H‐C‐F‐E
Cost z=54,200
y Any SFC or conforming curves could be
used to fill the vacant building
y Any vector can be used as the initial
y
layout vector y Optimal layout vector:
D‐E‐F‐B‐C‐H
y Alternative layouts can be generated by
Alternative layouts can be generated by Cost z=54 900
Cost z=54,900
trying different SFC
◦ The cost may not be much different
The cost may not be much different
y Optimal layout vector:
D‐E‐F‐H‐B‐C
Cost z=54,540
MIP‐Mixed Integer Programming MIP‐Mixed Integer Programming
◦ Generally construction type models y Obj i
Objective
◦ Could be used to improve a layout as well ◦ Minimize the total cost/total distance
◦ Distance –based objective
i b d bj i travelled
◦ All the departments are assumed to be
y Subject to
rectangular ◦ Rectangular department shapes
g p p
◦ The minimum and maximum sizes for the
◦ Centroid and the length (width) of the width and heights of departments
department will fully define its location and
p y
◦ The minimum area requirement of
The minimum area requirement of
shape departments
◦ Continuous representation ◦ Departments are completely located inside
the building
◦ Departments do not overlap
◦ All the departments are located on the floor
All the departments are located on the floor
Y
MIP‐Mixed Integer Programming MIP‐Mixed Integer Programming ( x , yi'' )
'
( xi'' , yi'' )
i
(1)
(2)
(3)
X
(4) BX
(5)
Makes the model nonlinear
Decision variables:
Decision variables: ((6))
(7)
(8) Make sure that
(9) departments do not
overlap
(10)
(11)
(12)
(13)
MIP Example
Example ‐‐ Results
MIP ‐‐ Example
MIP
¾Formulate MIP model for the Upper
X
35
Y
7.14
facility with the required A Lower 0 0
dimension and coordinates of
dimension and coordinates of Flow-between Chart Upper 27.49 12.14
the departments below. Given B Lower 7.49 7.14
is also Flow‐between chart and Upper 27.49 22.14
the costs of transfer among the
the costs of transfer among the C
C Lower
Lower 7 49
7.49 12 14
12.14
departments. The available
space for the facility is 39 X 43 =
1677m^2. 22.14
C
12.14
o Total cost calculation: 7.14
7.49 27.49 35
Conclusion
MIP‐‐ Comments
MIP
Layout generation algorithms
y Benefits of MIP Model
◦ Department
Department shapes as well as their areas can be modeled through
shapes as well as their areas can be modeled through
individually specified lower and upper limits
◦ MIP might be able to control length‐width ratio as well y There is no commercial package that will
x (xi’’ – xi’ ) <= R (yi’’‐yi’) or
x (yi
(yi’’ – yi’
yi ) <
) <= R (xi
R (xi’’‐xi’)
xi ) suit all the needs, partly due to the
suit all the needs, partly due to the
◦ However, to use the MIP model effectively, some flexibility in the
departmental specifications is required difficulty of the problem, but more due to
y May be used to improve a given layout as well
y Solving the problem exactly (optimal solution) is hard
the fact that facility layout is a
the fact that facility layout is a
◦ 7‐8 departments is the typical size solvable in a reasonable amount of
time
combination of Science and Art.
◦ In practice, the number of departments easily exceeds 15
In practice, the number of departments easily exceeds 15‐18 18
y Heuristically, CRAFT could be combined with MIP.
◦ Get an initial layout using CRAFT, use MIP to find the best rectangular
layout design
y A rectangle is not always an ideal shape for the department
Next lecture
Next lecture
y Quantitative methods