Facility Layout: Eng. Alexander Aragón Ch. M.SC

564201
Facility Layout
Eng. Alexander Aragón Ch. M.Sc.
Department of Operations and Systems - DOS
Faculty of Engineering
Class
2021-03
www.alexanderaragon.co
Art. 57° Res. CA. 666 Dic. 17 / 2020

«Student Regulations»
Art. 9° Res. CA. 6602 Oct. 30 / 2017
«Code of Ethics»
Personería jurídica, Res. No. 0618, de la Gobernación del Valle del Cauca, del 20 de febrero de 1970. Universidad Autónoma de Occidente, Res. No. 2766, del Ministerio de Educación Nacional, del 13 de noviembre de 2003, Acreditación Institucional de Alta Calidad, Res. No. 16740, del 24 de agosto de 2017, con vigencia hasta el 2021. Vigilada MinEducación.
Module 2
Plant Layout Design
Session 4
The PQRST Key / SPL Method – 84

Relationship Analysis – 87
Flow Costs Analysis – 94
Line Balancing – 99
Heuristics Methodologies – 103
Assessment Activity – 111
Glosary – 112
References Session 4 – 113
83
/-\\ 2021-03. Didactic support material – Eng. Alexander Aragón Ch. (www.alexanderaragon.co) – Universidad Autónoma de Occidente 564201 - Facility Layout
The PQRST key / SPL Method
The PQRST Key to Unlocking Distribution Problems1
There are two basic elements on which any distribution problem rests: The Product (Material or Service) and the Quantity (or Volume).
P S
Product / Service Support Services
What to produce? With what services will it be produced?
R Why?
Routing / Process Sequence
How will they occur?
T
Time
When will they produce?
Q
Quantity / Volume
How much of each?
84
The PQRST Key to Unlock Distribution Problems
P. Raw materials, product in process and the finished product and / or the services
provided. Forecasts, Product / Service Design.
Q. Quantity of goods manufactured or services provided. Forecast, Planning the
Capacity.
R. The process, equipment, operations and its sequence. Technological
Requirements, Selection of the Type of Process.
S. Auxiliary resources that provide support to the activities: maintenance, repairs,
tools, loockers, coffee shops, first aid, storage areas, etc. Facilities and Equipment,
Distribution, Technological Requirements.
T. Operation time, shifts, takt time, cycle times, etc. Job design.
Why ? A forever questionable reminder for you, of whether the basic

information with which the distribution is considered, is accurate, reliable.
85
The PQRST Key (also known as the SLP Method, Systematic Layout Planning)
follows the following development phases1:
Operations
Diagram
Factor
Evaluation
S.O. 4 S.O. 6
Products Route Space needs Influencing factors
S.O. 1 S.O. 5
Products-Quantities Relational diagram of Relational diagram of
Obtaining solutions
Analysis routes-activities spaces
Pareto Selection of
ABC analysis Relationship Practical
Available space Alternatives
between activities limitations
Normalizado
Normalizada
Prioridad
Prioridad
Propulsión Propulsión Propulsión con Propulsión
Valor
Gravedad Elasticidad Aire Mixta (si aplica)
Costo
Fabricación
20,0% 4,00 0,19 1,00 0,19 2,00 0,38 3,00 0,57 4,00 0,76
Peso Total 24,4% 6,00 0,29 4,00 1,14 3,00 0,86 2,00 0,57 1,00 0,29
Relations
CRITERIOS
Operarios
Requeridos
15,6% 3,00 0,14 1,00 0,14 3,00 0,43 2,00 0,29 4,00 0,57
Precisión 13,3% 2,00 0,10 4,00 0,38 3,00 0,29 2,00 0,19 1,00 0,10
Diagram
Tiempo
Ensamble
22,2% 5,00 0,24 1,00 0,24 3,00 0,71 2,00 0,48 4,00 0,95
Selection Velocidad
2,86
4,4%
100%
1,00
21
0,05
1,00
1,00 0,05
2,14
2,00 0,10
2,76
3,00 0,14
2,24
4,00 0,19
2,86
S.O. 3 Selected Implementation

Project
Student Student
Outcome 2 Outcome 7
86
Relationship Analysis
Relationship
between activities The Relations Diagram (Muther Grid), facilitates the analysis of relationships between different departments, showing
relative importance by matching them to each other2:
COD. NEARBY DEGREE
2
1 Departament 1 A Absolutely necessary
3
A1
4
2 Departament 2 A3 E Very important
5
E2 X5
6
3 Departament 3 U U I Important
1
X5 I O
4 Departament 4 A A3 O Mediumly Important
2
O X
3
5 Departament 5 A U Not important
4
A
5
6 Departament 6 X Undesirable
6
Muther accompanies the letters with a number to indicate the reason for each
relationship, according to the following list, although it can be adapted to the specific
needs of each case:
1. The same equipment or facilities are used. 4. Required to facilitate communication.
2. They share the same staff or records. 5. It could create unsafe or unpleasant conditions.
3. They require workflow sequence. 6. Similar jobs are executed.
87
Relationship
Mobile/fixed boards area
Practice area
Study area Archive/multimedia area
Entry and Registration

A
88
Relationship
89
Relationship
between activities For further analysis, the information collected in the Relationship Diagram is summarized in the Worksheet:
# Actividades / Activities A E I O U X
1 Fabricación 2, 6 3, 10 9, 11, 13, 14 4, 5, 12 7, 8
2 Soldadura 1, 3 6 9, 10, 12, 13, 5 7, 8, 4, 11, 14
3 Pintura 2, 4 1 6 12, 13, 9 5, 7, 8, 10, 11, 14
4 Ensamble y Empaque 3, 7 6, 8 9, 12, 13, 14 1, 5 2, 10, 11
5 Recepción 6 14 4, 2, 1, 9, 12, 13 3, 7, 10, 11 8
6 Almacenes 5, 1 4 3, 2, 14 9 8, 10, 11, 12, 13 7
7 Bodega 4, 8 14 5, 3, 2, 1, 9, 10, 11, 12, 13 6
8 Envíos 7 4 14 9, 12, 13 6, 3, 2, 1, 10, 11 5
9 Baños 12 13, 14 4, 1 8, 6, 5, 11, 3, 2, 10 7
10 Taller Mantenimiento 11 1 9, 2 8, 7, 6, 5, 4, 3, 12, 13, 14
11 Cuarto Herramientas 10 1 9, 14 8, 7, 6, 5, 4, 3, 2, 12, 13
12 Lockers 9 13 4 8, 5, 3, 2, 1 11, 10, 7, 6, 14
13 Cafetería 14, 12, 9 4, 1 8, 5, 3, 2 10, 11, 7, 6
14 Oficinas 13, 9 8, 6, 5, 4, 1 11, 7 12, 10, 2, 3
90
Relationship
between activities Subsequently, we prepare cards to build the Dimensionless Block Diagram, recording on them the information from the
Worksheet:
# Actividades / Activities A E I O U X
1 Fabricación 2, 6 3, 10 9, 11, 13, 14
9, 14 4, 5, 12 7, 8
2 Soldadura 1, 3 6 9,
9, 10,
10, 12, 13,
13, 55 7, 8, 4, 11, 14
3 Pintura 2, 4 1 6 12, 13, 9 5, 7, 8, 10, 11, 14
4 Ensamble y Empaque 3, 7 6, 8 9, 12, 13, 14 1, 5 2, 10, 11
5 Recepción 6 14 4, 2, 1, 9, 12, 13 3, 7, 10, 11 8
6 Almacenes 5, 1 4 3, 2, 14 9 8, 10, 11, 12, 13 7
7 Bodega 4, 8 14 5, 3, 2, 1, 9, 10, 11, 12, 13 6
8 Envíos 7 4 14 9, 12, 13 6, 3, 2, 1, 10, 11 5
9 Baños 12 13, 14 4, 1 8, 6, 5, 11, 3, 2, 10 7
10 Taller Mantenimiento 11 1 9, 2 8, 7, 6, 5, 4, 3, 12, 13, 14
11 Cuarto Herramientas 10 1 9, 14 8, 7, 6, 5, 4, 3, 2, 12, 13
12 Lockers 9 13 4 8, 5, 3, 2, 1 11, 10, 7, 6, 14
13 Cafetería 14, 12, 9 4, 1 8, 5, 3, 2 10, 11, 7, 6
14 Oficinas 13, 9 8, 6, 5, 4, 1 11, 7 12, 10, 2, 3
A E A E
1 2
Fabricación Soldadura
X X
I O I O
91
Relationship
between activities Now, with these cards a first distribution proposal will be built.
2,6 3,10 1,3 - 2,4 1 3,7 6,8
1 2 3 4
Fabricación Soldadura Pintura Ensamble y Empaque
9,11,13,14 4,5,12 6 5,9,10,12,13 6 9,12,13 9,12,13,14 1,5
6 - 5,1 4 4,8 - 7 4
5 6 7 8
Recepción Almacenes Bodegas Envíos
8 7 6 5
14 1,2,4,9,12,13 3,2,14 9 - 1,2,3,5,9,10,11,12,13 14 9,12,13
12 13,14 11 1 10 - 9 13
9 10 11 12
Sanitarios Taller Mantenimiento Cuarto de Herramientas Lockers
1,4 2,3,5,6,8,10,11 - 9,2 1 9,14 4 1,2,3,5,8
- 14,12,9 - 9,13
13 14
Cafetería Oficinas
1,4 2,3,5,8 1,4,5,6,8 7,11
92
Relationship
between activities
6 - 5,1 4 11 1 10 -
Now, with these cards a first distribution proposal will be built.
5 6 10 11
Recepción
8
Almacenes
7
Taller Mantenimiento Cuarto de Herramientas
Organize the cards by joining those whose close relationship is
categories A or E. Remember to avoid putting them together if they
- 9,2 1 9,14
14
1,3
1,2,4,9,12,13 3,2,14
- 2,6
9
3,10 7 4
have category X.
2
Soldadura
1
Fabricación
8
Envíos
It is important that you confirm the process sequence, such that
5 the respective areas are in the corresponding flow.
6 5,9,10,12,13 9,11,13,14 4,5,12 14 9,12,13
2,4 1 3,7 6,8 4,8 - TCR (Total Closeness Rating): You can assign a weight to each letter
according to its importance, for calculate the TCR, and order it to review
3 4 7
Pintura Ensamble y Empaque Bodegas a possible distribution.
6
6 9,12,13 9,12,13,14 1,5 - 1,2,3,5,9,10,11,12,13

Total Weight TCR
12 13,14 9 13
9 12
Sanitarios Lockers
1,4 2,3,5,6,8,10,11 4 1,2,3,5,8
- 9,13 - 14,12,9
14 13
Oficinas Cafetería
1,4,5,6,8 7,11 1,4 2,3,5,8
93
Flow/Costs Analysis
Functional Distribution, by Processes, Flexible Flow, Job-Shop or Intermittent Production
The general procedure to design this type of distribution follows the following scheme3:
1. List and describe each functional work center (required space, equipment and number of people) including special requirements and
restrictions.
2. Prepare a drawing and description of the installation to be designed.
3. Identify and estimate the amount of flow of both materials and people between work centers.
4. Use structured analytical methods to obtain a good overall distribution.
5. Evaluate and modify the distribution, incorporating details such as the orientation of the machines, the location of storage areas and
access to equipment.
The quantities of units (flow) and the costs between departments are usually presented in Flow or Cost Matrices
respectively:
FLOW MATRIX MATRIX OF COSTS (US$/Und)

Assembly Painting Workshop Reception Shipment Tests Assembly Painting Workshop Reception Shipment Tests
Assembly 50 100 20 Assembly 10 15 15 10 10
Painting 30 50 10 Painting 20 15 15 10
Workshop 20 100 Workshop 25 20 15
Reception 50 Reception 15 20
Shipment Shipment 20
Tests Tests
94
Flow/Costs Analysis
Example:
In a given process, there are 6 departments that want to be distributed in six available areas. The distances between contiguous areas is
10 meters and between separate areas, 20 meters. The movement costs of the forklift is $ 100 per use. The number of displacements
estimated per week are shown in the following Flow Matrix. By location of the entrance, the Reception must be maintained in area 4:
FLOW MATRIX
Assembly Painting Workshop Reception Shipment Tests
Assembly 50 100 20
Painting 30 50 10
Workshop 20 100
Reception 50
Shipment
Tests
20 m 10 m
What would be the best distribution of the

departments in the available areas, which minimizes Area 1 Area 2 Area 3
the costs of using the forklift? 10 m
There are 6! possibilities (720 possible arrangements) Area 4 Area 5 Area 6
95
Flow/Costs Analysis
As an analytical method, the location of the “departments” is usually considered in such a way that the costs of handling
materials between them are minimized4. Thus, for example, if we know the number of necessary journeys (loads, people,
etc.) and their respective costs, understanding that these are a function of the distance traveled, then:
𝒇=𝒏 𝒅=𝒏
𝑴𝒊𝒏 ෍ ෍ 𝑸𝒇𝒏 𝒅𝒏 𝑪𝒇𝒏 𝒅𝒏

𝒇=𝟏 𝒅=𝟏
Where:
n = Number of Departments
f = Source departments from 1 to n
d = Destination departments from 1 to n
C fndn = Cost of moving a load from Source n to Destination n
Q fndn = Number of Loads to be moved from Source n to Destination n
This formula will only evaluate one option, so it should be used in each of the possible
options to compare them and select the best one.
What Student Outcomes are involved in this topic?
96
Flow/Costs Analysis
1. In QM For Windows select the Layout module.

2. Indicate the Title, the Number of Departments and whether the distances are Symmetric or
not; press ok.
A→ B = B → A
A→ B ≠ B → A
3. In the Flow Table, write the names of the Departments and the respective amounts; in the
Distance Table, the names of the Areas and the respective distances.
Indicate the cost of each movement
(optional) only version 5,
Select the "explicit enumeration"
method thus is more accurate.
Indicate that reception is fixed in area

4.
Student
Outcome 7
97
Flow/Costs Analysis
4. Click on the Solve button.
5. Look at the Layout Results window:
Total distance traveled

Minimum total cost
Assignment of areas to departments.
Pruebas Ensamble Pintura

1 2 3
Recepción Taller Embarque

4 5 6
6. The distance between individual departments is shown in the minimized window.

98
Line Balancing
Product Distribution, repetitive, in line or assembly / manufacturing lines, Flow Shop.
The general procedure to design this type of distributions focuses on the Balancing of the Line to be installed, a topic
addressed in Method Engineering, Work Study or Methods, Times and Movements courses.
Example:
For a new installation, it is desired to assemble an assembly line capable of producing 192 units in an 8-hour shift. The
activities are shown in the following Precedence Diagram:
Time Immediate
Work item
(sec) predecessor
A 40 None
B 80 A
C 30 D, E, F
D 25 B Review your notes and confirm the results obtained in
E 20 B POM / QM For Windows
F 15 B
G 120 A
H 145 G
I 130 H
J 115 C, I
TOTAL 720
What Student Outcomes are involved in this topic?
99
Line Balancing
1. In QM For Windows, select the Line Balancing module.
2. Indicate the Title, the Work Elements (Number of Work Elements) and the Time Units for tasks;
press ok.
3. In the Table, write the names of the Work Items and the respective amounts; in the section
of Predecessors, the respective Work Elements.
Enter the Cycle Time
Select a Heuristic Decision Rule.
Indicate activity times and precedence

relationships.
100
Line Balancing
4. Click on the Solve button.
5. Look at the Line Balancing Results window:
• Tiempo de Ciclo: 150 seg/und.

• Número de estaciones: 5
• 96% de Eficiencia
• Retraso de balanceo de solo 4%
101
Line Balancing
The graph of precedents:
B D I
J
F
A G H C
Work Station 1 Work Station 2 Work Station 3 Work Station 4 Work Station 5
102
Heuristic Methodologies
Basically, a heuristic algorithm is an established set of steps that allows you to find good quality solutions5.
CORELAP (Computerized Relationship Layout Planning) it is a methodology that locates the departments according to the
qualiﬁcation of total proximity represented in a rectilinear trajectory, the one with the greatest proximity relationship
being located in the center of the layout and as a tie-breaking rule the department with the largest area is always
selected. The main objective that this method seeks is to develop a distribution where the departments with the greatest
proximity relationship are as close as possible.
The algorithm6:
• Calculate the TCR (Total Closeness Rating) for each department. To calculate the TCR value, add up the weighting of the proximity
values for each department, where the proximity values for each department are obtained from the ARC (Activity Relationship
Chart), and the FTC (From To Chart) . From the ARC and FTC above, we can calculate TCR for each department from the TCR.
• Select one of the departments with maximum TCR, then place it first in the layout center.
• If there is the same TCR, first select the area that has a larger area then if the area is the same, then choose the department with
the smallest number.
• Place the department with the link A, with the one chosen, then the linkages E, I, O, U, and X. If there are several of the same, the
criteria are used the same as the previous step.
• If a department has been selected, determine its placement based on the Placing Rating, if the number of Weighted Closeness
Ratings between departments that have entered with who will enter. If the Placing Rating is the same, then the length of the
boundary or the number of square units adjacent to adjacent ones is compared.
• Layout evaluation through layout score:
103
CORELAP (Computerized Relationship Layout Planning).
Download CORELAP 01 (for Windows only)7:
1. Executable Program (Do not require installation).

2. User Manual (Spanish).
104
1 2
Practice Boards
[5] [1]
4 3
Study Multimdia
[4] [2]
5
Register
[3]
105
WorkShop 2:
Receiving
E
Shipping A
O O
Raw Mat. Storage A I
O O O
Finished Goods Storage A U O
O U E I
Manufacturing O U E X VALORES DE
A A O X CERCANÍA /
WiP Storage E E U CLOSENESS
VALUES
A I U
Assembly O A 500
I U
Sales A 200
I
Testing 50
2
0
-100
106
CRAFT (Computerized Relative Allocation of Facilities Technique) it is a methodology that locates the departments
attempting to minimize transportation cost, where8:
FLOW MATRIX
DISTANCE MATRIX
𝒊=𝒏 𝒋=𝒏 Assembly Painting Workshop Reception Shipment Tests
Assembly 50 100 20 FLOW MATRIX
𝑴𝒊𝒏 ෍ ෍ 𝒇𝒊𝒋 𝒄𝒊𝒋 𝒅𝒊𝒋 Painting
Workshop
30 50
20
10
100
𝒊=𝟏 𝒋=𝟏 Reception 50
Shipment
Tests MATRIX OF COSTS (US$/Und)
Transportation cost = flow * unit cost * distance Assembly Painting Workshop Reception Shipment Tests
Assembly 10 15 15 10 10
Painting 20 15 15 10
Workshop 25 20 15
Reception 15 20
Shipment 20
Tests
Evaluates all possible exchanges, which can be adjacent to each other or be of the
same area, this procedure seeks to find a combination that results in the lowest
cost than the current one.
107
CRAFT (Computerized Relative Allocation of Facilities Technique).
Download FLAP (Facility LAyout Program for Windows only)9:
1. Executable Program.
2. Includes User Manual (English).
3. OCX File needed.
4. As Administrator in flap folder, run: flap_v2.0>regsvr32 /i msflxgrd.ocx
108
CRAFT (Computerized Relative Allocation of Facilities Technique).
3
Multi
2 mdia
1
Boar [2]
Practice
ds
[5]
[1]
4
Study
5 [4]
Register
[3]
2
Boards
5
[1]
Regis
ter
[3]
1
Practice 4
3
[5] Study
Multi
mdia [4]
[2]
109
Other Heuristics
Facilities Layout Applet/Application (FLAP) v1.010
Manual and Download. Requires Java.
110
Assessment activity
For week 10, solve Workshop 2. You can work it with a classmate.
For class in week 10, create a mind map of key concepts about this topics:
1. Tools for Layout Distribution
From this information, we will do a quiz test in the last 10 minutes of class.
111
Glosary
Incorporate in this Glossary page, at least 5 terms or acronyms used in this session, with their respective definitions. You will need for
incorporating it in the final report.
112
References Session 4:
1. MUTHER, Richard & HALES, Lee. Systematic Layout Planning. Management & Industrial Research Publications. Marietta. GA, USA. 2015. 416 p.
2. STEVENSON, William J. Operations Management. McGraw-Hill Irwin. 7 ed. 2012. 945 p.
3. KUMAR, S. Anil. Operations Management. New Age International. 2009. 290 p.
4. RENDER, Barry & HEIZER, Jay. Administración de la Producción. Pearson Educación, México. 2007. 472 p.
5. HERRERA, Juan Carlos, et. al. Enfoque técnicas de distribución y simulación. Rediseño de la planta de producción en una empresa del sector eléctrico industrial. Fundación Universirtara Tecnológico Comfenalco.
Corporación Universitaria Latinoamericana. 2017, 69 p.
6. PRASETYO, Nayoko, et. al. Facility Layout Design with Corelap Algorithm for Educational Tour. IOP Publishing Ltd.Conf. Series: Materials Science and Engineering 982 (2020) 012060 doi:10.1088/1757-
899X/982/1/012060
7. FERNANDEZ M. Benito. Desarrollo de una herramienta informática basada en el algoritmo CORELAP para la optimización de distribuciones en planta. Universidad de Sevilla. 2006. Software de Computadora.
8. SCHIFFAUEROVA, Anfrea. Methods for layout design. Class Material. Concordia Institute for Information Systems. 2013. 40 p.
9. SMITH, James M. Facility LAyout Program (FLAP) computer application. University of Massachusetts Amherst.
10. The Regents of the University of California. Facilities Layout Applet/Application – FLAP. 1998.
Material compiled by Alexander Aragón Ch. For academic use only.
Copyright notice: This presentation may contain copyrighted material cited in the sources consulted; Other material may conform to the uses allowed under the Multimedia guidelines and exemptions for academic use in Copyright laws in some
countries or under Creative Commons licensing. Use for other pourposes is prohibited.
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Icons: Graphic Resources SL (www.flaticon.com)
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/-\\ Last Update: September 7, 2021.
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564201

Art. 57° Res. CA. 666 Dic. 17 / 2020

The PQRST Key / SPL Method – 84

The PQRST Key to Unlocking Distribution Problems1

Why ? A forever questionable reminder for you, of whether the basic

Products Route Space needs Influencing factors

S.O. 3 Selected Implementation

Mobile/fixed boards area

Study area Archive/multimedia area

Entry and Registration

9,11,13,14 4,5,12 6 5,9,10,12,13 6 9,12,13 9,12,13,14 1,5

14 1,2,4,9,12,13 3,2,14 9 - 1,2,3,5,9,10,11,12,13 14 9,12,13

1,4 2,3,5,6,8,10,11 - 9,2 1 9,14 4 1,2,3,5,8

1,4 2,3,5,8 1,4,5,6,8 7,11

6 9,12,13 9,12,13,14 1,5 - 1,2,3,5,9,10,11,12,13

1,4 2,3,5,6,8,10,11 4 1,2,3,5,8

1,4,5,6,8 7,11 1,4 2,3,5,8

FLOW MATRIX MATRIX OF COSTS (US$/Und)

What would be the best distribution of the

There are 6! possibilities (720 possible arrangements) Area 4 Area 5 Area 6

𝑴𝒊𝒏 ෍ ෍ 𝑸𝒇𝒏 𝒅𝒏 𝑪𝒇𝒏 𝒅𝒏

What Student Outcomes are involved in this topic?

1. In QM For Windows select the Layout module.

Indicate that reception is fixed in area

5. Look at the Layout Results window:

Total distance traveled

Pruebas Ensamble Pintura

Recepción Taller Embarque

6. The distance between individual departments is shown in the minimized window.

Indicate activity times and precedence

5. Look at the Line Balancing Results window:

• Tiempo de Ciclo: 150 seg/und.

Download CORELAP 01 (for Windows only)7:

1. Executable Program (Do not require installation).

Download FLAP (Facility LAyout Program for Windows only)9:

Facilities Layout Applet/Application (FLAP) v1.010

Manual and Download. Requires Java.

1. Tools for Layout Distribution

Material compiled by Alexander Aragón Ch. For academic use only.

Icons: Graphic Resources SL (www.flaticon.com)

/-\\ Last Update: September 7, 2021.

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