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Initial Layout Construction: - Preliminaries
Initial Layout Construction: - Preliminaries
Initial Layout Construction: - Preliminaries
• Preliminaries
– From-To Chart / Flow-Between chart
– REL Chart
– Layout Scores
• Traditional Layout Construction
• Manual CORELAP Algorithm
• Graph-Based Layout Construction
– REL Graph, REL Diagram, Planar Graph
– Layout Graph, Block Layout
– Heuristic Algorithm to Construct a REL Graph
– General Procedure
• Two activities are (fully) adjacent in a layout if they share a common border of positive
lenght, i.e., not just a point.
• Two activities are partially adjacent in a layout if they only share one or a finite
number of points, i.e., zero length.
5 8 7
10 9 6
4 2 3
Activity Relationship
1
Diagram
5 8 7
(500) (200) (575)
9
(500) 6
10 (75)
(1750)
4 2 3
(350) (125) (125)
1
Space Relationship (1000)
Diagram
• For each department, the Total Closeness Rating (TCR) is the sum of the absolute
values of the relationships with other departments.
1. The first department placed in the layout is the one with the greatest TCR value. I|f a tie
exists, choose the one with more A’s.
2. If a department has an X relationship with he first one, it is placed last in the layout. If a
tie exists, choose the one with the smallest TCR value.
3. The second department is the one with an A relationship with the first one. If a tie exists,
choose the one with the greatest TCR value.
5. The third department is the one with an A relationship with one of the placed departments.
If a tie exists, choose the one with the greatest TCR value.
• For each position, Weighted Placement (WP) is the sum of the numerical values for all
pairs of adjacent departments.
• The placement of departments is based on the following steps:
1. The first department selected is placed in the middle.
around the current layout in counterclockwise order beginning at the “western edge”.
1. Receiving
A
2. Shipping A
CV values:
E E V(A) = 125
3. Raw Materials Storage A O
V(E) = 25
E U U
A U V(I) = 5
4. Finished Goods Storage O
E U U A V(O) = 1
5. Manufacturing O U E O V(U) = 0
A A E U V(X) = -125
6. Work-In-Process Storage A E A
A O U Partial adjacency:
7. Assembly O A = 0.5
X O
8. Offices A
X
9. Maintenance
Department Summary
Dept. TCR Order
1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 402 (5)
2 A - E A U O U E A 2 2 0 1 3 0 301 (7)
3 A E - E A U U E A 3 3 0 0 2 0 450 (4)
4 E A E - E O A E U 2 4 0 1 1 0 351 (6)
5 U O A E - A A O A 4 1 0 2 1 0 527 (2)
6 U O U O A - A O O 2 0 0 4 2 0 254 (8)
7 U U U A A A - X A 4 0 0 0 3 1 625 (1)
8 A E E E O O X - X 1 3 0 2 0 2 452 (9)
9 O U A U A O A X - 3 0 0 2 2 1 502 (3)
187.5 5 7 0 125 3 5 7 0
0.5 1 3 5 7 125
1 2 1 9 4 63.5
0.5 1 0.5
• Assumption:
1 if activities i and j are fully adjacent ,
a ij
0 otherwise.
• A Planar Graph is a graph that can be drawn in two dimensions with no arc crossing.
Planar Nonplanar
• Given a (block) layout with M activities, a corresponding planar undirected graph, called the
Relationship (REL) Graph, can always be constructed.
1 2 1 2
3 4 5 3 4 5
(Exterior)
6
Block Layout
REL Graph
• A REL graph has M+1 nodes (one node for each activity and a node for the exterior of
the layout. The exterior can be considered as an additional activity. The arcs correspond
to the pairs of activities that are adjacent.
• A REL graph corresponding to a layout is planar because the arcs connecting two
adjacent activities can always be drawn passing through their common border of positive
length.
Copyright © 1999. Created by Jose
Ventura for the College-Industry Cou
Relationship (REL) Diagram
• A Relationship (REL) Diagram is also an undirected graph, generated from the REL
diagram, but it is in general nonplanar.
• A REL diagram, including the U closeness values, has M(M-1)/2 arcs. Since a planar
graph can have at most 3M-6 arcs, a REL diagram will be nonplanar if M(M-1)/2 >
3M-6.
M(M-1)/2 > 3M-6 M 5.
An upper bound on LSa, LSaUB, is the sum of the 3M-6 longest V(rij)’s.
• A planar graph with exactly 3M-6 arcs is called Maximally Planar Graph (MPG).
• The interior faces of a graph are the bounded regions formed by its arcs, and its
exterior face is the unbounded region formed by its outside arcs.
IF3
Copyright © 1999. Created by Jose
Ventura for the College-Industry Cou
Maximally Planar Graph (MPG)
• The interior faces and the exterior face of an MPG are triangular, i.e., the faces are
formed by three arcs.
Not triangular
Not an MPG
Not an MPG
• An MPG whose sum of arc weights is as large as any other possible MPG is called a
Maximally Planar Weighted Graph (MPWG).
• Using the V(rij)’s as arc weights, a REL graph that is a MPWG has the maximum
possible LSa, close to LSaUB.
• Given a graph G, its dual graph GD has a node for each face of G and two nodes in GD
are connected with an arc if the two corresponding faces in G share an arc.
• Example.
G GD
• The number of nodes in G (primal graph) is the same than the number of faces in G D
(dual graph), and vice versa. In addition,
(GD)D = G.
(Exterior) h
Layout Layout Graph
• Given a REL graph (RG), its corresponding layout graph (LG) is LG = RGD. E.g.,
6
RGD
1 2 3
4 5
LGD
RG LG
Copyright © 1999. Created by Jose
Ventura for the College-Industry Cou
Layout Graph (Cont.)
• If LG is given, then RG = LGD, but for layout construction, the layout is not known
initially, so LG cannot be constructed without RG.
• If a planar REL graph (primal graph) exist, the corresponding layout graph (dual graph)
is also planar. Therefore, it is possible theorectically to construct a block layout that will
satisfy all the adjacency requirements. In practice, this is not straightforward because the
space requirements of the activities are difficult to handle.
Dept. Area
A B
A 300
B 200
F G C 100
D 200
C D
E 100
F (exterior)
A B
1 4
8 3 F G
2 5
C D
A
8 1 6 A B E
1 5
C B F 8
2 3
7 2 3 4 C D F
D E
5 7
• A corner point is a point where at least three departments meet, including the exterior
department.
• Note that each corner point in the block layout corresponds to a node in the layout graph.
In the first block layout, each corner point is defined by “exactly” three departments. In
this case, there is a one-to-one correspondence between corner points and nodes in the
layout graph. In the square block layout, there are two corner points defined by four
departments, i.e., (A, B, C, D) and (B, D, E, F). Each of these two corner points
corresponds to two nodes in the layout graph.
Copyright © 1999. Created by Jose
Ventura for the College-Industry Cou
Heuristic Procedure to Construct a Relationship Graph
TCRk =
i1
M a x { 0 , V ( r ik ) }
j= k + 1
M a x { 0 , V (rkj)} .
(Note that the negative values of V(rik) and V(rkj) are not included in TCRk).
2. Form a tetrahedron using activities 1 to 4 (i.e., the activities with the four largest TCR k‘s).
3. For k = 5, …, M, insert activity k into the face with the maximum sum of weights (V(r ij))
of k with the three nodes defining the face (where “insert” refers to connecting the inserted
node to the three nodes forming the face with arcs).
4. Insert (M+1)th node into the exterior face of the REL graph.
REL chart:
CV values:
A
I V(A) = 81
B O V(E) = 27
X I
C U O V(I) = 9
U U A V(O) = 3
D E E V(U) = 1
U E V(X) = -243
E E
O
F
Department Summary
Dept. TCR Order
A B C D E F A E I O U X
A - I O I O A 1 0 2 2 0 0 105 2
B I - X U U E 0 1 1 0 2 1 38 5
C O X - U E E 0 2 0 1 1 1 58 3
D I U U - U E 0 1 1 0 3 0 39 4
E O U E U - O 0 1 0 2 2 0 35 6
F A E E E O - 1 3 0 1 0 0 165 1
Step 2:
O
A I = rAD V(rAD) = 9
C
E U
F E D
Step 3: Insert B.
A
I
EF
Face LSa
I I
EF 9 + 1 + 27 = 37 *
IF1 IF2
E X C X IF1 9 + 27 - 243 = -207
E X U IF2 9 - 243 + 1 = -233
E IF3 U
IF3 27 - 243 + 1 = -215
F D
U Insert B in EF
A Face LSa
EF 5
B EF IF1 7
IF1
IF2 IF3
IF2 33 *
C IF3 31
IF4 IF4 31
F D IF5 5
IF5
Insert E in IF2
F D
• Using the Heuristic procedure, the generated REL graph will always be an MPG since
each face is triangular.
1. Given the REL chart, use the Heuristic procedure to construct the REL graph.
2. Construct the layout graph by taking the dual of the REL graph, letting the facility
exterior node of the REL graph be in the exterior face of the layout graph.
3. Convert (by hand) the layout graph into an initial layout taking into consideration the
space requirement of each activity.
Space
Requirements
B EX
E
C
F D
REL Graph
A
B EX
E
C
F
D
Layout Graph
Copyright © 1999. Created by Jose
Ventura for the College-Industry Cou
Example (Cont.)
Step 3:
Initial Layout
2. The area of each interior face of the layout graph constructed in step 2 does not correspond to
the space requirements of its activity.
3. In step 3, the overall shape of the initial layout should be usually be rectangular if it
corresponds to an entire building because rectangular buildings are usually cheaper to build;
even if the initial layout corresponds to just a department, a rectangular shape would still be
preferred, if possible.
4. In step 3, the shape of each activity in the initial layout should be rectangular if possible, or at
most L- or T-shaped (e.g., activities A and B), because rectangular shapes require less wall
space to enclose and provide more layout possibilities in interiors as compared to other shapes.
5. All shapes should be orthogonal, i.e., all corners are either 90 or 270 (e.g., a triangle is not
an orthogonal shape since its corners could all be 60).
6. In step 1, if the LSa of the REL graph is less than LSaUB, then the REL graph may not be
optimal. The following three steps may improve the REC graph for the purpose of increasing
LSa:
a) Edge Replacement: replace an arc in the REL graph with a new arc not previously
in the graph, without losing planarity, if it increases LS a.
b) Vertex Relocation: move a node in the REL graph connected to three arcs to
another triangular face if it increases LS a.
c) Use a different activity to replace one of the four activities of the tetrahedron
formed in step 2 of the Heuristic procedure to construct a new REL graph.