Systematic Layout

Planning
 Objectives of Plant Layout

 Minimise investment in equipment

 Minimise overall production time
 Utilise space most effectively
 Minimise material handling cost
 Facilitate manufacturing process
 Facilitate organisational structure
 Types of Layout

 Fixed Position Layout: Product stays and resources move to it.

 Product Oriented Plant layout: Machinery and Materials are
placed following the product path.
 Dictated by the product
 Assembly lines
 Process Oriented layout: Machinery is placed according to what
they do and materials go to them.
 Cell layout: Hybrid Layout that tries to take advantage of
different layouts types.
 P-Q Analysis

Quantity Product
Layouts

Mixed Layouts Process Layouts

Number of Different Products

 Systematic Layout Planning (SLP)

 To arrange a workplace by locating two areas with high

frequency and logical relationships close to each other.
 The process permits the quickest material flow in processing the
product at the lowest cost and least amount of handling.
 Methods for Layout design

 Layout Evaluation
 Distance based evaluation
 Adjacency based evaluation
 Layout Generation
 Construction Algorithms
 Building a block layout by iteratively adding departments
 Improvement Algorithms
 Incrementally improving an initial block layout
 Systematic Layout Planning (SLP)

 Objectives of SLP:
 Improvement ion process flow
 Space Optimisation
 All Layout Planning rests on:
 Relationship: Among activities in the layout
 Space: For each activity –area, kind and shape
 Adjustment: Relationships and space into effective plan

By Applying three fundamentals: Planner assures better

decisions and layouts
 Why It is Important…?

 Process Flow optimisation

 Space optimisation:- Space- One of the most constraint resource
Activity Relationship:
Value Closeness
A Absolutely
necessary
E Essentially
Important
I Important
O Ordinary close
U Unimportant
X Undesirable
Value Reason of closeness
1 Same deck
2 Flow of materials
3 Service
4 Convenience
5 Inventory control
6 Communications
 REL 1 2 3 4 5

Case Study 1
2
-
-
9
-
8
12
10
13
0
7
3 - - - 20 0
4 - - - - 2
5 - - - - -
 Graph-based construction method

construction => new layout

Steps:
1. Build a graph that represents adjacency
2. Convert to block layout
3. Evaluate block layout (usually A-based)
 Step 1: Construct the graph.

1. Select the two departments with the largest weights,

break ties arbitrarily.
2. Select the third department based on the sum of the
weights relative to the two departments already
selected.
3. Select the fourth department based on maximizing
the value to the first three departments in the graph.
4. Add departments maximizing value to a face until
all departments have been added to the graph.
 We begin with a relationship chart with weights,
instead of letter ratings.

REL 1 2 3 4 5
1 - 9 8 10 0
2 - - 12 13 7 Select the two departments
with the largest weights.
3 - - - 20 0
4 - - - - 2
5 - - - - -
(A direct link between two
departments means that they
will be adjacent)
Form graph with departments 3 & 4

3 20 4
 Select the 3rd department to enter
the graph.
REL 1 2 3 4 5
1 - 9 8 10 0 Select the next department
2 - - 12 13 7 with the largest sum of
weights with 3 & 4.
3 - - - 20 0
4 - - - - 2
5 - - - - -

12 13

Add department 2 to
graph

3 20 4
 Select the 4th department to enter the
graph.
REL 1 2 3 4 5
1 - 9 8 10 0 Select the next department
with the largest sum of
2 - - 12 13 7
weights with 2, 3 & 4.
3 - - - 20 0
4 - - - - 2
5 - - - - -

9
12 13

Add department 1 to
1
graph 8 10

3 20 4
 Select the 5th department to enter the
graph.
REL 1 2 3 4 5 Assign the next department
1 - 9 8 10 0 with the largest sum of
weights to a face.
2 - - 12 13 7
3 - - - 20 0
4 - - - - 2
5 - - - - -

2
2
Add department 5 7
13
to face 1-2-4
9 5
12
9
12 13 0

1 2
1
8 10
8 10

3 20 4
3 20 4
Construct Block Layout from graph

Total Weight
2 =
7
(9+8+10+0) +
13
5 (12+13+7) + 20
12 9
+ 2 = 81
0

1 2
8 10

3
20
4
 Improvement Procedures

 Pairwise exchange method

 Find a feasible solution
 Consider all pairwise interchanges
 Perform the interchange that yields greatest total cost reduction
 Continue until no more reduction

FL1 :
20
Pairwise Exchange

FL1
: 21
Pairwise Exchange

FL1
: 22
Pairwise Exchange

FL1
: 23
Pairwise Exchange

FL1
: 24
 A(1), B(2), C(3), D(4) A(2), B(1), C(3), D(4)
FL1 :
25

A(2), B(1), C(3), D(4) A(3), B(1), C(2), D(4)