Professional Documents
Culture Documents
Initial Layout Recovered)
Initial Layout Recovered)
Preliminaries
From-To Chart / Flow-Between Chart REL Chart Layout Scores
Given M activities, a From-To Chart represents M(M-1) asymmetric quantitative relationships. Example: f f
12 13
A Flow-Between Chart represents M(M-1)/2 symmetric quantitative relationships, i.e., gij = fij + fji, for all i > j, where gij = material flow between activities i and j.
f23
A number of factors other than material handling flow (cost) might be of primary concern in layout design. rij values when comparing pairs of activities: A = absolutely necessary 5% E = especially important 10 % I = important 15 % O = ordinary closeness 20 % U = unimportant 50 % X = undesirable 5%
Adjacency
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. Let aij [0, 1]: adjacency coefficient between activities i and j.
1 if activities i and j are adjacent, a ij = (0 < 1) if they are partially adjacent, and 0 if they are not adjacent.
1 3
2 4 5
(Fully) adjacent: a12 = a13 = a24 = a34 = Partially adjacent: a14 = a23 = a25 = , Non-adjacent: a15 = a25 = 0.
Layout Scores
Two ways of computing layout scores: Layout score based on distance:
M 1 M
LSa = V(rij ) a ij where aij [0, 1]: i=1 j=i +1 adjacency coefficient between activities i and j.
M 1 M
Example
REL chart:
1. Offices 2. Foreman 3. Conference Room 4. Parcel Post 5. Parts Shipment 6. Repair and Service Parts 7. Service Areas 8. Receiving 9. Testing 10. General Storage
O 4 I 5 U U O U E 3 U U E 3 U I E 4 3 U A 1 U 4 U U U A 1 U U U I 1 E 5 O 4 U O 3 I 2 U U U I 2 U I 2 U O 2 U U U U I 2 U
Code 1 2 3 4 5
U I 2
Reason Flow of material Ease of supervision Common personnel Contact Necessary Conveniences
Rating A E I O U X
Definition Absolutely Necessary Especially Important Important Ordinary Closeness OK Unimportant Undesirable
Example (Cont.)
5 8 7
10
Example (Cont.)
5 (500) 8 (200) 7 (575)
10 (1750)
9 (500)
6 (75)
4 (350)
2 (125)
3 (125)
1 (1000)
For each department, the Total Closeness Rating (TCR) is the sum of the absolute values of the relationships with other departments.
Consider the figure on the right. Assume that a department is placed in the middle (position 0). Then, if another department is placed in position 1, 3, 5 or 7, it is fully adjacent with the first one. It is placed in position 2, 4, 6 or 8, it is partially adjacent.
8 1 2
6 5 4
0
3
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. 2. The placement of a department is determined by evaluating all possible locations around the current layout in counterclockwise order beginning at the western edge. 3. The new department is located based on the greatest WP value.
Example
1. Receiving
A
2. Shipping 3. Raw Materials Storage 4. Finished Goods Storage 5. Manufacturing 6. Work-In-Process Storage 7. Assembly 8. Offices 9. Maintenance
A E A E E A A X X O A O O A O A E O U U A O U E E A U U U U A E A U O
CV values: V(A) = 125 V(E) = 25 V(I) = 5 V(O) = 1 V(U) = 0 V(X) = -125 Partial adjacency: = 0.5
Example (cont.)
125
62.5 125
62.5
0 0 0
0 0 0
5 9
7
187.5 62.5
5 9
1
7
1.5 0.5
62.5 125
Example (cont.)
25
12.5
3 1
25
5 9
12.5
125
3 1
5 9
125
7 4
125
137.5 62.5 0
62.5 125
0 0.5 1 0.5 1
62.5 125
188 62.5
3 1
1
5 9
1.5
7 4
1.5
2
1
Example (cont.)
6 7 4
6 8 2 3 1 5 9 7 4
3 1
75
5 9
12.5 87.5
Planar Graph
Assumption:
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 2 1 3 4
(Exterior)
Block Layout
4 6
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.
A REL graph is a subgraph of the REL diagram. For M 5, at most 3M-6 out of M (M-1)/2 relationships can be satisfied through adjacency in a REL graph. 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). Not MPG since has only 5 arcs (5 < 6 = 3M-6) MPG since has 6 arcs
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.
The tetrahedron has three interior faces (IF1, IF2 and IF3) and an exterior face (EF)
Not an MPG
Layout
REL Graph
Layout Graph
Example.
GD
The number of nodes in G (primal graph) is the same than the number of faces in GD (dual graph), and vice versa. In addition, (GD)D = G.
4
(Exterior) Layout
d h
Layout Graph
Given a REL graph (RG), its corresponding layout graph (LG) is LG = RGD. E.g.,
6
1 4
2 5
RGD
LGD RG LG
Example
Space Requirements:
Dept.
A B
A B
E F
C D E F
Example (Cont.)
6 A 1 8 2 C D 7 3 E 5 B 4 F
Example (Cont.)
Block Layout: A B
2
A F
8 1 2
B
5 3
E F
C
7
3 5
C
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.
i k k (Note that=the negative values of V(rik)j and V(rkj) are not included in i 1 j= k + 1 TCRk).
M a V x { ( ) 0r }+ , M a V x { () 0r} , .
k -1
2. Form a tetrahedron using activities 1 to 4 (i.e., the activities with the four largest TCRks). 3. For k = 5, , M, insert activity k into the face with the maximum sum of weights (V(rij)) 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.
Example
REL chart:
A B C D E F
I X U E U E O E O U U I O A E
Example (Cont.)
Step 2:
A
O A C E F E U D I = rAD V(rAD) = 9
Example (Cont.)
Step 3: Insert B.
A
I EF IF1 E E E
I IF2 X U U
X C X IF3
F
U
IF3
Insert B in EF
Example (Cont.)
Face EF
LSa 5 7 33 31 31 5 *
B
IF1 IF2 IF3
EF
C
IF4
F
IF5
IF5
Insert E in IF2
Example (Cont.)
B E
EX
Since arcs (AB), (BD), and (DA) are the outside arcs, EX connects to nodes A, B, and D.
Example (Cont.)
LSaUB is the sum of the 3M - 6 ( 3 6 - 6 = 12), largest V(rij)s. In the last example, LSaUB = V(rAF) + V(rBF) + V(rCE) + V(rCF) + V(rDF) + V(rAB) + V(rAD) + V(rAC) + V(rAE) + V(rEF) + V(rBD) + V(rBE) = 81 + 27 + 27 + 27 + 27 + 9 +9+3 + 3 + 3 + 1 + 1 = 218. For the final REL graph, LSa = 218. LSaUB = LSa The final REL graph is an MPWG It is optimal. LSaUB > LSa The final REL graph may not be an MPWG It may not be optimal. Using the Heuristic procedure, the generated REL graph will always be an MPG since each face is triangular.
Space Requirements
Example
Step 1: (from before)
A
B E
EX
REL Graph
Example (Cont.)
Step 2: take the dual of RG
A B E C F D
EX
Layout Graph
Example (Cont.)
Step 3:
A
E B F
C D
Initial layout is drawn as a square, but could be any other shape. Only A and B are nonrectangular.
Initial Layout
Comments
1. If an activity is desired to be adjacent to the exterior of a facility (e.g., a shipping/receiving department), then the exterior could be included in the REL chart and treated as a normal activity, making sure that, in step 1 of the general procedure, its node is one of the nodes forming the exterior face of the REL graph. 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.
Comments (Cont.)
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 LSa. b) Vertex Relocation: move a node in the REL graph connected to three arcs to another triangular face if it increases LSa. 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.