IOP Conference Series: Materials Science and Engineering

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Design and improvement layout of a production floor using automated

layout design program (ALDEP) and CRAFT algorithm at CV. Aji Jaya
Mandiri
To cite this article: D Suhardini and S D Rahmawati 2019 IOP Conf. Ser.: Mater. Sci. Eng. 528 012062

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ISIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 528 (2019) 012062 doi:10.1088/1757-899X/528/1/012062

Design and improvement layout of a production floor using

automated layout design program (ALDEP) and CRAFT
algorithm at CV. Aji Jaya Mandiri

D Suhardini1 and S D Rahmawati2

1,2
Industrial Engineering Department, Universitas Trisakti, Jakarta 11440, Indonesia
1
[email protected], [email protected]

Abstract. Different computerized algorithms are used to assist the layout planner in generating
alternate layout. CRAFT (Computerized Relative Allocation of Facilities Technique) has been
developed to improve an existing layout, while ALDEP (Automated Layout Design Program) is
a construction layout. The improvement given by ALDEP over CRAFT technique was found to
reduce annual material handling cost by 23% [1]. This study hypothesize that better result could
be gained by combined two algorithms rather than their independent application. The hypothesis
is verified by taking layout problems of CV Aji Jaya Mandiri. The objective of the study is to get
the optimal layout of CV Aji Jaya Mandiri using ALDEP and followed by improving it with
CRAFT. ALDEP based on the value of proximity (total closeness rating). The layout resulted
from ALDEP is improved by exchanging machines positions. The newly layout obtained by
ALDEP is compared with the result layout improved by CRAFT. There are two criteria for
comparing the layout: material handling cost taken from MHES (material handling evaluation
sheet), and the manufacturing lead time or processing time using Promodel simulation. The
material handling cost of the layout resulted by CRAFT was decreased by 6,24%, that is mean
that CRAFT was improved the layout effectively. The result of simulation showed the
manufacturing lead time of the improved layout decreased 23 minutes. Layout evaluation using
Adjacency Based Scoring for the CRAFT layout increase 15% compare with the initial layout so
it was selected as the best layout. This study concluded that combined use of computerized
layout design algorithms provides better result,
Keywords: ALDEP, CRAFT, Facility layout Design, ProModel, Simulation

1. Introduction
Facility layout design is the field of selecting the most effective arrangement of physical facilities to
allow the greater efficiency. It reduces the total cost of manufacturing activity provides optimum space
to give maximum output. The plant layout or facilities layout can be defined as an arrangement of the
factory facilities to support the smooth running of the production process. These settings will increase
the utilization of the area for the placement of the machinery or other production support facilities,
smooth movement transfer of material, material storage which is either temporary or permanent,
operator and so on other personnel. Setting a good and planned layout will determine the efficiency of
the production process. According to [2] a good layout will give more output although the cost is the
same or less, less man hours, and or machine hours.

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ISIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 528 (2019) 012062 doi:10.1088/1757-899X/528/1/012062

2. Method
The hypothesis is developing a new layout using construction routine followed by improvement routine
is more fruitful than constructing new layout with a construction routine alone or improving a working
existing layout using improved routine [1]. The hypothesis is verified by taking CV Aji Jaya Mandiri
layout problems. The initial layout of production floor of the CV Aji Jaya Mandiri was not well-ordered.
The flows of material are not efficient. The first step evaluated of current layout using adjacency based
scoring. The optimal layout of CV Aji Jaya Mandiri was obtained using ALDEP and followed by
improving it with CRAFT. Data collection for designing layout, such as the initial layout, characteristic
of the product, operation process chart (OPC), standard times, capacities and size of machines. These
data was processed to develop routing sheet, material handling planning sheet (MHPS), from to chart,
total closeness rating, and material handling evaluation sheet.
The first method used to design the layout of the production floor is ALDEP (Automated Layout
Design Program). This method is one of many construction algorithms for designing layout. The use of
ALDEP method is expected to make a better layout proposal. After getting the results of ALDEP layout
then calculate material handling cost based on material handling evaluation sheet (MHES). The proposed
layout was improved by CRAFT and compare the cost of material handling of improved layout than the
previous layout. Next, running a simulation to obtain the processing time of the proposed layout by
ALDEP and the improved layout as well, which further evaluated the optimal layout using Adjacency
Based Scoring to make sure the optimal layout the better layout.

3. Result and Discussion

The important things in facility layout design is reducing cost by maximizing adjacency of highly
interacting components of a system or reducing material handling cost or distance between work
stations. The first step is to evaluate the initial layout CV. Aji Jaya Mandiri using Adjacency Based
Scoring method resulted the value of the relationship of proximity calculation. The priority scale is from
FTC (from to chart) and MHPS (material handling planning sheet). Which for calculation using the
following formula:
Max Z =∑! !
%#$ ∑"#$ 𝑓𝑖𝑗 𝑥𝑖𝑗 (1)

Table 1. The Value of Adjacency Based Scoring for Initial Layout

Inflow Value
From To Rank Rating Score
Coefficient of ABS
Finishing area Circular Saw Machine 1.17 1 A 16 16
Radial Drilling Machine - Circular Saw Machine 1.04 2 A 16 0
Painting Area - drying area 1.04 3 A 16 16
Packing Area - Warehouse 1 4 A 16 16
Welding Machine Finishing Area 0.96 5 E 8 8
Finishing area - Packing Area 0.94 6 E 8 0
Storage - Cutting Area 0.89 7 E 8 0
Cutting Area - Puttying Area 0.74 8 E 8 8
Patching area - drying area 0.69 9 E 8 8
Patching area - Puttying Area 0.51 10 I 4 0
Auxiliary storage - Painting Area 0.39 11 I 4 0
Finishing Area - Radial Drilling Machine 0.33 12 I 4 0
Puttying area - Painting Area 0.3 13 I 4 4
Auxiliary storage - Puttying area 0.26 14 I 4 4
Warehouse - Circular Saw Machine 0.2 15 O 2 2
Welding Machine Radial Drilling Machine 0.15 16 O 2 2
Cutting Area - drying area 0.11 17 O 2 2
Auxiliary storage - Patching area Puttying area 0.07 18 O 2 2
Auxiliary storage - Packing Area 0.06 19 O 2 2
Auxiliary storage - Welding Machine 0.05 20 O 2 2
Auxiliary storage - Finishing Area 0.04 21 U 1 1
Patching area - Finishing Area 0.04 22 U 1 1
Finishing area drying area 0.03 23 U 1 1
Total Score 139 95
Percentage of Adjacency Based Scoring 68%

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ISIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 528 (2019) 012062 doi:10.1088/1757-899X/528/1/012062

The value of the Adjacency Based Scoring for initial layout is 68% that is mean the layout must to
be improved to reduce cost by maximizing adjacency of highly interacting machines or work station or
reducing material handling cost or distance between work stations. Facility layout design requires
diverse field of knowledge. Among other the application and use of computers become an advantage.
The computerized layout methods, either construction or improvement-type routines are heuristics.
Construction-type layout routine generates a block layout based on the relationship between different
departments. Automated Layout Program design (ALDEP) is commonly use software for construction-
type layout. A newly constructed layout alone will not be nearly optimal, the new construction must be
evaluated by an improvement routine. The most popular improvement-type methods are Computerized
Relative Allocation of Facilities Technique (CRAFT).
Before designing a new layout, the number of machines needed must be checked using Routing
Sheet. From the Routing sheet of CV. Aji Jaya Mandiri the number of machines which need to be
increase are 3 machines there are Grinding, adjustable work benches 1, adjustable work benches as seen
below.

Table 2. Number of Machines

Number of Number Number
Number of
machine/work of Number of of
No Machine machine +/-
station machine machine/Station machine
(round-up)
Two Way Bench available
Circular Saw
1 0.087 0.286 0.373 1 1 0
Machine
2 Drying Area 0.295 0.128 0.423 1 1 0
Radial Drilling
3 0.105 0.667 0.772 1 1 0
Machine
4 Spray Gun 0.071 0 0.071 1 1 0
5 Welding Machine 0.48 0.501 0.981 1 2 -1
6 Grinding Machine 0.929 1.462 2.391 3 2 +1
Adjustable Work
7 0 0.258 0.258 1 0 +1
benches 1
Adjustable Work
8 0 0.198 0.198 1 0 +1
Benches 2
9 Packing Area 0.037 0.084 0.121 1 1 0
10 Work Table 0.108 0.114 0.222 1 0 +1
11 Cutting Table 0.04 0.103 0.143 1 1 0

From to Chart made after the number of machines will be arranged, are obtained from the routing
sheet and compared to the number of machines available. The space of Department of specified machine
was defined and then calculated the distance between the departments multiplied by the number of
products being transferred and the frequency of removal to get the cost of material handling between
Department.
To determine the rating of closeness used coefficient of inflow that calculate from the chart above
(formula 2), which can be seen below. The coefficient then used as closeness rating A,E,I,U and X. The
quantitative methods used to design the layout, particularly concerning the transfer of material with the
minimal possible distance. Furthermore, the results of calculations used as input from FTC Inflow,
which for calculation using the following formula:
'() )*+,
FTC Inflow = ,*,-. /*.012 345 1-/6724 (2)
Legend: X Storage 6 Grinding Machine
Y Storage of Auxiliary Materials 7 Adjustable Work Benches 1
1 Circular Saw Machine 8 Adjustable Work Benches 2
2 Drying Area 9 Packing Area
3 Radial Drilling Machine 10 Work Table
4 Spray Gun 11 Cutting Table
5 Las Machine Z Warehouse

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 ISIEM 2018

9
8
7
6
5
4
3
2
1

Z
Y
X

11
10

Total
From \To
X

0
Y

0
1

405212.5 267998 25127.4 112087.1

2

261488.6 37017.2 224471.4

3

192643.4 192643.4
4

79505.16 22664.88 21777.08 35063.2

4
5

282121.3 208152 54684.5 19284.76

6

520735.9 108412.5 124288.5 20770.56 264551.1 2713.32

7

79709.6 37098.6 30286.8 12324.2

8

98164.1 60391.18 37772.92

9

98000.9 85208.68 12792.22

10

52034.04 11830.14 22597.9 17606

Table 3. From to Chart Between Department
11

58968.81 11033.49 47935.32

Z

84842.52 84842.52

2213426.88 0 60391.18 85208.68 84842.52 59763.48 48847.34 498747.93 108412.5 224471.44 204100.35 83867.93 457194.51 137556.62 160022.4
Total
IOP Publishing
IOP Conf. Series: Materials Science and Engineering 528 (2019) 012062 doi:10.1088/1757-899X/528/1/012062
ISIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 528 (2019) 012062 doi:10.1088/1757-899X/528/1/012062

Table 4. Coefficient of Inflow

X Y 1 2 3 4 5 6 7 8 9 10 11 Z Total
X 0.28 0.81 1.09
Y 0.44 0.24 0.69 0.16 0.48 0.16 0.22 2.39
1 1.06 0.86 0.51 2.43
2 0.27 0.04 0.38 0.14 0.19 1.02
3 0.19 0.24 0.43
4 0.29 0.29
5 0.95 0.95
6 0.43 0.43
7 0.47 0.23 0.7
8 0.62 0.62
9 0.87 1 1.87
10 0
11 0
Z 0
Total 0 0 0.28 0 1.06 1.57 0.43 2.43 0.54 1.38 0.16 1.75 1.62 1 12.22

ALDEP allows the department to provide specific placed and can enter a dummy. Design with
Algorithm ALDEP is subdivided into 2 procedures i.e. procedures of selection and placement procedures
[3]. Input is needed to run the software of ALDEP it is the maximum value of TCR (Total Closeness
Rating), the number and area of the Department that will be iterated, spacious layout dimensions and
the minimum degree of closeness of relationship that is used.
The first elected Department to get done at random, for the next selected departments taken from
departments that have a relationship "A" with the Department's first elected, if there is more than one
Department, which is worth A then the Department will be selected randomly, but when there is no
Department of value A, then Department of equal value or the value is equal to the lower limit of the
level of closeness that is already put before by the user will be elected. The next selected departments in
a manner that is similar to the previous one, this process is continued until the entire Department goes
into the layout.
Procedure for placement on the first Department of ALDEP i.e. placing selected at the top left corner
of the layout and continued towards the bottom. The length and width layout is determined by the user
who entered earlier. This is also known as placement process with vertical sweep pattern (vertical road
pattern). Total Closeness Rating (TCR) score become input in using software ALDEP can be seen at
Table 1 below. Space available that is 447.11 m2, but as an input of ALDEP it is inserted in the template
that is the number of 117 unit with a length of 13 and a width of 9. The number of departments that will
be as much iteration 14 departments. Minimum degree of relationship of the TCR already calculated
earlier U (unimportant).

Tabel 5. Total Closeness Rating

From\To X Y 1 2 3 4 5 6 7 8 9 10 11 Z Total
X U O U U U U U U U U E U U 21
Y U U U I O E U E U O U U 31
1 U A A U E I U U U U U 51
2 U O U U U U U U O U 12
3 U O O U U U U U U 11
4 U U U I U U U U 11
5 A U U U U U U 22
6 U I U I U U 12
7 U U O U U 6
8 U U E U 11
9 A U A 33
10 U U 2
11 U 1
Z 0
Total 0 1 2 1 1 1 1 1 1 1 1 8 1 1 224

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ISIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 528 (2019) 012062 doi:10.1088/1757-899X/528/1/012062

The data processing software of ALDEP found optimum layout design of a product, with closeness
rating 630, can be seen in Figure 6 as follows.

Figure 1. The optimum layout from ALDEP software

Improvement-type routines require an input from ALDEP block layout and aim to reduce internal
transport cost by attempting simultaneous pair-wise position exchanging among the departments. The
basic concept of the CRAFT is the exchange location/department activities on initial layout in order to
find a better solution based on the flow of materials. Exchange will further bring to facility layout
direction approaching the optimum costs. Algorithm of CRAFT can exchange 2 or 3 departments, so it
can be used to generate a better layout. [4]. The data required as input CRAFT:
1. Initial layout from ALDEP block plan
2. Flow of material (frequency displacement)
3. Cost (material handling cost per meter)
4. The number of departments that have not changed (fixed)

CRAFT is a useful for improve the previous layout. The result layout obtained from CRAFT software
as follows can be seen in Figure 2. MHES is a table used to calculate the cost of materials handling.
MHES optimize the flow of materials by planning a sequence of operations and equipment settings.
Material handling used here is manual, where the operator performs the transfer of materials from one
Department to another Department. The result of the calculation of the MHPS will be as input for the
FTC. Unlike the Material Handling Planning Sheet (MHPS), the Material Handling Evaluation Sheet
(MHES) using real distance from the layout. The distance in the study using aisle distance. The purpose
of doing an evaluation of the design of the layout using material handling that is to know the difference
in the cost of material handling. Evaluation performed towards the cost of material handling on the
layout of ALDEP and layout of the CRAFT, The Material Handling cost of proposed layout from
ALDEP was Rp. 2,562,331, which when compared with the improved layout of the results of CRAFT

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 ISIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 528 (2019) 012062 doi:10.1088/1757-899X/528/1/012062

was Rp. 2,402,358, the results of CRAFT showed a decrease in the cost of material handling Rp. 159,973
(6,24%)

Figure 2. Output CRAFT Layout

Simulation is a tool that can be used to predict performance. The simulation could not design a system
by itself. The user must provide various design scenarios and evaluate each scenario simulation tool to
determine which scenario has the best performance. The simulation can also be defined as a technique
that mimics the operation of the computer manufacturing real or system services from time to time. [5].
In the simulation model development, the basic elements are required are location, entities, arrival,
processing and resource.

Table 6. The Result of Evaluation Layout with Adjacency Based Scoring

From To Rank Rating Score ALDEP CRAFT

Circular Saw Machine Radial Drilling Machine 1.06 1 A 16 16 16
Packing Area Warehouse 1 2 A 16 16 16
Las Machine Grinding Machine 0.95 3 A 16 16 16
Packing Area Work Table 0.87 4 A 16 16 16
Circular Saw Machine Spray Gun 0.86 5 A 16 0 0
Warehouse Cutting Table 0.81 6 E 8 8 8
Auxiliary storage Grinding Machine 0.69 7 E 8 8 8
Awb2 Cutting Table 0.62 8 E 8 8 8
Circular Saw Machine Grinding Machine 0.51 9 E 8 8 8
Auxiliary storage Adjustable Work Benches 2 0.48 10 E 8 8 8
Adjustable Work Benches 1 Adjustable Work Benches 2 0.47 11 I 4 0 0
Auxiliary storage Spray Gun 0.44 12 I 4 4 4
Grinding Machine Work Table 0.43 13 I 4 4 4
Drying Area Adjustable Work Benches 1 0.38 14 I 4 0 0
Spray Gun Adjustable Work Benches 2 0.29 15 I 4 0 4
Warehouse Circular Saw Machine 0.28 16 I 4 0 0
Drying Area Spray Gun 0.27 17 O 2 2 2
Auxiliary storage Las Machine 0.24 18 O 2 2 2
Radial Drilling Machine Grinding Machine 0.24 19 O 2 2 2
Adjustable Work Benches 1 Work Table 0.23 20 O 2 2 2
Auxiliary storage Work Table 0.22 21 O 2 2 2
Drying Area Cutting Table 0.19 22 O 2 2 2
Radial Drilling Machine Las Machine 0.19 23 O 2 2 2
Auxiliary storage Adjustable Work Benches 1 0.16 24 U 1 1 1
Auxiliary storage Packing Area 0.16 25 U 1 1 1
Drying Area Adjustable Work Benches 2 0.14 26 U 1 1 1
Dying Area Grinding Machine 0.04 27 U 1 1 1
Total Score 162 130 134
Percentage of Adjacency Based Score 80% 83%

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ISIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 528 (2019) 012062 doi:10.1088/1757-899X/528/1/012062

This percentage of adjacency based score by applying ALDEP algorithm followed by improvement
routine methodology CRAFT was better than that of ALDEP construction routine alone. Evaluation of
improved layout resulted from CRAFT generate Adjacency Based Score percentage of 83% than 80%
of ALDEP. There are also significant consistency between the cost of Material handling, and
manufacturing lead time. There are also significant consistency between the cost of Material handling
and manufacturing lead time.

4. Conclusion
This paper has shown federated usage of construction and improvement routine results better
performance of factory layouts. The improved layout of CRAFT was the best layout according to the
cost of material handling, manufacturing lead time and adjacency based score. Further research can be
apply in other industries and other method of construction as well improvement type algorithmic.

5. References
[1] Deshpande V, Patil N D, Baviskar V and Gandhi J 2016 Plant Layout Optimization using CRAFT
and ALDEP Methodology. Productivity Journal by National Productivity Council ISSN: 0032-
9924 57(1) pp 32-42
[2] Wignjosoebroto S 2009 Tata Letak Pabrik dan Pemindahan Bahan. 3rd Ed. (Surabaya: Guna
Widya)
[3] Tompkins, White, Bozer, Frazelle, Tanchoco and Trevino 2010 Facilities Planning. 3rd Ed.
(Canada: John Wiley & Sons)
[4] Heragu S S 2016 Facilities Planning. 4th Ed. (New York: CRC Press)
[5] Apple J M 1990 Tata Letak Pabrik dan Pemindahan Bahan, 3rd Ed. (Bandung: Penerbit ITB)
[6] Pamularsih T, Mustofa F H and Susanty S 2015 Usulan Rancangan Tata Letak Fasilitas Dengan
Menggunakan Metode Automated Layout Design Program (ALDEP) di Edem Ceramic. Reka
Integra (Bandung: Jurusan Teknik Industri Itenas) 3(2)