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A LITERATURE REVIEW ON EFFICIENT PLANT LAYOUT DESIGN

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DOI: 10.34218/IJIERD.7.2.2016.005

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International Journal of Industrial Engineering Research and Development (IJIERD)
Volume 7, Issue 2, May-December 2016, pp.43–51, Article ID: IJIERD_07_02_005
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ISSN Print: 0976 – 6979 and ISSN Online: 0976 – 6987
DOI: 10.34218/IJIERD.7.2.2016.005
© IAEME Publication

A LITERATURE REVIEW ON EFFICIENT

PLANT LAYOUT DESIGN
Sanjeev B. Naik
Assistant Professor, Department of Mechanical Engineering
Walchand Institute of Technology, Solapur, India

Dr. Shrikant Kallurkar

Principal, Atharv College of Engineering, Malad, Mumbai, India

ABSTRACT
Facility layout design involves a systematic physical arrangement of
different departments, work stations, machines, equipments, storage areas and
common areas in a manufacturing industry. In today's competitive global
environment, the optimum facility layout has become an effective tool in cost
reduction by enhancing the productivity. It has become very essential to have a
well organised plant layout for all available resources in an optimum manner
to achieve the maximum returns from the capacity of facilities. To achieve the
optimisation objectives a lot of techniques are developed by many researchers
in the domain area. The objective of this paper is to review the contributions in
the field not only for plant layout but re-layout also.
Key words: Facility layout, optimum facility layout, re-layout
Cite this Article: Sanjeev B. Naik and Dr. Shrikant Kallurkar, A Literature
Review on Efficient Plant Layout Design, International Journal of Industrial
Engineering Research and Development, 7(2), 2016, pp. 43–51.
http://www.iaeme.com/IJIERD/issues.asp?JType=IJIERD&VType=7&IType=2

1. INTRODUCTION
A facility layout is an integration of the physical arrangement of departments,
workstations, machines, equipments, materials, common areas etc, within an existing
or proposed industry. Most plant layouts are designed properly for the initial conditions
of the business. However these layouts provide many bottlenecks during growth period.
Hence as long as capacity grows, it has to adapt the internal and external changes for
which a re-layout is necessary. The reasons for a re-layout are due to changes in
production volume, changes in process and technology and changes in the product.
The frequency of re-layout depends upon requirement of the present situation.
Hence facility layout design is a continuous iterative process based upon the changing

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 A Literature Review on Efficient Plant Layout Design

constraints of dynamic environment. So optimization of facility layout is situation

based requirement of the industry, The symptoms that allow the need for a re-layout
are congestion and bad utilization of space, excess stock in process at the facility, high
material handling distances , bottleneck at workstations, idle time of facilities and
workers, labour anxiety and discomfort, accidents and difficulty in controlling
operations and personnel.

2. TOOLS FOR OPTIMIZING LAYOUT DESIGN: HEURISTIC

METHODS
The most well known heuristic methods in optimizing layout design are Tabu Search
(TS), Simulated Annealing (SA), and Genetic Algorithms (GA). The popularity of these
heuristics has flourished in recent years and several published studies can be found in
the literature. Arostegui, et al [5] classify heuristics methods into tailored and general.
While tailored heuristics have a limited applicability to a specific problem while general
algorithms define a strategy for obtaining approximate solutions and thus are widely
applicable to various forms of combinatorial optimization problems.
Tabu Search (TS) is a mathematical optimization method, belonging to the class of
local search techniques [5]. Tabu search enhances the performance of a local search
method by using memory structures. Once a potential solution has been determined, it
is marked as taboo, so that the algorithm does not visit that possibility repeatedly.
A genetic algorithm (GA) is a search technique used in computing to find exact or
approximate solutions to optimization and search problems [5]. Genetic algorithms are
categorized as global search heuristics. Genetic algorithms are a particular class of
evolutionary algorithms (EA) that use techniques inspired by evolutionary biology such
as inheritance, mutation, selection, and crossover [7]. Simulated annealing (SA) is a
generic probabilistic metaheuristic for the global optimization problem of applied
mathematics, namely locating a good approximation to the global minimum of a given
function in a large search space [5]. It is often used when the search space is discrete.
For certain problems, simulated annealing may be more effective than exhaustive
enumeration, provided that the goal is merely to find an acceptably good solution in a
fixed amount of time, rather than the best possible solution [7].

3. SIMULATION TECHNIQUE
Simulation technique is also recommended in the facility planning analysis. Nica, et al
[25] reported that queuing phenomena of parts before entering assembly area is in
uncertainty arrival time. Simulation is an appropriate tool to help the designer to define
the storage spaces of assembly system in this stochastic situation. In this research, a
concept of ordered parts buffer is proposed for sequencing parts arrived in the assembly
process by robot systems. Simulation based on experimental design is developed by
Ekren and Ornek [9] for typical manufacturing job-shop system. They investigated the
effects of layout types and their interactions with other manufacturing parameters that
can affect performance of the system.
A simulation model has been developed as an analysis tool for line reconfiguration
to accommodate the future demand fluctuation. Line balancing becomes the main issue
in the research and fuzzy knowledge base of technique was proposed to help define
more realistic scenarios [30]. The necessity of sequence coordination within a complex
assembly system is reported. This is due to the fact that the complex assembly system
generally includes preassembly section for part preparation and this can only be
determined by computer aided simulation.

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 Sanjeev B. Naik and Dr. Shrikant Kallurkar

Simulation tools that commonly used in facility planning are Arena [9], QUEST
[24], IGRIP [24], Pro Model [35] and Witness [31]. Another tool that can be used in
layout simulation is Flexsim software. Flexsim is discrete event simulation software,
used for evaluating, planning or designing manufacturing, warehousing, logistics and
other operational and strategic situations [11]. The limitation of many software is they
only provide the two dimensional visualization (2D), which is not easy to visualise,
understand and evaluate. Flexsim provides the three dimensional (3D) visualization.
Flexsim software helps researchers to test multiple alternatives in a short time without
any risk, disruption and expenses.

4. A SUMMARY OF WORK DONE BY RESEARCHES

SL.No Title and Author Methodology Finding

01 Layout design for Low Empirical In the present work, the results of
capacity manufacturing Line a fashion manufacturing line re-
- A case study layout were compared by
Flippo De Carlo et.al10 analysing the current situation
with the solutions provided by a
homemade company design, both
through a systematic layout
planning approach and a lean
reengineering activity,
02 A Heuristic procedure for Proposed a novel Performed the experimental study
the integrated facility layout integrated heuristic to assess the performance of the
design and flow assignment procedure based on a proposed procedure .The
problem perturbation algorithm experimental results demonstrate
Ali Taghavi et.al02 and sequential location that proposed heuristic procedure
heuristic. is both efficient and effective in
identifying quality solutions.
03 A genetic algorithm with the The paper presents a The efficiency of the proposed
heuristic procedure to solve Genetic Algorithm- method has been proved through
the multi-line layout based meta heuristic to solving examples and comparing
problem solve FLP results with other genetic
Amir Sadrzadeh03 algorithm, CRAFT algorithm
04 Using Simulation for A discrete event It was found that the simulation
Facility Design: A Case simulation model was able to achieve this because of
Study was developed and used its ability to both store attribute
to estimate values and to show queuing levels
(Greasley, 2008)13
the storage area at an individual product level. It
required for a proposed was also found that the process of
overseas textile undertaking the simulation project
manufacturing facility. initiated useful discussions
regarding the operation of the
facility.

05 A methodology for solving A mixed binary In addition to the distance

the unequal area facility nonlinear programming measure, the impact of geometry
layout problem using model is formulated or the shape of the departments is

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 A Literature Review on Efficient Plant Layout Design

distance and shape based quantified in the formulation of the

measures R. Logendran model. A higher level heuristic
et.al26 solution algorithm, based on a
concept of " Tabu search" is
proposed and the results are
compared with the published
alternatives in the problem area
and has demonstrated the
effectiveness of the proposed
method.
06 An alternative multiple The proposed In the proposed methodology
attribute decision making methodology is based appropriate facility design is
methodology for solving on Preference selection selected for a given application.
optimal facility layout index (PSI) Two different types of facility
design selection problems layout design selection problems
K.D.Maniya et.al 20 are examined to demonstrate,
validate and to check the reliability
of proposed methodology. It is
concluded that FLP design
selection methodology based on
PSI method is simple, logical and
more appropriate.
07 An Empirical Compare the relative The results indicate that TS shows
Comparison of Tabu performance of Tabu very good performance in most
Search, Simulated Search (TS), Simulated cases. The performance of
Annealing, and Genetic Annealing (SA), and SA and GA are more partial to
Genetic Algorithms problem type and the criterion
Algorithms for Facilities
(GA) on various used. Thus, in general it may
Location Problems. conclude that TS should be tried
Facilities Location
(Arostegui et al, 2006)5 Problems (FLP). first to the extent that it always
yields as good or better results and
is easy to develop and implement.

08 Genetic Algorithms for Proposed a new The result of this study indicate
Integrating Cell Formation approach to that:
with Machine Layout and concurrently make the (1) The concurrent approach often
Scheduling. cell formation found better solutions than the
(Xiaodan et al, 2007)34 (CF), group layout (GL) sequential one.
and group (2) With the proposed heuristic
scheduling (GS) operators, the hierarchical genetic
decisions for a algorithm (HGA) procedure
successful Cellular performed better than without
manufacturing them. A hierarchical genetic
(CM). A conceptual algorithm (HGA) is developed to
framework and solve the integrated cell design
problem. Two heuristic operators
mathematical model,
are proposed to enhance its
which integrates
computational performance.
these decisions, are
proposed

09 A Study on Facility Comparing two This paper found that U-shape

Planning in alternative design of flow pattern design has increase
the efficiency utilization of labour,

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 Sanjeev B. Naik and Dr. Shrikant Kallurkar

Manufacturing Process layout : U-shape and S- equipment, space and reduces idle
Using Witness. shape. time.
(Roslin et al, 2008)31 The study is conducted
in Dinamika Pelumas
Sdn. Bhd. Simulation
tool using Witness
software.
10 Metaheuristic methods Comparison of Both methods produced the known
for a class of the facility simulated annealing optimal solution for a facility
Layout problem. (SA) and Tabu Search layout problem set with high
(TS). frequency and low computation
(Alvarenga et al, 2000)4
time.
11 Solving the failure-to-fit Apply Artificial Artificial intelligence could solve
problem for plant layout intelligence (AI) to the scenario of failure-to- fit
by changing department FLP solutions, when no feasible layouts
are generated.
shapes and sizes.
(Lin et al, 1996)28
12 Simulation Model for Existing layout is This paper proved that the
Production evaluated by simulation model is capable to
Line Layout. Using Pro model predict the capacity of initial
(Zuhdy et al,2008)18 software by system and test the proposed
Integrating Process design.
layout, constant
period scheduling and
Short Processing time.
13 Design and Analysis of a All production Virtual factory layout helps in
Virtual machines created in evaluating plant layout before
Factory Layout. AutoCAD and imported actually building them and assists
(Iqbal and Hashmi,2001)18 to 3D in avoiding the cost involved in
Studio Max software. doing physical re-layout. By
virtual factory layout, a designer
Layout problem was
can have feel of the actual setting
visualized and
of the factory, easy to visualize,
modified by applying understand and evaluate. Re-
Facility location of the machine can be
Layout Problem (FLP) done such that the material
solving handling cost reduced as well
techniques. as the bottleneck removed.
14 Layout Design in Group Literature review A review and consolidation of the
Technology Manufacturing emerging literature in the GT
(Hassan, 1994)14 layout and a suggestion framework
of analysis for developing the GT
layout.
15 Advances in Discrete Literature review This paper presents an outline of
Material Handling System trends seen in layout and material
Design. (Rajagopalan and handling flow path design
Heragu, 1997)27 research. The current trends are to
integrate the different aspects of
the manufacturing system design
problem. Also present an idea for

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 A Literature Review on Efficient Plant Layout Design

solving P/D (Pick-up/Drop off)

point location and material
handling flow path problem.
16 A Classification of Different Literature review This paper discusses on the
Type objectives of facility layout design,
of Facility Layout Design. flow pattern and material
(Taha et al, 2008)32 Handling systems and finally
discusses the different type of
layout.
17 Multiple objective facility Using Heuristic and Both methods find sub optimal or
layout: a heuristic to metaheuristic methods near optimal solution have been
generate efficient to solve FLP. successful on some problems but
alternatives. not on a universal level. However,
(Malakooti, 1989)23 it is depend on decision
assumption made by problem
solver and the time required to
compute solution is lengthy.
18 FACOPT : A user friendly Comparison of genetic The genetic algorithm model
Facility algorithm performed better than the
Layout optimization System. (GA) and simulated simulated annealing model in
(Balakhrishnan et al, 2003)7 annealing terms of time required to compute
(SA). solution.

5. DISCUSSION
Based on the literature survey as above, it is revealed that there are several studies
investigated the effective design of facility planning in a production line of
manufacturing process. However, there are some difficulties and limitations in finding
the optimum layout configuration with general heuristic methods such as Tabu Search
(TS), Simulated Annealing (SA), and Genetic Algorithms (GA). The limitations are
such as time consuming and cannot get the feel of the actual setting and actual
dimension of the machine and equipment in the facility design. Simulation technique is
a powerful tool to asses and evaluates the possible configuration in layout optimization.
According to Mc Lean and Kibira [24], simulation could be the best aid in decision
making during design, analyse and improvement of manufacturing systems and
computer simulation also shows great promise for raising productivity, improving
product quality, shortening lead time and reducing cost in the future. Some researchers
used Arena, Witness, and Pro model, which are (2D) simulation software. However,
2D view layout could not provide actual setting and actual dimension of the machine
and equipment. In recent years, the development of discrete event simulation softwares
grows rapidly. One of them is Flexsim software. It provides three dimensional (3D)
view of the layout. This software allows designer to build virtual reality (VR)
environment and can have feel of the actual setting of the factory. Potential problems
such as safety issues, aisle and other layout problems can be visualized and modified
by applying plant layout problem solving techniques. In the future research of some
literatures, there are some new approaches of facility design analysis. One of them is
combining the basic heuristic methods with 3D simulation technique in evaluating the
existing layout arrangement. The objective is to create more comprehensive analysis to
find the optimum layout arrangement.

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 Sanjeev B. Naik and Dr. Shrikant Kallurkar

6. CONCLUSION
In order to achieve maximum returns from the capacity of facilities, it is very essential
to optimize plant layout for proposed units or re-layout of existing manufacturing units
as per the changing market scenario. Many researchers have developed lot of models
based on heuristic and meta-heuristic approach by considering different case studies.
Heuristic methods such as Tabu Search (TS), Simulated Annealing (SA), and Genetic
Algorithms (GA) are common tools in optimization. Limitations of those heuristic
methods are time consuming and cannot get the feel of the actual setting and actual
dimension of the machine and equipment. Beside the heuristic methods, simulation
technique is a powerful tool used by many researchers in creating and evaluating the
proposed layout design before implementation. Simulation tools that commonly used
in facility planning are Arena [12], QUEST [27], IGRIP [24, ProModel [35] and
Witness [31].
Looking towards the limitations of the methods discussed so far, it is revealed that
the more efficient and comprehensive method can be developed by using combination
of heuristic methods and simulation technique. It is also revealed that there is a scope
for developing multi-objective optimization techniques particularly for small scale
sectors having few departments.

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