FACILITY LAYOUT AND
LOCATION
C O M P I L E D B Y:
P R O F. A . M . G O H I L
INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
Factors affecting facility location
Market proximity
Proximity to Raw Materials
Availability of land
Availability of Utilities
Labour supply and Unionization
National taxes
Legal restrictions
Stability of demand
Modes of transportations
Security
Single Facility Location - MINISUM
Single Facility Location - MINISUM
Rectilinear distance measure Euclidean distance measure
Manhattan distance
Right-angle distance
Rectangular distance
Single Facility Location - MINISUM
Single Facility Location - MINISUM
There are 6 existing plants which have a material
movement relationship with a new plant. The existing
plants have locations of (300,400), (500,800),
(1000,700), (900,200), (300,750) and (1200,500).
The number of tons of materials transported per year
from the new plant to various existing plants are 500,
900, 400, 900, 800 and 1600, respectively.
Determine the optimum location for the new plant
such that the distance moved in transporting the
materials to the existing facilities is minimized.
Single Facility Location - MINISUM
X=900
Single Facility Location - MINISUM
X=900
Y=500
Multi-facility Location – Transportation Problem
Multi-facility Location – Transportation Problem
Multi-facility Location – Transportation Problem
Balanced Transportation Problem
Multi-facility Location – Transportation Problem
Unbalanced Transportation Problem – Total Supply exceeds Total demand
Multi-facility Location – Transportation Problem
Unbalanced Transportation Problem – Total demand exceeds Total supply
North-West corner method
A company has three plants A, B and C which supply a product to six
major distribution centres 1, 2, 3, 4, 5, and 6. The table below gives the
transportation costs per unit, the annual plant capacities and the
forecast of the demands at various centres.
Formulate a transportation model and thus determine how the products
should be supplied from the plants to the distribution centres as per
North-West corner method.
North-West corner method
North-West corner method
North-West corner method
North-West corner method
North-West corner method
FACILITY LAYOUT
C O M P I L E D B Y:
P R O F. A . M . G O H I L
INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
9/20/2024 8:50:27 AM
CONTENT
Computerized Relative Allocation of Facilities
Techniques (CRAFT)
Automated Layout Design Program (ALDEP)
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Overview of plant layout problem
How plant layout problem arise?
Communication for effective plant layout.
‘Satisfactory solution’ using ‘component approach’
Objectives
Constraints
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• Input Data and Activities
• Assembly chart
• Bill of materials
• Operation process chart
Systematic layout planning procedure 9/20/2024 8:50:27 AM
Horizontal flow pattern
Factors affecting
flow pattern
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Vertical flow pattern
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Types of layout
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Activity relationship analysis
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Activity relationship diagram
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CRAFT
Developed by Armour and Buffa
Improvement type algorithm
Minimizes – transportation cost
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CRAFT Procedure
1. Inputs
1. Number of departments
2. Number of interchangeable departments
3. Initial layout
4. Cost matrix
5. Flow matrix
6. Area of departments
2. Compute centroids of departments in present layout
3. Form distance matrix using the centroids
4. Compute total handling cost of the present layout
5. Find all the pair wise interchanges of departments based
on ‘common border’ or ‘equal area’
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CRAFT Procedure
6. Find the pair with minimum handling cost
7. Is the cost less than the total cost of present layout? If
yes, goto step 8. If not, goto step 11.
8. Interchange the selected pair of departments. Call this as
NEW LAYOUT. Compute centroids, distance matrix and
total cost.
9. Is the cost of new layout less than the cost of present
layout? If yes go to step 10. If not, go to step 11.
10. New layout is considered as PRESENT LAYOUT. Goto
step 5.
11. Print the present layout as FINAL LAYOUT
12. Stop
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CRAFT
6 4
4 A B
4 C D
4 6
•Number of departments
•Number of interchangeable departments
•Initial layout
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CRAFT
To
A B C D
A - 1 1 1
B 1 - 1 1
From
C 1 1 - 1
D 1 1 1 -
•Cost matrix
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CRAFT
To
A B C D
A - 1 1 3
B 2 - 2 1
From
C 0 2 - 2
D 1 4 3 -
•Flow matrix
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CRAFT
6 4 Centroid
X Y
4 A B A 3 6
4 C D B 8 6
C 2 2
4 6 D 7 2
•Centroid
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CRAFT
Centroid
X Y •Rectilinear distance measure
•Di = |X-Xi|+ |Y-Yi|
A 3 6
B 8 6 To
C 2 2 A B C D
D 7 2 A - 5 5 8
From B 5 - 10 5
C 5 10 - 5
D 8 5 5 -
•Distance matrix
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CRAFT
To To
A B C D A B C D
A - 1 1 1 A - 1 1 3
From
B 1 - 1 1
From
B 2 - 2 1
C 1 1 - 1 C 0 2 - 2
D 1 1 1 - D 1 4 3 -
•Cost matrix •Flow matrix
To To
A B C D A B C D
A - 5 5 8 A - 5 5 24
142
From
B 5 - 10 5
From
B 10 - 20 5
C 5 10 - 5 C 0 20 - 10
D 8 5 5 - D 8 20 15 -
•Distance matrix •Total cost matrix
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CRAFT
6 4 Pair Remark
A&B Common Boarder
4 A B A&C Common Boarder
A&D Equal Area
4 C D
B&C Equal Area
B&D Common Boarder
4 6
C&D Common Boarder
•Pair wise interchange
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CRAFT
4 6
4 B A
4 C D
4 6
•A & B interchange
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CRAFT
Centroid
X Y To
A 7 6 A B C D
B 2 6 A - 1 1 1 CM
From
B 1 - 1 1
C 2 2 C 1 1 - 1
D 7 2 D 1 1 1 -
To To
A B C D A B C D
A - 5 9 12 A - 1 1 3
FM
From
From
B 10 - 8 9 B 2 - 2 1
C 0 8 - 10 C 0 2 - 2
D 4 36 15 - D 1 4 3 -
To
TCM A B C D
126 A - 5 9 4
From
B 5 - 4 9
C 9 4 - 5 DM
D 4 9 5 -
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ALDEP
Automated Layout Design Program
Construction type algorithm
Data required
Total number of departments
Area of each department
Length and width of layout
Closeness ratings of various pairs of departments
Minimum department preference (MDP) value
Sweep width
Number of iterations to be performed
Fixed area if any
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ALDEP
Department Area sq m No. of square
1 16000 40
2 24000 60
3 10000 25 Number of
4 20000 50 department
5 16000 40 1 Sq. = 400 sq m
6 12000 30
98000 245
L 18
W 14
Total 252
9/20/2024 8:50:27 AM
Facility Layout Design
Automated Layout Design Program(ALDEP)
Construction type algorithm
Data required
Total number of departments
Area of each department
Length and width of layout
Closeness ratings of various pairs of departments
Minimum department preference (MDP) value
Sweep width
Number of iterations to be performed
Fixed area if any
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ALDEP
Department Area sq m No. of square
1 16000 40
2 24000 60
3 10000 25 Number of
4 20000 50 department
5 16000 40 1 Sq. = 400 sq m
6 12000 30
98000 245
L 18
W 14
Total 252
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ALDEP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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ALDEP
To
1 2 3 4 5 6
1 - A O E I E
2 A - U E A I
From
3 O U - I U O
4 E E I - I E
5 I A U I - A
6 E I O E A -
Relationship chart
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ALDEP
Closeness Notation Value
Absolutely necessary A 64
Essentially important E 16
Important I 4
Ordinary closeness OK O 1
Unimportant U 0
Not desirable X -1024
Closeness rating
Minimum department preference value MDP = 4
Sweep width =2
Location of fixed department = Nil
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ALDEP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 4 4
2 4 4
3 4 4
4 4 4 4 4
5 4 4 4 4
6 4 4 4 4
7 4 4 4 4
8 4 4 4 4
9 4 4 4 4
10 4 4 4 4
11 4 4 4 4
12 4 4 4 4
13 4 4 4 4
14 4 4 4 4
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ALDEP
To
1 2 3 4 5 6
1 - A O E I E
2 A - U E A I
From
3 O U - I U O
4 E E I - I E
5 I A U I - A
6 E I O E A -
List A = { Nil}
List B = {1, 2, 3, 5, 6 }
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ALDEP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 4 4 1 1 1 1
2 4 4 1 1 1 1
3 4 4 1 1 1 1
4 4 4 4 4 1 1
5 4 4 4 4 1 1
6 4 4 4 4 1 1
7 4 4 4 4 1 1
8 4 4 4 4 1 1
9 4 4 4 4 1 1
10 4 4 4 4 1 1
11 4 4 4 4 1 1
12 4 4 4 4 1 1 1 1
13 4 4 4 4 1 1 1 1
14 4 4 4 4 1 1 1 1
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ALDEP
To
1 2 3 4 5 6
1 - A O E I E
2 A - U E A I
From
3 O U - I U O
4 E E I - I E
5 I A U I - A
6 E I O E A -
List A = { 3}
List B = {2, 5, 6}
9/20/2024 8:50:27 AM
ALDEP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 4 4 1 1 1 1 2 2 2 2
2 4 4 1 1 1 1 2 2 2 2
3 4 4 1 1 1 1 2 2 2 2
4 4 4 4 4 1 1 2 2 2 2
5 4 4 4 4 1 1 2 2 2 2
6 4 4 4 4 1 1 2 2 2 2
7 4 4 4 4 1 1 2 2 2 2
8 4 4 4 4 1 1 2 2 2 2
9 4 4 4 4 1 1 2 2 2 2
10 4 4 4 4 1 1 2 2 2 2 2 2
11 4 4 4 4 1 1 2 2 2 2 2 2
12 4 4 4 4 1 1 1 1 2 2 2 2
13 4 4 4 4 1 1 1 1 2 2 2 2
14 4 4 4 4 1 1 1 1 2 2 2 2
9/20/2024 8:50:27 AM
ALDEP
To
1 2 3 4 5 6
1 - A O E I E
2 A - U E A I
From
3 O U - I U O
4 E E I - I E
5 I A U I - A
6 E I O E A -
List A = { 3}
List B = {5,6}
9/20/2024 8:50:27 AM
ALDEP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 4 4 1 1 1 1 2 2 2 2 5 5 5 5
2 4 4 1 1 1 1 2 2 2 2 5 5 5 5
3 4 4 1 1 1 1 2 2 2 2 5 5 5 5
4 4 4 4 4 1 1 2 2 2 2 5 5 5 5
5 4 4 4 4 1 1 2 2 2 2 5 5 5 5
6 4 4 4 4 1 1 2 2 2 2 5 5 5 5
7 4 4 4 4 1 1 2 2 2 2 5 5 5 5
8 4 4 4 4 1 1 2 2 2 2 5 5 5 5
9 4 4 4 4 1 1 2 2 2 2 5 5 5 5
10 4 4 4 4 1 1 2 2 2 2 2 2 5 5
11 4 4 4 4 1 1 2 2 2 2 2 2 5 5
12 4 4 4 4 1 1 1 1 2 2 2 2
13 4 4 4 4 1 1 1 1 2 2 2 2
14 4 4 4 4 1 1 1 1 2 2 2 2
9/20/2024 8:50:27 AM
ALDEP
To
1 2 3 4 5 6
1 - A O E I E
2 A - U E A I
From
3 O U - I U O
4 E E I - I E
5 I A U I - A
6 E I O E A -
List A = { 3}
List B = {6}
9/20/2024 8:50:27 AM
ALDEP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 4 4 1 1 1 1 2 2 2 2 5 5 5 5 3 3 3 3
2 4 4 1 1 1 1 2 2 2 2 5 5 5 5 3 3 3 3
3 4 4 1 1 1 1 2 2 2 2 5 5 5 5 6 6 3 3
4 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3
5 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3
6 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3
7 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3
8 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3
9 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3
10 4 4 4 4 1 1 2 2 2 2 2 2 5 5 6 6 3 3
11 4 4 4 4 1 1 2 2 2 2 2 2 5 5 6 6 3 0
12 4 4 4 4 1 1 1 1 2 2 2 2 6 6 6 6 0 0
13 4 4 4 4 1 1 1 1 2 2 2 2 6 6 6 6 0 0
14 4 4 4 4 1 1 1 1 2 2 2 2 6 6 6 6 0 0
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ALDEP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Neighbour
Rel. Rel.
Grade Value
1 4 4 1 1 1 1 2 2 2 2 5 5 5 5 3 3 3 3
4-1 E 16
2 4 4 1 1 1 1 2 2 2 2 5 5 5 5 3 3 3 3
1-2 A 64
3 4 4 1 1 1 1 2 2 2 2 5 5 5 5 6 6 3 3 2-5 A 64
4 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3 2-6 I 4
5 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3 5-6 A 64
5-3 U 0
6 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3
6-3 O 1
7 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3 SCORE 213
8 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3 Two-way
426
9 4 4 4 4 1 1 2 2 2 2 5 5 5 5 6 6 3 3 Rel. Score
10 4 4 4 4 1 1 2 2 2 2 2 2 5 5 6 6 3 3
11 4 4 4 4 1 1 2 2 2 2 2 2 5 5 6 6 3 0
12 4 4 4 4 1 1 1 1 2 2 2 2 6 6 6 6 0 0
13 4 4 4 4 1 1 1 1 2 2 2 2 6 6 6 6 0 0
14 4 4 4 4 1 1 1 1 2 2 2 2 6 6 6 6 0 0
9/20/2024 8:50:27 AM
