Incorporating heterogeneous distance metrics within block layout design

This paper focuses on optimal design of block layouts when using more than one distance metric within a single facility. Previous work in block layout has assumed a single distance metric, usually the shortest rectilinear distance between department centroids, during the design step. However, most facilities have more than one method of material handling and alternative material handling systems can imply alternative distance metrics and cost structures. Specifically, up to three distance metrics within a single facility are considered--the shortest rectilinear distance between centroids (appropriate for automated guided vehicles and forklift trucks), the Tchebychev (maximum) distance (appropriate for overhead cranes) and the shortest Euclidean distance between centroids (appropriate for conveyor lines). Optimal block layouts using each of these distance metrics individually and then collectively are compared and contrasted. This approach can also be used to compare layouts when the choice of material handling system is not clear. It is argued that incorporating the distance metric that best reflects the planned material handling device is more realistic than previous formulations, avoids block layouts that are sub-optimal for the material handling systems installed, and is quite workable within a heuristic optimization framework.     

Design of flexible plant layouts

In this paper, we present an approach for the design of plant layouts in stochastic environments. We consider systems where the, product mix and product demand are subject to variability and where duplicates of the same department type may exist in the same facility. In contrast to a job shop layout, we allow these duplicates to be placed in non-adjacent locations on the plant floor and for flow allocation between pairs of individual departments to be made as a function of the layout and the product demand realization. We present a scenario-based procedure that iteratively solves for layout and flow allocation. We show that having duplicates of the same departments, which can be strategically located in different areas of the plant floor, can significantly reduce material handling cost while effectively hedging against fluctuations in flow patterns and volumes. We show that the effect of duplication is of the diminishing kind, with most of the cost reduction occurring with relatively few duplicates. We also show that the quality of the obtained layouts can be quite insensitive to inaccuracies in estimating demand scenario probabilities.     

Computer-based FMS facilities design tool

FMS layout design is a complex process, involving a large number of alternatives, which contributes generously to the usual two-year FMS planning lead time. The need for a comprehensive, yet easy-to-use methodology or tool which can reduce this large number of alternatives to a more reasonable figure has motivated this research. A survey of existing FMSs was undertaken with the intention of identifying some of the more common (dominant) types of layouts, and to develop, if possible, a methodology for the selection of such layouts. However, almost every FMS was found to have a unique layout. For a given FMS under consideration, the capabilities with respect to the parts which can be manufactured is essentially given. The determining features of the resultant design of the FMS, therefore, are primarily based upon the design of the material handling system which integrates the FMS. However, as the number of machines in a FMS increase, the number of part sequences and alternate configurations increase at a dramatic rate. To assist in the preliminary design process, an interactive computer-based program has been developed to aid the search for non-inferior layouts to suit the exact part sequence needs of each FMS. Six criteria-three related to the distances parts travel during manufacturing and three related to the capital costs of the FMS-are provided to assist the user in selecting an appropriate arrangement. The program is described and its use is demonstrated in developing improved arrangements over an example FMS which was published in the literature. Although the reader is cautioned that the results were developed using only static measures, the results do indicate that significantly improved designs are possible using the proposed methodology     

The facilities layout problem: a multi-goal approach

This paper presents a combined quantitative and qualitative (subjective) approach to the plant layout problem. The two objectives, which may be conflicting, are minimizing the material handling cost and maximizing a closeness rating measure. A heuristic algorithm is developed which results in a discrete efficient frontier set, including only 'efficient layouts’. By specifying the different weights, or range of weights, for these goals, the 'best’ solution (layout) is generated.     

Analysis on high throughput layout of container yards

The operational efficiency of handling resources plays an important role in promoting container flows at a container terminal. As these handling resources operate on specific yard layouts, a well-designed layout will promote the performance of the handling activities. This study aims to discuss a design process to maximise the throughput capacity, as well as minimise the resource configuration when designing the yard layout. Various experiments were conducted and analysed to demonstrate the effects on the layout structure and the resource configuration for the two types of parallel yard layouts: the double-lane yard layout where vehicles can access the block at both side and the single-lane yard layout where two adjacent blocks in a row are grouped together and vehicles can access each block at only one side. According to the findings, the container flows by vehicles exert greater influence on the design of a container yard compared to the time taken for container processing by quay cranes and yard cranes. It is also found that the single-lane yard layout is preferable when high throughput capacity is required, whereas the double-lane yard layout is superior in favour of high efficiency of vehicle flows.     

Sharing clearances to improve machine layout

This paper considers a double-row layout problem with shared clearances in the context of semiconductor manufacturing. By sharing some clearances, reductions in both layout area and material handling cost of approximately 7–10% are achieved. Along with minimal clearances for separating adjacent machines, clearances that can be shared by adjacent machines are considered. The shared clearances may be located on either or both sides of machines. A mixed integer linear programming formulation of this problem is established, with the objective to minimise both material flow cost and layout area. A hybrid approach combining multi-objective tabu search and heuristic rules is proposed to solve it. Computational results show that the hybrid approach is very effective for this problem and finds machine layouts with reduced areas and handling costs by exploiting shared clearances.     

Facility layout objective functions and robust layouts

In this paper we examine the adjacency-based, distance-based, and weighted-criteria facility layout objective functions in an attempt to relate them to actual layout costs, which are typically dependent on material handling costs. As a result of this examination, we develop an objective function based on a basic material handling cost structure. We then show that this objective function is a generalization of the traditional weighted objective. Since specifying weights may not be an exact process, we explore the impact of imperfect weighting-value information on solution quality. In the process, we illustrate with test problems from the literature that robust solutions—good solutions as measured by more than one set of weights—can be found with a simple procedure we call the robust layout method. This leads us to our general conclusion that using imperfect weighting-value information while we generate the layouts is better than using complete weighting-value information only after we generate the layouts.     

EXCITE: Expert consultant for in-plant transportation equipment

The cost of handling material is a vital factor in the facilities design process, whether it is for a new facility or for the redesign of an existing facility. Handling activities generally account for 30 to 40% of production costs, but in some industries they can be as high as 70%. Well designed handling systems are thus crucial for reduced costs and increased profits.

A key task in the material handling system design process is the selection and configuration of equipment for transport and storage in a facility. Material handling equipment selection is a complex, tedious task, and there is usually more than one good answer for any particular situation. A number of good quantitative techniques are available to aid the industrial engineer in determining layout design with the aim of reducing material handling cost. Unfortunately, there are few tools other than checklists to aid the engineer in the selection of appropriate, cost-effective material handling equipment. Analytical models are not often applied in industry because they generally consider only quantifiable factors such as cost and utilization and are difficult to implement.

This paper describes a knowledge-based approach for addressing the major factors that influence equipment selection. The research effort involved two major activities: compilation of a knowledge base from an in-depth review and modification of traditional checklists and published literature on equipment selection; and development of a prototype expert system for material handling equipment selection.     

Fuzzy approach to the robust facility layout in uncertain production environments

The proposed method approaches the problem of the optimal facility layout using fuzzy theory. The optimal layout is a robust layout that minimizes the total material handling cost, when the product market demands are uncertain variables, which are defined as fuzzy numbers. Since each department has a limited production capacity, not all possible combinations, deriving from each product's market demand, are taken into account because some combination could exceed the overall department's productivity. Therefore, the optimal solution results by solving a 'constrained' fuzzy optimization problem, in which the fuzzy material handling costs corresponding to the layouts are evaluated, and a ranking method, which considers the grade of pessimism of the decision maker, is established to determine the optimal layout.     

An interactive approach to computer aided facility layout

In all manufacturing and service industries the layout of facilities is an important determinant of operating efficiency and costs. Whenever the flow of materials or people is complex, computerized procedures offer the only feasible means of developing and evaluating alternative arrangements.

This paper describes an interactive approach to construction and improvement procedures which utilizes a refresh graphics terminal (IMLAC)linked to a PRIME 400 computer. Input includes projected materials flow, estimates of material handling costs, 2-D templates of machines, etc., and an initial layout which can be either existing, proposed, or constructed using the procedure INLAYT. A heuristic procedure, S-ZAKY, utilizes multi-pairwise facility exchange to develop improved layouts based upon an analysis of materials flow. The improved layout is displayed in detail alongside the initial layout at the graphics terminal together with relevant material handling costs. The user may then accept, reject or modify the improved layout using the light-pen attached to the terminal before proceeding to successive iterations until satisfied. An economic evaluation of the projected savings in material handling costs against costs of relayout may be displayed at each iteration. On completion, a fully documented record including drawings may be obtained for every stage in the. procedure.     

Optimal urban sewer layout design using Steiner tree problems

This article introduces a novel method using mixed-integer linear programming for optimizing sewer layouts. The research concept was obtained from the obstacle-avoiding rectilinear Steiner minimal tree technique in integrated circuit routing design. The Steiner nodes serve as optional nodes to link each sewer discharge node and flow to sinks on an optimal sewer layout. Those nodes are utilized for minimizing the total cost required for constructing pipes. All the nonlinear constraints and the objective function are transformed into a simple linear format. The optimization model analysed three types of objective function conditions—solely considering the pipe cost, solely considering the ground-cutting cost, and combining both considerations—to illustrate the importance of considering all conditions to obtain an optimal sewer layout design. The proposed optimization model can save more than 38.83% of the cost required to realize the expert’s manual sewer layout design.     

An expert system using priorities for solving multiple-criteria facility layout problems

In this paper we develop an expert system for multiple-criteria facility layout problems. The facility layout problem is identified as an ill-structured problem; our approach for solving it is based on expert systems and multiple-criteria decision making (MCDM). The expert system interacts with the decision maker (DM), and reflects the DM's preferences in the selection of rules and priorities. The inference engine is a forward-chaining reasoning procedure which is discussed in detail. The approach consists of two parts: (a) construction of a layout based on a set of rules and restrictions, and (b) improvement of the layout based on interaction with decision maker. The MCDM expert system approach considers and incorporates the multiple criteria in these two parts as follows. In (a) it uses priorities on the selection of rules, adjacency of departments, and departments for construction purposes. In (b) it uses different objectives such as materials handling cost, flexibility, and materials handling time for paired comparison of generated layouts for improvement purposes. Some experiments with the developed computer package are reported and an example is solved.     

MULTI-HOPE: A tool for multiple floor layout problems

The objective of most facility layout problems is to minimize material handling cost, which is directly proportional to both the distance between the machines and the mix, as well as the volume of products handled. The mix and volume of products are dependent on the demand patterns, and the distance is dependent on the layout plan used for the facility. Because it is relatively difficult to change the demand patterns, and hence the mix and volume of products, the primary focus of most designers has been to deal with the distance attribute of the material handling costs. The limitations of available horizontal space create a need to explore vertical expansion of facilities. This brings up new aspects of vertical material handling and flow that need to be considered in the facility design problem. In this paper, we present a genetic algorithm-based heuristic for generating block layouts for multiple-floor layout problems. This approach produces better solutions than existing simulated annealing-based heuristics for all but one of five multiplefloor test problems available in the literature.     

Routing methods for warehouses with multiple cross aisles

This paper considers routing and layout issues for parallel aisle warehouses. In such warehouses order pickers walk or drive along the aisles to pick products from storage. They can change aisles at a number of cross aisles. These cross aisles are usually located at the front and the back of the warehouse, but there can also be one or more cross aisles at positions in between. We describe a number of heuristics to determine order picking routes in a warehouse with two or more cross aisles. To analyse the performance of the heuristics, a branch-and-bound algorithm that generates shortest order picking routes is used. Performance comparisons between heuristics and the branch-and-bound algorithm are given for various warehouse layouts and order sizes. For the majority of the instances with more than two cross aisles, a newly developed heuristic appears to perform better than the existing heuristics. Furthermore, some consequences for layout are discussed. From the results it appears that the addition of cross aisles to the warehouse layout can decrease the handling time of the orders by lowering average travel times. However, adding a large number of cross aisles may increase average travel times because the space occupied by the cross aisles has to be traversed as well.     

A hybrid approach for concurrent layout design of cells and their flow paths in a tree configuration

The layout design of multiple-cell automated manufacturing systems includes cell layout design and flow path layout design. Traditional layout methods often treat these two as separate problems and the sequence for solving them is usually cell layout first and flow path layout later. However, approaches of these kinds have one major drawback, that is, they may produce cell layouts that are awkward or difficult for designers to conduct flow path layouts, or cell layouts that do not turn out to be as good as expected after flow path layouts have been performed. Other drawbacks of traditional layout methods include irregular shapes of cells, inaccurate calculations of flow distances, etc. This paper addresses the layout problem of cells and their connecting flow paths in a tree configuration. The proposed layout procedure is designed to avoid the aforementioned drawbacks of traditional layout methods by emphasizing concurrent layout design of cells and flow paths. It combines a search algorithm and mathematical programming models. The search algorithm has a backtracking procedure that allows one to explore alternative layouts, while the mathematical programming models help one obtain accurate layouts of cells and flow paths. The proposed layout procedure also interacts with designers and allows designers to include their qualitative consideration into the layout design. As a result, one can obtain more accurate and good-quality layouts with the proposed layout procedure.     

Evaluation of an application of graph theory to the layout problem

When designing a facility layout it is desirable to obtain an optimum design which satisfies certain necessary relationships among departments. Recent research has indicated that applying graph theory to the layout problem can result in the development of improved solutions, but little can be found to indicate how much better the resultant solutions are. The objectives of this paper are to develop a graph theory approach based on research experience and suggestions of Moore, Carrie and Seppanen, to develop a general computer program implementing the procedure and to compare its performance with that of CRAFT, CORELAP and ALDEP. The comparisons are based upon the adjacency relationships satisfied in the resultant layouts. The procedure finds the graph G equivalent to the problem being solved and then generates one of its maximal spanning trees, which after being transformed to its ‘string’ equivalent, is used to extract a maximal planar sub-graph of G. The dual of this sub-graph represents the desired solution. This approach allowed two usual problems to be avoided; firstly, testing for planarity of a graph and secondly, testing for cycles in the generation of a maximal spanning tree. The resultant PL/1 program, called graph and string-oriented layout (GASOL), is used to solve a standard set of eight problems, i.e. Nugent's problem set. The generated layouts were then compared to those obtained by CRAFT, CORELAP, and ALDEP on the same set of problems. The results of these comparisons showed that GASOL satisfies more of the number of layout adjacencies and achieves higher ‘scored’ layout arrangements than either CRAFT, CORELAP, or ALDEP, As a consequence more flow or material handling volume is included in a GASOL layout. The increase in the number of adjacencies ranges from a low of 53% to a high of 63.1%. This computational experience suggests that a graph theory approach to the layout problem can provide significantly improved results over those obtained by these existing computerized layout routines, with moderately increased computational times.     

Generalisation of unidirectional loop layout problem and solution by a genetic algorithm

Unidirectional loop layouts (ULLs) are the preferred layouts in manufacturing systems owing to their relative low investment costs, high material handling elasticity and routing flexibility. Existing formulations of the unidirectional loop layout problem are concentrated on the arrangement of workstations under the assumption that the number and location of loading and unloading stations are known. In this study, the unidirectional loop layout problem is generalised by consideration of potentially attachable loading/unloading equipment to each workstation and releasing of the predetermined number of loading and unloading stations. Thus, more efficient and effective loop layout designs are allowed by eliminating some artificial restrictions. The present ULL model is generalised and a genetic algorithm is developed to solve the problem. Solutions obtained by the genetic algorithm outperformed those obtained by conventional methods. Additionally, comparisons of the generalised model with existing models on randomly generated test problems yielded encouraging results.     

Utilizing Cut Trees as Design Skeletons for Facility Layout

Facility layout provides a fertile area for the application of optimization models. There is a major cost associated with constructing or reconfiguring a facility. In addition, the number of layout possibilites is so large that human designers frequently have difficulty in generating good layouts. A cut tree is proposed here as the design skeleton for a family of facility layouts. It has some very attractive properties when used as part of an interactive system to support the designer in the analysis, construction and improvement of facility layouts. The cut tree has proven to be both easy to use and very powerful in aiding designers to generate quality layouts.     

Optimizing the yard layout in container terminals

The main activities of container terminals are to load outbound containers on to vessels, discharge inbound containers from vessels, and store those containers in the yard before loading (or after discharging) them. This study proposes a method for determining an optimal layout of container yards taking into consideration the storage space requirements and throughput capacities of yard cranes and transporters. Two types of yard layout are under consideration: a layout where blocks are laid out parallel to the quay and transfer points are located beside a bay per block, and a layout whose blocks are laid out perpendicular to the quay and transfer points are located at both ends of each block. Various cost factors are used for optimizing the yard layout, which include the construction cost of the ground space, the fixed overhead cost of yard cranes, and the operating costs of yard cranes and transporters. Sensitivity analysis is performed to investigate the effect of various design parameters on the optimal layout of the yard. The two types of yard layout are compared with each other, and the results of this study are compared against those for real-world yard layouts from the perspective of throughput capacity and storage space capacity.     

A bi-directional path layout for conflict-free routing of AGVs

Automated Guided Vehicles (or AGVs for short) are now widely used in automated material handling systems. Much research has been done on developing path layout and algorithms for the optimal routing and scheduling of AGVs. However, with the drastically increased number of AGVs in some recent applications (e.g. in the order of a hundred in container terminals), algorithms that can achieve a high degree of concurrency of AGV moves are urgently needed. This paper presents a bi-directional path layout and an algorithm for routing AGVs. To route the vehicles without conflicts and to minimize the space requirement of the layout, critical conditions for certain key parameters of the path and vehicle are derived. We further show theoretically that a high degree of concurrency of AGV moves can be achieved, although the routing decision takes only a constant amount of time for each vehicle. The routing efficiency is analysed in terms of the distance traversed and the time requirement for AGVs to complete all pickup and drop-off (or P/D for short) jobs. Results of this study could form a basis for more complicated path layouts and routing algorithms.