Afro - Asian International Conference on Science, Engineering & Technology

AAICSET-2015
ISBN: 9-780993-909238

Techniques for Solving Facility Layout Problem: A

Survey
Nitish D.Patil1 Jaivesh Gandhi2 Vivek Deshpande3
ME-Advance Manufacturing System Asst. prof.Mech Engg, ME- Asst. prof.Mech Engg
production
Shri S’ad vidhya Mandal, Shri S’ad vidya Mandal, G H Patel College of Engg. & Tech
Bharuch, India Bharuch, India V V Nagar, Anand, India

Abstract: Facility planning is concerned with design, layout and problem in which the objective is to configure facilities, so as
accommodation of people, machine and activity of the system or to minimize the cost of transporting materials between them
enterprise within a physical spatial environment. The facility [3].Facility layout planning is simply the allocation of
planning plays a vital role in manufacturing process due to there in
resources at the right place. Optimum plant layout exhibit the
achieving an efficient product flow it reduces the cost of
features like minimum material handling cost, total production
manufacturing activity and provides more space to give maximum
output with minimum effort at the floor area.The objective of facility cost, work in process etc. The layout design process consist of:
planning is to achieve the lower work-in-process inventory, lower - (a) formulating the layout design problem, (b) Analyzing the
material handling and production cost. The different methods or design problem, (c) searching for alternative layout designs,
techniques are employed to design the facility layout. The most (d) Evaluating the layout design alternatives, (e) Selecting the
widely used techniques for facility design is Systematic Layout preferred design, (f) Specifying the layout design to be
Planning (SLP) by muther. Other techniques considered for solving installed [4].
these problems are CRAFT, ALDEP and CORELAP etc. These
techniques are used to formulate a new plant layout. This paper is an II. FACILITY LAYOUT PROBLEM: AN OVERVIEW
overview of different techniques to solve facility layout
Facility layout problem is common industrial problem which
problems.After carrying out the literature survey it has been found
minimizes the cost of transporting materials. Researcher wants
that comparative study of facility layout problem in CRAFT And
ALDEP has not been done along with the validation of results with to define facility layout problem such as:
VIP-PLANOPT (Virtual interface packages). This paper focuses on A. Determination of the relative location among a given
research methodology to be carried out to fill this research gap. number of facilities.
Keywords: Facility design, SLP, CRAFT, ALDEP. B.Arranging unequal area facilities of different size within a
given total space, which can be bounded to the length or width
I. INTRODUCTION:-
of size area in a way to minimize the total material handling
When the changes in an existing plant layout are made or a cost and slack area cost.
new plant layout is designed, it produces a brilliant chance of C. Facility layout is an optimization problem that tries to make
getting improved process flow and a minimum wasted space. layout more efficient by taking into the account various
Facility layout design and architectural design should be interactions between facilities and material handling system
integrated with each other to fulfil the objective of better while designing the layout.
quality results [1]. A facility layout is an arrangement of D.Designing the facility layout for improving the efficiency
everything needed for production of goods or delivery of [5,6].
services. A facility is an entity that facilitates the performance
of any job. It may be a machine tool, a work Centre, a Many researchers around the world have used various
manufacturing cell, a machine shop, a department, a software’s and techniques to solve facility layout problem.
warehouse, etc. Due to the variety of considerations found in Among these the widely used software’s and techniques are
the articles, researchers do not agree about a common and SLP (Systematic layout planning), CRAFT (Computerized
exact definition of layout problems [2]. The most encountered relative allocation facility technique), QAP (Quadratic
formulations are related to static layout problems. Were assignment problem), AHP (Analytical hierarchy process),
among the first to consider this class of problems, and they QALAAP (Qualitative layout analysis using automated
defined the facility layout problem as a common industrial recognition patterns), ALDEP (Automatic layout and design

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 Afro - Asian International Conference on Science, Engineering & Technology
AAICSET-2015
ISBN: 9-780993-909238

problem). Different software’s and techniques are used to SLP frame work uses activity relationship diagram as
achieve different objectives of facility layout problem [1-20]. a foundation activity. Based on the on the input data and an
CRAFT employs two way or three way exchanges of understanding of the roles and relationship between activities,
the centroid of non-fixed departments. These departments are a material flow analysis and an activity relationship analysis
either of same area or adjacent [3]. An estimation of reduction are performed. From the analysis perform, a relationship
in cost and selection of the steepest descent i.e. the exchange diagram is developed which position activities spatially [4].
with largest estimated reduction is computed. PLANOPT is a general purpose layout optimization
ALDEP is basically a construction algorithm but it algorithm but an enhanced version of this i.e. VIP-PLANOPT
can also be used to evaluate two layouts. It uses basic data on is used to produce high quality optimal layouts for small,
medium and large sized problems. It gives the flexibility to
facilities and builds a layout by successively placed in the
specify any number of rectangular blocks (used to specify
layout used in relationship information between the resources) to be “anchored” at fixed locations. VIP-
departments [4]. PLANOPT develops optimal layouts putting these anchored
blocks strictly at the user-specified locations [4].

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III. LITERATURE SURVEY

Sr Title and
Year Process parameter output Technique Outcomes
no author
Introduction of
different
software
The facility layout packages(FAC
Departmental
problem: Recent and Minimizing the TORY OPT, Introducing
adjacencies and
1 1996 Emerging Trends material SPIRAL, different tools and
interdepartmental
and Perspectives- handling cost LAYOPT) techniques of FLP
distances
Russel D. Miller BLOCKLAYO
UT,QAP AND
GRAPH
APPROCH
Simulate Guidelines for
Automated facilities
Automated space annealing and future
layout: Past, Present space
2 2000 layout, flow plan genetic implementation of
and future- Robin s. allocation
layout optimization, commercial
Liggett.
QAP systems

Reduce Combinatorial
A review of Current and future
manufacturing optimization
2006 different approaches trends of research on Survey of FLP
3 cost. (graph theory)
to the facility layout facility problems problems
Improve QAP
problems –S.P.Singh
productivity MIP

WIP,
Optimization
lead times ,
Facility layout Plant area, method Meta-heuristics is
2007 Productivity,
4 problems: A survey- manufacturing system Static and more useful
Overall
Amine Drira feature dynamic technique
efficiency of
problem
operations
Application Of Maximize sales Un-conventional
Application in
Systematic Layout with customers criterion like net
2010 hypermarkets,
5 Planning In satisfaction and SLP profit per square
Customers store
Hypermarkets – minimize foot and service
experience
Rajshekhar S Inglay overall cost convenience
Improvement plant
Decrease the
layout using SLP for Flow of material, Distance reduced
distance of SLP, Activity
increased the Distance, utility of from 227.61 m to
6 2010 material flow, relationship
productivity- W. area, material 190.08 m (reduced
increased the chart
Wiyaratn, A. handling equipment by 37 m),
productivity
Watanapa

Operation process Decreased the

Analysis plant To eliminate the
(sand mold, cold transportation cost
layout design for obstruction in
warehouses, core and rearranged
7 2011 effective material flow SLP
making, disassembly, layout, decreased
production- A. and maximize
surface finishing, distance and time
Watanapa the productivity
inspection section consumption in

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material flow

Facility layout
simulation and
optimization: an MCDM, QFD,
integration of Survey of FUZZY Reduced the cost
8 2011 advanced quality --------------------- production Analytical and increased the
and decision maling system hierarchy production cost
tools and process
techniques-
Arashshahin
Rapid
Improvement in
movement of
Layout Design using
2012 Space utilization material SLP does not
9 SLP of a small size SLP
And completely satisfy
manufacturing unit:
improvement in
-Chandra shekhar
existing layout
Design problems-
Layout planning: a Increased SLP algorithm and
Unit production –
case study on productivity, FLOW procedural
2012 customers individual
10 engineering-to-order decrease the ANALYSIS approaches
order
company – distance of flow HEURISTIC Success in
Production shop floor
miroslawmatusek material TECHNIQUE procedural
approach
COMPARE
PROJECT 1 AND
SLP
Optimizing Design PROJECT 2
SHA(system
of Layout 1-
Lowest handling
Arrangement for Work come from SHA(SYSTEMA
11 2012 transportation analysis)
Workshop Logistics material movement TIC HANDLING
amount. Logistics
System-yang ANALYSIS,2-
system
jianhua SLP
analysis
BEST IS
PRIJECT 2
Efficiency reduce
Work come from SLP,CRAFT, by the accidents
Reduce
Innovative practices material movement QAP, ,hazards and
manufacturing
2012 in facility layout And FMS,GT, increase easiness
12 cost.
planning- Operation of ASSEMBLY and convenience
Improve
mahendrasingh production system LINE, Material handling
productivity
Facilitating material BALANCING and transportation
improved

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ISBN: 9-780993-909238

Reduce time
consumed,
Improvement plant reduce un- Reduce by 68 m
Material flow, SLP,
2013 layout based on necessary work floor space
13 process area and plant layout
systematic layout eliminated, and Original 176 m
space requirement
planning-w.wiyaratn possible
rearrangement
plant layout
Cost reduce by
10% to 30%
Compare three
Layout Design for a Maximize
Small batch size SLP, technique
2013 Low Capacity productivity,
14 production, Lean (empirical ,SLP,
Manufacturing Line- And WIP AND
complexity of product production Lean) measure
filippo De carlo TT
actual
performance best
is LEAN
Increased
Decease flow of SLP
Productivity In
Equipment size and material and Flow analysis 86.5 m reduced
Factory Layout By
15 2013 area increased Relationship from 127.5m
Using Systematic
production chart
Layout PLANNING
(SLP)-C.R.Shah
Increased
Productivity and
Planning By Increased
SLP, Flow Reduce warehouse
Improved Plant flow work or productivity,
analysis to packing
2013 Layout Using production route decrease the
16 Activity approximate 20
Systematic And equipment size distance of flow
relationship meter
Layout Planning at and area material
chart
NCRM Division,
Bhushan
Steels Ltd.
Intelligent
Current and future techniques(fuz Improve the
Simulation
trends of Improve zy logic performance of
Methodology for
research,Customized material ,genetic production
17 2013 Facility Layout
products in small handling and algorithm)Met lineDecrease
Problems –
batch,Material cost reduction a- bottleneck
C.N.Kulkarni
handling heuristicsSA,G problem
A
Minimized the
total distance of
the
Efficiency Distance moved per travelledExisting
Maximize the ARENA
Improvement of a unit produced layout –simulated
18 2014 capacities of SOFTWARE
Plant Layout- (m)AndEfficiencyAn efficiency
facilities for simulation
Vivekanand s Gogi dSimulated efficiency 68.67%Proposed
layout -
94.767%Reductio
n transportation

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length 46%

Development of
plant layout using Cost Total distance
Least amount of Activity
systematic reductionAndTh reduce by 292m
material relation
19 2014 layoutPlanning (slp) roughput Original layout
handling(M/C, chart,Lean,SL
to maximize timesAnd distance covered
EQUIPMENT) P
production productivity by 339.05
-orvillesutari
Machine
Analysis and
utilization(cutting Optimize
Simulation of Solved the
time and inter activity (floor ARENA
20 2014 Factory Layout organization
arrival),(for area and simulation
using ARENA- through efficiency
individual machine) manufacturing
Bobby john of the work
and employee’s process
amenities

 I: important.
IV. METHODOLOGY  O: ordinary.
 U: unimportant.
There are different methods and techniques for  X: undesirable.
solving the facility layout problems such as SLP, CRAFT, In the next step these coded (ASME notations)
ALDEP, CORELEP, M-CRAFT, BLOCK PLAN, MIP, activities in the relationship chart are connected with lines.
MULPTIPLE etc. The numbers of lines joining two different activities are the
SLP:- function of level of nearness.
In 1961, Richardmuther introduced planning
technique called as systematic layout planning. User can FIVE IMPORTANT ELEMENT
identify visualize and rate the various activities, Following are the key elements for the ease of solving
relationship, and alternatives concerned with the layout plant layout problems according to SLP [1, 17, 18, 19,
project [15]. The progressive planning procedure of SLP and 20]
facilitates the user to solve the layout problems. The 1. P- product
relationship, adjustment and space are the three basic area of It involves the end product, raw material,
this techniques. The combine effect of quantitative machining component and service project. The product
measurement of material movement and non-flow influences contents and inter-relationship of available
considerations like temperature, movement noise etc. are facilities material handling systems and equipment. The
evaluated .the collection of input data, actual relationship product comprises of raw material, machining facilities,
activity, material flow are the major sub content of SLP. span of service
The progressive phases of SLP are 2. Q- Quantity:
 Data collection and its analysis; Thequantity shows the volume of production,
 Identify the possible layout solutions; it also shows volume of supply, its utilization. This
 Evaluation of alternatives and selection of best information of quantity indicates the volume, number of
layout[16]; pieces, weight and prize. The quantity influences the
area of layout, specification of equipment, material
With the help of information like material flow, in between handling systems and total plant area.
work stations, their requirement etc. the relationship chart 3. R- Route:
(buff diagram) is formulated. In a relationship chart, some Route gives the inter-relationship among works
alphanumeric codes are assigned to the different operations stations the route of material flow and the location
written on the right side of the codes. Each codes are certain of buffer storages and central store. The facility
meaning as follows:[16] location is greatly affected by this element
4. S- supporting service:-
 A: absolutely necessary. The services like tools, health stations,
 E: especially important. changing rooms, canteen and toilets etc. fall under

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ISBN: 9-780993-909238

supporting services. It provides necessary support to the It indicates the duration of production
production system and in some sense helps in including every aspect of it. It comprises of the run
increasing production efficiency. of every process of production activity.
5. T- Time:

Fig: - Relationship Activity chart[1, 17, 18, 19, 20]

STAGE SRUCTURE:-
Stage structure of the SLP method as shown in following figure:-

Fig: - SLP Stage Structure [17]

STAGE 1: ORIENTATION DETERMINNG: the shape of every operating unit, also it is necessary to
know how the operating units relate with each other.
The initial orientation is determine in this stage. STAGE 3: DETAILED PLANNING:
The suitable and appropriate location of every facility is
needed to be determine irrespective of the overall layout of A very detailed planning activity is required for
workshop. every work unit and equipment. The input output point
STAGE 2: OVERALL PLANNING: locations exact facility locations and the layout of each
departments are the key factors for detailed planning.
The overall facility layout is planned in this stage. STAGE 4: PLANNING IMPLEMENTATION:
The zoning arrangement and basic model of logistic is to be
combine with the layout. A very important data needed to All the detailed planning done in stage 3 is
draw a preliminary zoning map, is the shape of every implemented in this stage. The ultimate stage presents the
operating unit. When it draw the preliminary zoning map, test runs of layout after implementation, post stage 4.
CRAFT

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CRAFT employs two way or three way exchanges interface packages). This paper focuses on research
of the centroid of non-fixed departments. These departments methodology to be carried out to fill this research gap.
are either of same area or adjacent [3]. An estimation of
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