Facility Layout Design Research Articles

The joy of eating: how eating experiences enhance the well-being of older adults.

The active aging strategy has as its policy implications the health, security, and participation of older people. The joy of eating is the main goal of establishing community-based service facilities for older people, as well as a source of health and well-being and a sense of meaning in the lives of older people. Based on the theory of human-environment relations and cognitive-emotional personality systems (CAPS), the study constructed a structural equation model of the eating experience, nostalgia, place attachment, and the well-being of the older adults in the community canteens as an interactive situation, and explored the relationship between the eating experience and the well-being of older people in the community canteens through the partial least squares structural equation modeling (PLS-SEM). The results of the study show that the older adults' eating experience has a significant positive effect on their well-being, and "eating" can make older adults feel happy. Older adults' eating experience has a significant effect on nostalgia, place attachment, and well-being, but nostalgia does not have a significant effect on older adults' well-being, and place attachment in the community canteens can enhance older adults' well-being. Meanwhile, the study further confirmed that place attachment plays a mediating role in the effect of eating experience on older adults' well-being. The findings of the study promote the development of the fields of healthy eating, quality of life assessment, and dietary memory management for older people to a certain extent and provide an important reference for promoting the balanced layout and effective spatial design of community service facilities for older people.

Redesign The Layout of Production Facilities at a Garment Company Using the BLOCPLAN Method to Optimize Material Handling

Facility layout design is crucial in production layout setups. The composition of facilities that corresponds to the flow of materials between departments will help to ensure the production system's continuity. PT. KMC is a garment company in West Jakarta that manufactures shirts, dresses, and t-shirt bloats. The company's current layout facilities have not run optimally. This is because inefficient movement distances result in wasted material handling costs, and crossing production flows between departments cause production processes to be disturbed. The objective of this project is to rethink facility layouts using the BLOCPLAN approach in order to optimize material handling. The BLOCPLAN approach may examine layout performance and generate new layout ideas for efficient material handling. The discussion is limited because this research was only conducted on one company. Based on the results of the layout redesign using the BLOCPLAN approach, various improvements were obtained, including a 37.12% increase in material handling cost efficiency. The proposed layout with the BLOCPLAN method is able to provide a reduction in material transfer distance of 22.6 meters and a material handling cost of Rp 155,346 when compared to the initial layout, which had a total overall displacement distance of 35.8 meters and an initial layout material handling cost of Rp 247,059, making it much cheaper.

Smarter facility layout design: leveraging worker localisation data to minimise travel time and alleviate congestion

This paper introduces a novel methodology leveraging worker localisation data from ultrawide-band sensors to formulate alternative facility layouts aimed at minimising travel time and congestion in labour-intensive manufacturing systems. The system preprocesses sensor data to discern flow patterns between existing stations within the production facility, such as machine tools, workbenches, and stores. This information about the movement of people and materials informs the generation of optimised layouts through scenario-based optimisation. We explored two methods to devise these new layouts: a mixed-integer linear programming method and a simulated annealing metaheuristic, the latter being specifically developed to find high-quality solutions to the quadratic layout design formulation. Both methods employ biobjective formulations, focussing on the minimisation of travel time and the reduction of congestion risk on the manufacturing floor, an aspect often neglected in prior studies. Our methodology, applied to a real-world manual assembly line case study, demonstrated the potential to reduce travel time by a minimum of 32% and alleviate congestion while maintaining significant safety distances between facilities. This was achieved by automatically identifying design features that position high-traffic facilities closely and align them to eliminate movement overlaps.

Facility layout design of bag and apparel factory with systematic layout planning and computerized relative allocation of facilities technique method

The high market attractiveness index and competitive position made Dewi Media Lestari invest in building a new factory. The factory specifically is used to produce convection products and apparel. Development is carried out using a systematic layout planning and computerized relative allocation of facilities technique. The objective of this research is to obtain an ideal layout that can minimize the distance between departments. As a result, there are nine departments with a total area of 385 m2 consisting of 18 m2loading dock department, 36 m2 raw material department, 86 m2cutting department, 42 m2 branding department, 21 m2 screen printing department, 105 m2 sewing department, 28 m2 finishing department, 28 m2 packing department, and 21 m2 warehouse department. Material handling costs for the initial layout produced using the systematic layout planning method are IDR 29,808.95 per day. After adjusting with Computerized Relative Facility Allocation Technique, the most ideal final layout was produced with minimal material handling costs of IDR 24,411.40 per day.

Facility Layout Design Through Genetic Algorithm

Facility Layout Design Through Genetic Algorithm

Blocplan Algorithm for Facility Layout Design in Various Industry in Indonesia

Blocplan Algorithm for Facility Layout Design in Various Industry in Indonesia

Facility layout design improvement in bottled drinking water at teaching factory

The Bottled Drinking Water Teaching Factory (Tefa) at State Polytechnic of Jember (Polije) produces mineral water packaged in several sizes of bottles, glasses, and gallons. The efficiency and effectiveness of the bottled drinking water production process is influenced by the layout of production facilities. The mismatch of machine layout arrangement and the number of unused equipment causes material flow to be longer. This study aims to redesign the layout of the Tefa Bottled Drinking Water facility to maximize area utilization and reduce empty space. This research provides recommendations for facility layout improvements using the Systematic layout planning (SLP) method. Alternative designs were proposed and compared the performance of each design with the initial layout. The results of the proposed method’s distance processing affect the total material handling cost. The total distance of the proposed method facility is 11.7 meters while the distance of the current facility is 28.8 meters so that can save material handling costs by 59%.

Visibility-based layout of a hospital unit - An optimization approach.

Apatient fall is one of the adverse events in an inpatient unit of a hospital that can lead to disability and/or mortality. Themedical literature suggests that increased visibility of patients by unit nurses is essential to improve patient monitoring and, in turn, reduce falls. However, such research has been descriptive in nature and does not provide an understanding of the characteristics of an optimal inpatient unit layout from a visibility-standpoint. To fill this gap, we adopt an interdisciplinary approach that combines the human field of view with facility layout design approaches. Specifically, we propose a bi-objective optimization model that jointly determines the optimal (i) location of a nurse in a nursing station and (ii) orientation of a patient's bed in a room for a given layout. The two objectives are maximizing the total visibility of all patients across patient rooms and minimizing inequity in visibility among those patients. We consider three different layout types, L-shaped, I-shaped, and Radial; these shapes exhibit the section of an inpatient unit that a nurse oversees. To estimate visibility, we employ the ray casting algorithm to quantify the visible target in a room when viewed by the nurse from the nursing station. The algorithm considers nurses' horizontal visual field and their depth of vision. Owing to the difficulty in solving the bi-objective model, we also propose a Multi-Objective Particle Swarm Optimization (MOPSO) heuristic to find (near) optimal solutions. Our findings suggest that the Radial layout appears to outperform the other two layouts in terms of the visibility-based objectives. We found that with a Radial layout, there can be an improvement of up to 50% in equity measure compared to an I-shaped layout. Similar improvements were observed when compared to the L-shaped layout as well. Further, the position of the patient's bed plays a role in maximizing the visibility of the patient's room.Insights from our work will enable understanding and quantifying the relationship between a physical layout and the corresponding provider-to-patient visibility to reduce adverse events.

Discrete Event Simulation for Facility Layout Design of Precise Molecular Diagnostic Centers

Discrete Event Simulation for Facility Layout Design of Precise Molecular Diagnostic Centers

Optimal placement of multiple finite-size rectangular facilities in an existing layout

ABSTRACT In this paper, we investigate a new problem of optimal placement of multiple finite-size rectangular facilities with known dimensions in the presence of existing rectangular facilities. This problem has applications in facility layout (re)design in manufacturing, distribution systems, services, and electronic circuit design. Three types of facility interactions are considered: between new facilities and existing facilities; between pairs of existing facilities; and between pairs of new facilities. All interactions are serviced through a finite number of input/output points located on the facility boundaries. Travel is assumed to occur according to the rectilinear (or Manhattan) metric and travel through facilities is prohibited. The objective is to find the simultaneous and non-overlapping placement of new facilities, which minimises the total weighted distance (Minisum objective) between the interacting facilities. To arrive at a solution, we divide the feasible region into sub-regions and prove that the candidates for optimal placement of the new facilities can be drawn from the sub-region boundaries. Being a continuous generalisation of the quadratic assignment problem, the solution complexity of this procedure is exponential in the number of new facilities. Our main contribution is the rigorous treatment of an important problem that unifies facility location and layout theories with minisum objective and rectilinear metrics.

Facilities Layout Design Optimization of Production Workshop Based on the Improved PSO Algorithm

Facilities Layout Design Optimization of Production Workshop Based on the Improved PSO Algorithm

Designing the service delivery system for prevention-oriented goals: insights from two case studies

PurposeThis research explores how to design service delivery systems to facilitate a customer experience that enables the realisation of prevention-oriented goals.Design/methodology/approachCase-based research is undertaken to inform the design of service delivery systems for prevention-oriented consumption goals. Data from multiple informants, from both the provider and customer perspective, in two in-depth case studies, provide empirical insights.FindingsDrawing on customer and provider perspectives, a model of service design for prevention-oriented goals is presented. The model is informed through the identification of service delivery system characteristics (facility layout, staff service orientation, facility appearance and staff presence/appearance) and perceived experience quality dimensions (control, duration, privacy and reliability impressions) that contribute to the fulfilment of prevention-oriented consumption goals.Practical implicationsThe research affirms that it is critical for organisations to comprehend the goals they want their service delivery systems to enable in the customer experience. Specific attention should be given to the design of facility layout, staff-service orientation, facility appearance, staff presence/appearance to positively impact perceived quality dimensions and to facilitate the realisation of customer prevention goals.Originality/valueThe main research contribution lies in the articulation of the design characteristics of the service delivery system that enables a customer experience supporting the fulfilment of prevention goals. The empirical study draws on both customer and organisational perspectives to identify prevention-oriented goals, and corresponding experience quality dimensions, to inform service delivery system design.

Layout Design of Work Facilities in the Home Industry of the Papuan Community, Wania District

One of the efforts offered is Designing the Layout of Work Facilities in the Home Industry of the Papuan Community, Wania District. Designing the Layout of Work Facilities in Irul's Home Industry by making spoons from coconut shells and wood. The aim of this service is to increase the potential of a wide open market, a selling price that is able to compete with other craftsmen. So the problem that occurs in this home industry is the lack of conventional equipment used, in the form of drills, saws, planers and sandpaper. The layout of the production room facilities is still not organized, so the production flow is still less effective and efficient. in the production process. Apart from that, the livestock pen, cooking area and production area are still one space without partitions, so it gives the impression of being untidy, so it takes a lot of time to sand the coconut shells. Sanding was carried out three times, starting with coarse, medium and fine sandpaper. This product is marketed by selling it in traditional markets in the Secang area and in several areas outside the city. The methods used to solve this problem are: counseling, training and mentoring. The results achieved in this activity are that the equipment becomes more modern, gets a bigger market, a better layout to support the production process and the amount of production can increase. The waste produced has economic value and is sold to oyster mushroom entrepreneurs as a planting medium, so that the products produced will increase compared to before.

Facility Layout optimization through Quality Function Deployment

The paper addresses the critical concern of facility layout planning and design, driven by the imperative to maximize space utilization, enhance product flow, minimize manufacturing costs, and boost employee satisfaction. Effective facility layout design emerges as a cornerstone for achieving these objectives, contributing significantly to a company's overall success. It aligns production processes with strategic goals, optimizing spatial resources and fostering a conducive work environment. A central focus of this research is the exploration of Quality Function Deployment (QFD) as a tool for facility layout design. The author investigates its applicability across different industries, offering insights into its adaptation for specific needs. Case studies spanning sectors like healthcare, manufacturing, and education illustrate the versatility of QFD in addressing unique requirements. Ultimately, this study seeks to provide a generalized approach that can be readily tailored to meet the specific needs of any company, thereby advancing the field of facility layout planning and design.

Perancangan Ulang Tata Letak pada Galangan Kapal Tradisional menggunakan Blocplan-90

CV. Rasya Jaya is a traditional fishing boat manufacturing company located in Padang Seurahet, Kec. Johan Pahlawan, Aceh Barat Regency. The facility layout of CV. Rasya Jaya has several workstations that are not in the correct location for the production process or the relationship between related rooms. This results in inefficient and ineffective material handling, as well as reduced worker comfort. The poorly organized facilities also contribute to production constraints. Therefore, it is necessary to evaluate the production facility layout at CV. Rasya Jaya. The goal is to provide an alternative design for the production facility layout that is more efficient and effective in terms of the relationship between the production process flow and minimizing material flow in the production process. The purpose of this study is to determine the optimal layout at CV. Rasya Jaya using the Blocplan algorithm. Blocplan-90 is an algorithm for solving spatial layout problems that can handle both quantitative and qualitative data. Mathematical models within the design are developed with computer applications for models that work with the limitations of workstation shapes. Based on the results of the layout design of facilities at CV. Rasya Jaya, three main layouts were created: office layout, facility layout, and production layout. The total area of the three layouts is 1739 m2.

Plant Layout Factor Impact to Attaining Optimal Approach in facility Layout Design in Plywood Industry

Plant Layout Factor Impact to Attaining Optimal Approach in facility Layout Design in Plywood Industry

Locomotive maintenance facility layout design using systematic layout planning method: Case study of Semarang Poncol locomotive depot

The Locomotive Depot has a maintenance layout with 6 main lines as maintenance lines. The layout of the facilities is also a problem at the Semarang Poncol locomotive depot because only 1 line can effectively carry out maintenance and repairs so this is a disadvantage because of the dense queue of locomotives wishing to be on duty carrying out daily checks or monthly checks. The problem is that these 3 routes are often 2 of which are not maximized properly and are only used as a place to wait for the repair process and 1 route is effective as a place for maintenance. The Systematic Layout Planning method is a method that plans the layout. The aim of arranging facilities is to increase work productivity and optimize the use of facilities such as work areas, machines and labor. One way to design a facility layout is to pay attention to the sequence of processes and the degree of closeness between units in the facility to be designed. Then, to calculate material handling at the Semarang Poncol Locomotive Depot using the systematic layout planning method, the results obtained from calculating material handling costs from the Semarang Poncol Locomotive Depot were Rp. 99,990/meter and for material handling equipment data, forklifts require material handling costs of Rp. 3,759,649 and for the high diesel speed (HSD) pump requires material handling costs of Rp. 84,288. For the proposed space requirements for each department or room, starting from the spare parts warehouse, the distance changes after calculating 0. Then the used spare parts warehouse changes the distance by -4.7, the lubricant warehouse by -0.1 and the fuel tank by +12.1. Space requirements are seen from the process (towards the maintenance route) after calculating the varying space requirements. From the very first lubricant warehouse and workshop, the distance change after calculating -3. Then followed by TPS B3 used lubricant of -1.9. Then the tool space is +1.1. Then the monitoring room is -5.5. Then the backup generator is -1.5. Furthermore, warehouse facilities are -6. Then the KR/staff space is -3.6. Then the TPS B3 filter is -0.3. Then the rotary spoiler is +13.4 and finally the lubricant warehouse II is +6.3 m2. With these calculations, after carrying out various data processing calculations, the proposed calculation using the systematic layout planning method is in accordance with the character of the Semarang Poncol Locomotive Depot as a service workshop owned by PT. Indonesian Railways. The proposal submitted to the Semarang Poncol Locomotive Depot can be used as a reference in designing the layout of the existing facilities at the Semarang Poncol Locomotive Depot in order to shorten the process flow and material flow for the maintenance process.

Facility layout problem with auxiliary systems for energy efficiency

In the Facility Layout Design (FLD), little research considers the energy costs even though increasing attention is placed on the energy consumption related to auxiliary systems (i.e. electrical supply, process heat, refrigeration and compressed air). The approaches to solving the Facility Layout Problem (FLP) traditionally consider the costs related to the material flows, while the auxiliary systems are designed after the definition of the facility’s placement. However, the arrangement of departments/machines influences the investment cost, associated with the installation of the auxiliary systems and their operating costs which, in several cases, represent a relevant part of the overall costs. Considering an energy-efficient solution, the FLD should be based not only on the material flows but also on the auxiliary systems. The objective of this study is to present a novel approach to FLP that jointly allows the optimization of the machines arrangement by considering both investment and operating costs related to the electrical service jointly to material flows. A solution algorithm to address the positioning of the electrical panel board and the selection of electrical cable sections are presented. The results obtained show an overall total cost minimisation with consistent savings compared to the traditional FLP approach.

Inventory Management Model Integrating Lean and FLD to Increase Service Level in an Automotive Retail: An Empirical Research in Peru

The automotive industry has had large participation in the Peruvian economy, as well as a large market penetration; however, there is not optimal retention of these customers, since there is a knowledge gap regarding loyalty strategies, which could impact the level of service offered. It is essential to have good inventory planning and a good distribution of the workshop to meet agreed dates. Also, correct execution of the service, which integrates quality control to avoid problems attributed to defects. This case study proposes a model that integrates Lean Manufacturing, Facility Layout Design, and ABC inventory management, intending to achieve an improvement in the current service. After the implementation of the model, on-time service was increased by 30.55%, reprocessed vehicles were reduced by 6.50%, labor efficiency was increased by 16.66%, open work orders were reduced by 13.79%, and transfer times were reduced by 20.90%.

A systematic decision-support approach for healthcare facility layout design integrating resource flow and space adjacency optimization with simulation-based performance evaluation

Healthcare facilities are recognized as significant public architectural design, given their design complexity. Particularly in the early stages of design process, the spatial configuration cannot be overlooked and it has a significant impact on the functional performance of a building. Existing research on healthcare facility layout design focused on the methods of simulation, procedural and algorithmic approaches with limited consideration of building operational performance, or the well-being of future occupants. In light of this, this article proposes a systematic decision-support approach that combines multi-objective optimization and simulation-based occupancy performance evaluation to offer a well-performance healthcare facility layout solution. The mathematical model's purpose is to optimize building operational objectives, namely, minimizing resource transportation costs and maximizing adjacent requirements between facilities. Then the performance of the mathematical model's Pareto solutions is evaluated using a simulation module that takes user-building interactions into account. To further validate the effectiveness of our approach, we conducted a comparative experiment involving three healthcare architects in the design of a surgical ward layout. Results indicate that the proposed approach can assist architects in achieving a balance between efficiency and safety in healthcare facility layout design, resulting in a more occupant-centric building design. Moreover, this systematic approach provides the theoretical basis on describing how to integrate the widely researched models for architectural layout planning and occupancy performance evaluation.