Facility Layout Design Research Articles

Usulan Perbaikan Tata Letak Fasilitas Terhadap Optimalisasi Jarak dan Ongkos Material Handling Dengan Pendekatan Systematic layout planning (SLP) di PT Transplant Indonesia

Abstract – Unplanned layout and inefficient material flow between work units can lead to increased cost. PT Transplan Indonesia's current material flow path is inefficient with material flow distance 115.5 meters and material handling cost that has not been taken into account. This study aims to find out how big the role of facility layout design in cutting the distance of material transfer and pressing the cost of material handling. The method used in this research is Systematic Layout Planning (SLP) approach, which is comparing the distance of material transfer between initial layout with proposed layout. The results of this study indicate that the distance of the material flow path on the production floor with proposed layout changed to 71,7 meters, with material handling cost per meter reduced from Rp. 1,105,954 to Rp. 712,402 or decrease as much as 35%. Based on the results of the research, the layout of the proposal is considered more effective and efficient because it can reduce the distance of material transfer and reduce the cost of material handling on the packing/shipping floor.Keywords: Layout Design; Material handling cost; Systematic Layout Planning (SLP)

Simulation-based Optimization for Facility Layout Design in Conditions of High Uncertainty

Despite the increased use of Simulation based Optimization, the design of facility layout is challenged by high levels of uncertainty associated with new production processes. Addressing this issue, this paper aims to understand the conceptual modeling activities of Simulation-based Optimization for facility layout design in conditions of high uncertainty. Based on three in-depth case studies, the results of this paper show how characterization criteria of production systems can be used in conceptual modelling to reduce uncertainty. These results may be essential to support managers and stakeholders during the introduction of new production processes in the design of facility layouts.

Design of facility layout with lean service and market basket analysis method to simplification of service process in the supermarket

Supermarket company is a retail company in the field of services that sell various daily necessaries such as food, beverages, fruits, cosmetics, detergents, glassware and so forth. Problems that occur in this company is consumers are still looking for items to be purchased, notices of goods that are still wrong by the salesperson, miss communication occurs, the goods have not been neatly arranged, price tags are often lost, and items that are not complete. This resulted in longer service process time. The method used in overcoming this problem is using Lean Service and Market Basket Analysis method. The result of Lean Service method is eliminating waste in the company by using 5W + 1H concept. After the identification of waste, the company's layout is improved by using Market Basket Analysis method. In Market Basket Analysis method determined the number of samples, calculate the value of support factor, confident, and improvement ratio. The result of Market Basket Analysis method there is 14 products that have influence between one product with another. From these results obtained 3 alternative layouts and chosen the best layout alternative.

Design and Optimization of Loop Layout in Flexible Manufacturing System using Particle Swarm Optimization

To design any manufacturing setup we need to focus on design of facility layout and it has a huge impact on the performance of the manufacturing system. so the Optimum arrangement of layout is important in order to achieve high productivity in flexible manufacturing system (FMS). The objective of the loop layout problem is the determination of the ordering of machines around a loop, to minimize the total number of loop traversals for a family of parts. The problem we address is to design the layout of the system so that the number of machines that the part types cross in their manufacturing process is minimized. We formulate the problem mathematically and solve it by a meta-heuristics that obtains consistently better results than an earlier popular method. Since, optimum arrangements of layout is a combinatorial problem so finding the best combination out of millions of combinations is a challenging task and can't be solve using conventional techniques. Therefore, this paper details the design, development and testing of particle swarm optimization (PSO) technique to solve the loop layout problem. The proposed method is validated with bench mark problems. Here PSO algorithm is proposed for obtaining the optimal solution of unidirectional loop layout design problem of various FMS models.

Integrated simulation-based facility layout and complex production line design under uncertainty

When designing production lines, a series of complex, interdependent phases need to be considered. These phases include the facility layout design, the allocation of tasks to available resources, the workload balancing as well as the validation of the proposed design against demand.This paper addresses all these phases in an integrated way, with the aim of reducing the overall time required to finalise the layout and production line design, while improving the overall performance of the manufacturing system under process and demand uncertainty, utilising a sophisticated, simulation-based software framework. The proposed approach is demonstrated using a realistic case scenario.

A Review On Facility Layout Design Of An Automated Guided Vehicle In Flexible Manufacturing System

This paper presents a review on facility layout design of an Automated Guided Vehicle in Flexible Manufacturing system. We address many issues related to layout design, location of pickup and delivery points and flow path design. We discuss various developments in layout design, comparison of tandem layout with other layouts, various developments in location of pickup and delivery points and flow path design. We further classify different models and results from key publications in literature.

A Hybrid Fuzzy DEA/AHP Methodology for Ranking Units in a Fuzzy Environment

In this paper, a novel approach combining fuzzy data envelopment analysis (DEA) and the analytical hierarchical process (AHP) is proposed to rank units with multiple fuzzy criteria. The hybrid fuzzy DEA/AHP approach derives the AHP pairwise comparisons by fuzzy DEA and utilizes AHP to fully rank units. It shows that the proposed approach generates a logical ranking of units that has perfect compatibility with fuzzy DEA ranking and there is no any form of subjective analysis engaged within the methodology. A study on the facility layout design in manufacturing systems is provided to illustrate the superiority of the proposed approach and show the compatibility between the proposed approach and fuzzy DEA ranking.

An efficient algorithm for unequal area facilities layout planning with input and output points

ABSTRACTThe facility layout problem is to determine a layout design of facilities so as to minimize a total material handling cost (TMHC). In this paper, unequal area rectangular facilities with fixed dimensions are considered. Each of them has an input and output (I/O) points which can be located within or on the boundaries of facility. On the continual plane, facilities must be placed without overlaps. A two-heuristic algorithm is proposed to deal with this kind of problem. The first step is based on a construction method which places facilities sequentially. A median method is modified to set the position of facility. The second step improves a result of the first step. A facility group which can be moved horizontally or vertically without incurring an overlap is constituted and a group movement is done when it reduces a TMHC. Computational experiments show the proposed algorithm produces comparable quality of layouts to previous research within much shorter time.

A closed loop based facility layout design using a cuckoo search algorithm

Facility layout problems (FLPs) are design problems that involve determining the most favorable arrangement of facilities in a given space. The closed loop layout problem (CLLP) is an FLP that employs a closed loop guided configuration. This type of layout is commonly discussed when designing a flexible manufacturing system (FMS). The CLLP is concerned with determining the efficient arrangement of manufacturing cells on a central loop based material handling system. Because the material flow between cells must pass through the loop path, distance is not measured in the conventional manner (i.e. the rectilinear or Euclidean distance). The problem is more complicated than a generic FLP because there are additional constraints that restrict cell shape and orientation as well as the positions of the pick-up and drop-off points. In this study, we propose a random-key and cuckoo search (CS) based approach to solve the CLLP. CS is a rather recently developed algorithm, and it has not yet been applied to FLPs in the literature. To evaluate the present algorithm, computational experiments are conducted using benchmark problems from a previous study. The obtained results show the remarkable performance of the proposed approach.

Loop-based facility layout design under flexible bay structures

We develop heuristic procedures for concurrent design of block layout, material flow network, and input and output stations. Unlike the common practice in the flexible bay structure layout design, our objective function includes both loaded and empty flow between pairs of I/O stations. This measure of effectiveness is the main determinant of the fleet size of the vehicles, which in turn is the major driver of the total investment and operational costs in vehicle-based material handling. Our work is the first to design flexible bay structure layouts for loop-based material flow patterns. We first develop heuristic algorithms to configure the layout on the foundations of a unidirectional loop flow pattern. The loop and stations are then designed on the promising layouts. A set of improvement algorithms provide a better integration of the layout, loop, and stations.

A high-fidelity three-dimensional simulation method for evaluating passenger flow organization and facility layout at metro stations

This research proposes a high-fidelity simulation method that integrates the strengths of microscopic pedestrian modeling and three-dimensional (3D) virtual reality (VR) for the evaluation of passenger flow organization and facility layout at metro stations. Passenger flow movements, with detailed spatial–temporal information of each agent, are modeled using agent-based micro-simulation. Simulation results are then imported into a 3D VR environment for the assessment of passenger flow organization and its interactions with facility layout. Focusing on the technical implementation of the method, we discuss in detail (1) finely resolved pedestrian simulation using AnyLogic; (2) bookkeeping of spatial positions of agents at the specific temporal intervals in XML format; and (3) interactive photo-realistic 3D visualization of pedestrian movements using UC-win/Road through its micro-simulation player plug-in, OpenMicroSim. Successfully applied to case studies of three major metro stations in Shenzhen China, this methodology is demonstrated to be capable of evaluating passenger flow organization through visual and quantitative analyses for improving facility layout design.

Optimization Design of Facilities Layout in a Certain Machining Shop

The workshop facility layout design is an important link in the development process of enterprise management, production, reasonable layout of workshop facilities can not only improve the production efficiency, reduce cost and reduce the amount of logistics handling, but also conducive to employee safety and health, improve enterprise's comprehensive competitiveness, and less effective. In this paper, based on the theory of facility layout, this paper designs and improves the current situation of the facility layout of a machining workshop.

Performance Analysis of Intelligent Robust Facility Layout Design

Design of a robust production facility layout with minimum handling cost (MHC) presents an appropriate approach to tackle facility layout problems in a dynamic volatile environment, in which product demands randomly change in each planning period. The objective of the design is to find the robust facility layout with minimum total material handling cost over the entire multi-period planning horizon. This paper proposes a new mathematical model for designing robust machine layout in the stochastic dynamic environment of manufacturing systems using quadratic assignment problem (QAP) formulation. In this investigation, product demands are assumed to be normally distributed random variables with known expected value, variance, and covariance that randomly change from period to period. The proposed model was verified and validated using randomly generated numerical data and benchmark examples. The effect of dependent product demands and varying interest rate on the total cost function of the proposed model has also been investigated. Sensitivity analysis on the proposed model has been performed. Dynamic programming and simulated annealing optimization algorithms were used in solving the modeled example problems.

Interactive facility layout problem: a bi-objective design

Facility layout has an important impact on the performance of a manufacturing organization. The problem concerns the modeling, planning and design determination of the human activities and the physical resources. The manufacturing activities require an interaction between several management departments of the organization such as procurement, storage and maintenance; thus the necessity of the consideration of various interactive criteria and factors in the design process of the facility layout. We propose in this paper a bi-objective resolution model for facility layout design determination. Our aim is to design a manufacturing system respecting the environmental restrictions and production efficiency requirements. The proposed approach is based on a balancing methodology between the flow circulation and CO\(_2\) emissions of the manufacturing system.

Application of an Aggregation Technique to Facility Layout Design Selection

Facility layout in manufacturing and service systems affects the productivity and efficiency of the systems. Generally, more than one appropriate location is available based on associations among facilities. This leads to alternative facility layout designs. It is not an easy activity to select the best facility layout design among alternatives for facility engineers and decision makers. Many number of ranking of alternative facility layout designs can be generated by the use of different approaches. However, rankings obtained from these approaches do not suggest unique ranking. In this study, an aggregation technique is conducted to sort facility layout design alternatives generated by multiple conventional approaches. It is mainly based on a linear programming model. The results of this study show that alternative facility layout designs can be easily ranked in descending order by the aggregation technique.

Modelling of layout design and selection of appropriate design with a case study

Facility location problem (FLP) is a subject that deals with arrangement of different departments in working environment. An efficient location design will lead to amelioration in performance efficiency, effective use of spaces, and reduction in logistics costs. Accordingly, it is considered as a strategic problem, which has a significant influence on the performance of production system. That is why companies try to assess and reassess their current layout designs, and try to plan a proper layout design for their production and service departments. In this regard, this paper presents a mathematical model for selecting a proper layout design. Current paper concerns with facility layout design based on mathematical model. Considering special features of each department and the relation of activities between every one of them, the most significant model was selected. Then, according to the departments' special features and by means of mathematical model the departments were located in a two-dimension space thru CPLEX 12. In this way the initial solution of location problem was attained. The results reflect that the observed hospital did not make a good use of the available space and that there was too much empty space which could be used for building new rooms and providing more accessibility among departments.

Modelling of layout design and selection of appropriate design with a case study

Facility location problem (FLP) is a subject that deals with arrangement of different departments in working environment. An efficient location design will lead to amelioration in performance efficiency, effective use of spaces, and reduction in logistics costs. Accordingly, it is considered as a strategic problem, which has a significant influence on the performance of production system. That is why companies try to assess and reassess their current layout designs, and try to plan a proper layout design for their production and service departments. In this regard, this paper presents a mathematical model for selecting a proper layout design. Current paper concerns with facility layout design based on mathematical model. Considering special features of each department and the relation of activities between every one of them, the most significant model was selected. Then, according to the departments' special features and by means of mathematical model the departments were located in a two-dimension space thru CPLEX 12. In this way the initial solution of location problem was attained. The results reflect that the observed hospital did not make a good use of the available space and that there was too much empty space which could be used for building new rooms and providing more accessibility among departments.

Modified genetic algorithms for solving facility layout problems

A facility layout design is one of the most commonly faced problems in the manufacturing sectors. The problem is mixed-integer in nature and usually an NP-hard problem. Due to mixed-integer nature of the problem, it is difficult to solve the problem using classical optimization techniques. The classical optimization techniques are better for local search of the optimal solution. However, these algorithms are not efficient when there are multiple optimal solutions and alternate optimal solutions. To overcome these limitations, this paper proposed a new interactive evolutionary algorithm based local search algorithm for solving static facility layout problems with unequal compartments. This is an iterative based two steps algorithm. The evolutionary algorithm creates the new solutions for the local search algorithm to obtain a local optimal solution. The designer can interact between these processes to derive the best possible solution of the problem. The objective function of the problem is non-linear one in which the sum of the material handling cost has been minimized. Apart from the conventional evolutionary operators, i.e. selection, crossover, mutation and elitism, this paper has also proposed exchange and rotation operators. The rotation operator is used to avoid mixed-integer formulation of the problem for the local search problem. The use of rotation operator has also reduced the number of variables of the problem significantly. The performance of the model is tested over previously solved problems selected from the literature. The evaluation of the results shows that the performance of the proposed model is better than many existing algorithms and has the potential for real-world applications.

Formulating and solving sustainable stochastic dynamic facility layout problem: a key to sustainable operations

Facility layout design, a NP hard problem, is associated with the arrangement of facilities in a manufacturing shop floor, which impacts the performance, and cost of system. Efficient design of facility layout is a key to the sustainable operations in a manufacturing shop floor. An efficient layout design not only optimizes the cost and energy due to proficient handling but also increase flexibility and easy accessibility. Traditionally, it is solved using meta-heuristic techniques. But these algorithmic or procedural methodologies do not generate effective and efficient layout design from sustainable point of view, where design should consider multiple criteria such as demand fluctuations, material handling cost, accessibility, maintenance, waste and more. In this paper, to capture the sustainability in the layout design these parameters are considered, and a new sustainable stochastic dynamic facility layout problem (SDFLP) is formulated and solved. SDFLP is optimized for material handling cost and rearrangement cost using various meta-heuristic techniques. The pool of layouts thus generated are then analyzed by data envelopment analysis to identify efficient layouts. A novel hierarchical methodology of consensus ranking of layouts is proposed which combines the multiple attributes/criteria. Multi attribute decision-making techniques such as technique for order preference by similarity to ideal solution, interpretive ranking process and analytic hierarchy process, Borda–Kendall and integer linear programming based rank aggregation techniques are applied. To validate the proposed methodology data sets for facility size $$N=12$$ for time period $$T=5$$ having Gaussian demand are considered.

Unequal-area, fixed-shape facility layout problems using the firefly algorithm

ABSTRACTIn manufacturing industries, the facility layout design is a very important task, as it is concerned with the overall manufacturing cost and profit of the industry. The facility layout problem (FLP) is solved by arranging the departments or facilities of known dimensions on the available floor space. The objective of this article is to implement the firefly algorithm (FA) for solving unequal-area, fixed-shape FLPs and optimizing the costs of total material handling and transportation between the facilities. The FA is a nature-inspired algorithm and can be used for combinatorial optimization problems. Benchmark problems from the previous literature are solved using the FA. To check its effectiveness, it is implemented to solve large-sized FLPs. Computational results obtained using the FA show that the algorithm is less time consuming and the total layout costs for FLPs are better than the best results achieved so far.