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SYSTEMATIC LAYOUT
PLANNING (SLP)
Additional Slides
ACTIVITY RELATIONSHIP
ANALYSIS
2
Graph Based Process
In summary,
The graph based approach provides a structured approach for developing the REL diagram
Graph based approach is widely used in activity-based lock layouts
It emphasizes the importance of constructing a planar graph of the REL chart if the block diagram is to be constructed to satisfy the relationships
It is used to determine by just inspection which activities/departments are adjacent with each other in order to construct the block layout. (There are multiple solutions in constructing the block layout.)
3
RELATIONSHIP DIAGRAMMING
4
Steps in RDP (Stage 1)
Step 1
The numerical values are assigned to the closeness rating as: A= 10 000, E= 1000, I= 100, O= 10, U= 0, X= 10 000
Step 2
TCR (Total Closeness Rating) for each department is computed. TCR refers to the sum of the absolute values for the relationships with a particular department.
Step 3
The department with the greatest TCR is selected as the first placed department in the sequence of placement.
Step 4
Department having X relationship with the first placed department is labelled as the last placed department.
Step 5
Second department in the sequence of placement is determined to satisfy the highest closeness rating with the first placed department. With respect to the closeness priorities A>E>I>O>U
5
Steps in RDP (Stage 1)
Step 6
Department having X relationship with the second placed department is labelled as the next-to-the-last or last placed department.
Step 7
Next department in the sequence of placement is the one with the highest closeness relationship (A>E>I>O>U) with the already placed departments.
Step 8 Procedure continues until all departments have been placed.
*Note: If ties exist during this process, TCR values are utilized to break the ties
arbitrarily.
6
Steps in RDP (Stage 2)
*Note: If ties exist during this process, first location with the largest WPV is selected.
Step 9
Calculate Weighted Placement Value (WPV) of locations to which the next department in the order will be assigned. WPV refers to the sum of the numerical values for all pairs of adjacent department(s).
When a location is fully adjacent, its weight equals to 1.0, and when it is partially adjacent its weight equals to 0.5.
Step 10
Evaluate all possible locations in counter clock-wise order, starting at the western edge of the partial layout.
Step 11
Assign the next department to the location with the largest WPV.
7
Example
Given the relationship chart below, determine the order of
placement of the departments and the relative location of each
department.
Example
Below is the table of Total Closeness Rating (TCR) values for each department. The first department placed in the layout is the one with the greatest TCR value. If there is a tie, then choose the one with more A (E, etc.).
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 -
Example
If a department has an X relationship with the first one, it is placed last in
the layout. If a tie exists, choose the one with the smallest TCR value.
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 - - 8
Example
The second department is the one with an A relationship with the first one
(or E, I, etc.). If a tie exists, choose the one with the greatest TCR value.
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 - 5 - - 8
Example
The next department is the one with an A (or E, I, etc.) relationship with the
already placed departments. If a tie exists, choose the one with the
greatest TCR value.
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 - 5 - 9 - - 8
Example
The next department is the one with an A (or E, I, etc.) relationship with the
already placed departments. If a tie exists, choose the one with the
greatest TCR value.
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 - 5 - 9 - 3 - - 8
Example
The next department is the one with an A (or E, I, etc.) relationship with the
already placed departments. If a tie exists, choose the one with the
greatest TCR value.
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 - 5 - 9 - 3 - 1 - - 8
Example
The next department is the one with an A (or E, I, etc.) relationship with the
already placed departments. If a tie exists, choose the one with the
greatest TCR value.
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 - 5 - 9 - 3 - 1 - 4 - - 8
Example
The next department is the one with an A (or E, I, etc.) relationship with the
already placed departments. If a tie exists, choose the one with the
greatest TCR value.
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 - 5 - 9 - 3 - 1 - 4 - 2 - - 8
Example
The sequence of the placement of the departments has been identified.
Next, is to determine the relative location of each department.
Dept. Department Summary
TCR 1 2 3 4 5 6 7 8 9 A E I O U X
1 - A A E O U U A O 3 1 0 2 2 0 31,020
2 A - E A U O U E U 2 2 0 1 3 0 22,010
3 A E - E A U U E A 3 3 0 0 2 0 33,000
4 E A E - E O A E U 2 4 0 1 1 0 24,010
5 O U A E - A A O A 4 1 0 2 1 0 41,020
6 U O U O A - A O O 2 0 0 4 2 0 20,040
7 U U U A A A - X A 4 0 0 0 3 1 50,000
8 A E E E O O X - X 1 3 0 2 0 2 33,020
9 O U A U A O A X - 3 0 0 2 2 1 40,020
Placing Order: 7 - 5 - 9 - 3 - 1 - 4 - 2 - 6 - 8
WPV1 = 1(10,000) = 10,000
WPV2 = 0.5(10,000) = 5,000
WPV3 = 1(10,000) = 10,000
WPV4 = 0.5(10,000) = 5,000
WPV5 = 1(10,000) = 10,000
WPV6 = 0.5(10,000) = 5,000
WPV7 = 1(10,000) = 10,000
WPV8 = 0.5(10,000) = 5,000
Example
7
3
1 5
8 6
4 2
Department 5?
*Relationship of dept. 7 - 5 = A (10,000)
10
5 7 7 6
4 3 2
1
9 8 7
5
WPV1 = 1(10,000) = 10,000
WPV2 = 0.5(10,000) = 5,000
WPV3 = 1(10,000) + 0.5(10,000) = 15,000
WPV4 = 1(10,000) + 0.5(10,000) = 15,000
WPV5 = 0.5(10,000) = 5,000
WPV6 = 1(10,000) = 10,000
WPV7 = 0.5(10,000) = 5,000
WPV8 = 1(10,000) + 0.5(10,000) = 15,000
WPV9 = 1(10,000) + 0.5(10,000) = 15,000
WPV10 = 0.5(10,000) = 5,000
*Relationship of dept. 7 - 9 = A (10,000)
Relationship of dept. 5 - 9 = A (10,000)
Department 9?
Compute the Weighted Placement Value of each location. If the location is fully
adjacent, its weight equals to 1.0, and if it is partially adjacent its weight equals to 0.5.
1
WPV1 = 15,000
WPV2 = 15,000
WPV3 = 5,000
WPV4 = 10,000
WPV5 = 5,000
WPV6 = 15,000
WPV7 = 0
WPV8 = 0
WPV9 = 0
WPV10 = 5,000
WPV11 = 10,000
WPV12 = 5,000
Example
Department 3?
Compute the Weighted Placement Value of each location. If the location is fully
adjacent, its weight equals to 1.0, and if it is partially adjacent its weight equals to 0.5.
12
5
Department 1?
9
7
9
8
7 6
5 4 3
2
11 10 14
3
13 12 11 10
9
8 7
6 5 4
3 2
1
9
5 7
WPV1 = 10,000
WPV2 = 5,000
WPV3 = 10,015
WPV4 = 5
WPV5 = 10
WPV6 = 5
WPV7 = 15
WPV8 = 0
WPV9 = 0
WPV10 = 0
WPV11 = 5
WPV12 = 5,010
WPV13 = 10,005
WPV14 = 5,000
Example
Department 4?
Compute the Weighted Placement Value of each location. If the location is fully
adjacent, its weight equals to 1.0, and if it is partially adjacent its weight equals to 0.5.
Department 2?
WPV1 = 6,000
WPV2 = 10,500
WPV3 = 5,000
WPV4 = 10,000
WPV5 = 10,000
WPV6 = 10,000
WPV7 = 5,000
WPV8 = 10,000
WPV9 = 5,000
WPV10 = 0
WPV11 = 0
WPV12 = 5,000
WPV13 = 10,000
WPV14 = 5,000
14
3
13 12 11 10
9
8 7
6 5 4 3
2
1
9
5 7
1
WPV1 = 1,500
WPV2 = 1,500
WPV3 = 500
WPV4 = 1,000
WPV5 = 500
WPV6 = 0
WPV7 = 10,500
WPV8 = 5,000
WPV9 = 10,000
WPV10 = 5,000
WPV11 = 10,500
WPV12 = 6,000
WPV13 = 1,500
WPV14 = 5
14
3
13 12 11 10
9
8
7 6 5 4 3
2
1
9
5 7
1 4
Example
Department 6?
Compute the Weighted Placement Value of each location. If the location is fully
adjacent, its weight equals to 1.0, and if it is partially adjacent its weight equals to 0.5.
Department 8?
WPV1 = 10
WPV2 = 5
WPV3 = 10
WPV4 = 10
WPV5 = 15
WPV6 = 10
WPV7 = 5
WPV8 = 5,010
WPV9 = 10,005
WPV10 = 5,000
WPV11 = 10,500
WPV12 = 10,500
WPV13 = 5,000
WPV14 = 0
WPV15 = 10
WPV16 = 5
14
3
13 12 11 10
9
8
7 6 5 4 3 2
1 9
5 7
1 2 4
16 15
16
3
2 1
5 7
6
9 4 1
2 3 5 4 6 7
8
10
9
13 12 11
15 14
17 18
WPV1 = 1,000
WPV2 = 500
WPV3 = 6,000
WPV4 = 5,500
WPV5 = -4,500
WPV6 = -4,000
WPV7 = 500
WPV8 = -4,000
WPV9 = -9,495
WPV10 = -4,990
WPV11 = 5
WPV12 = 10
WPV13 = 5
WPV14 = -9,480
WPV15 = 1,005
WPV16 = 500
WPV17 = 7,000
WPV18 = 500
Example
Final Layout
3
2 1
5 7
6
9 4
8
ALDEP (Automated Layout Design Program)
the size of the facility and the size of the departments are expressed in terms of blocks.
Score is determined using the numerical values assigned to the closeness rating).
A = 43 = 64 I = 41 = 4 U = 0
E = 42 = 16 O = 40 = 1 X = 45 = 1.024
The area per grid is subjective but it is recommended that it is divisible to all the departments areas.
The sweep width defines the width in number of blocks/grids. For example, let sweep width = 3 then the
offices is allocated 3x4 =12 grids plus the two remaining
blocks
23
SPACE REQUIREMENT AND
AVAILABILITY
24
1. Production-Center Method
The production center consists of a single machine plus all the
associated equipment and space required for its operation. Work space
(front, rear, left side, right side), additional maintenance space, and storage
space are added to the space requirements for the machine
2. Converting Method
The present space requirements are converted to those required for
the proposed layout
3. Roughed-out layout method
Templates or models are placed on the layout to obtain an estimate of
the general configuration and space requirement
Methods of Determining Space Requirements
4. Space-standards method
Use of industry standards, or past successful applications
5. Ratio trend and projection method
Establish a ratio of floor area to some other factor that can be
measured and predicted for the proposed layout.
Ex.: Square-feet per machine
Square-feet per operator
Square-feet per direct labor hour
Square-feet per unit produced
Methods of Determining Space Requirements
In determining the space requirements of the facility, the number of equipment
and number of employees must first be determined. Some parameters needed
to compute for the resources needed:
Production Rate
Batch Production Quantity
Methods of Determining Space Requirements
Determination of Employee Requirements
The number of machine operators required depends on the number of machines tended by one or more operators. The determination of the number of machines to be assigned to one operator can take two approaches:
Deterministic -Multiple activity chart
Probabilistic -Queuing models, Monte Carlo Simulation
A deterministic approach is to employ the multiple activity chart. This chart shows the multiple activity relationships graphically against a time scale. The chart is useful in analyzing multiple activity relationships, specially, when non-identical machines are supervised by a single operator.
Multiple Activity Chart
Charts on which activities of workers, product and machines are recorded on
a common time scale to show their relationships.
There are various charts with different names but serve almost the same
purpose:
1) Work-Machine Process Chart (Man-Machine Chart)
Seeking most effective relationship between operator(s) and
machine(s), i.e. minimum total %idle time
2) Gang Process Chart (Multi-Man Chart)
Multiple activity chart applied to a group of workers, seeking most
effective relationship between several workers
Worker-Machine Relationship
Worker-machine relationships can be of three types:
1) synchronous servicing
2) random (asynchronous) servicing
3) combination of both - real-life
Types of Worker-Machine Relationships
Types of Worker-Machine Relationships