Facilities Planning and Warehouse Operations

INDU 6251 – Fall 2023

Layout Planning Models and Design Algorithms

Makbule Kandakoglu, PhD

Some of the slides are adapted from the course textbook and the lecture notes provided by Prof. Andrea Schiffauerova and Prof. Ali Akgunduz
Outline
• Layout Generation Algorithms
• CORELAP
• ALDEP
• MULTIPLE
• MIP

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Algorithm Classification

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CORELAP: Computerized Relationship Layout Planning
• Developed for main frame computers
• Construction type
• Adjacency-based method
• CORELAP uses A=4, E=3, I=2, O=1, U=0 and X=-1 values

• Selection of the departments to enter the layout is based on Total Closeness Rating
• Total Closeness Rating (TCR) for a department is the sum of the numerical values
assigned to the closeness relationships between the department and all other
departments.

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CORELAP
Department selection
1. 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’s (E’s, etc.).
2. If a department has an X relationship with the first one, it is placed last in the layout and not
considered. If a tie exists, choose the one with the smallest TCR value.
3. The second department is the one with an A (or E, I, etc.). relationship with the first one. If a
tie exists, choose the one with the greatest TCR value.
4. If a department has an X relationship with the second one, it is placed next-to-the-last or last
in the layout. If a tie exists, choose the one with the smallest TCR value.
5. The next department is the one with an A (E, I, etc.) relationship with the already placed
departments. If a tie exists, choose the one with the greatest TCR value.
6. The procedure continues until all departments have been placed. ➔ Placement sequence

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CORELAP
Procedure to Place Departments 8 7 6
• Department neighbors 1 0 5
• Adjacent (in position 1, 3, 5 or 7) with department 0 2 3 4
• Touching (in position 2, 4, 6 or 8) department 0

• Placing rating (PR) is the sum of the weighted closeness ratings between the department to
enter the layout and its neighbors.
TC =  wik where k = {departments already placed}
k

• The placement of departments is based on the following steps:

1. The first department selected is placed in the middle.
2. The placement of a department is determined by evaluating PR for all possible locations around the
current layout in counterclockwise order beginning at the “western edge”.
3. The new department is located based on the greatest PR value.
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CORELAP – Example 1
• Given the relationship chart and the departmental dimensions below determine the sequence
of the placement of the departments in the layout based on the CORELAP algorithm.
• Place the departments in the layout while evaluating each placement.

50 sq ft. per grid

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• 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’s (E’s, etc.). Any X relationships?

The placement sequence: 5

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• 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. Any X relationships?

The placement sequence: 5-6

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• The next department is the one with an A (E, I, etc.) relationship

with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X relationships?

The placement sequence: 5-6-7

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• The next department is the one with an A (E, I, etc.) relationship

with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X relationships?

The placement sequence: 5-6-7-9

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• The next department is the one with an A (E, I, etc.) relationship

with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X relationships?

The placement sequence: 5-6-7-9-3

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• The next department is the one with an A (E, I, etc.) relationship

with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X relationships?

The placement sequence: 5-6-7-9-3-8

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• The next department is the one with an A (E, I, etc.) relationship

with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X relationships?

The placement sequence: 5-6-7-9-3-8-1

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• The next department is the one with an A (E, I, etc.) relationship

with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X relationships?

The placement sequence: 5-6-7-9-3-8-1-2

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

• The next department is the one with an A (E, I, etc.) relationship

with the already placed departments. If a tie exists, choose the
one with the greatest TCR value. Any X relationships?

The placement sequence: 5-6-7-9-3-8-1-2-4

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CORELAP – Example 1
A=4, E=3, I=2, O=1, U=0, X=-1

Final table of TCR Values with the placement sequence:

The placement sequence: 5-6-7-9-3-8-1-2-4

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CORELAP – Example 1 A=4, E=3, I=2, O=1, U=0, X=-1

Departments: 5 & 6 Entering department: 7

Both options gives the

same PR Score
PR = A[5,7] + I[6,7]
=4+2=6

If the location for the

department 7 is chosen
as shown, the PR would
be
PR = A[5,7] = 4

The placement sequence: 5-6-7-9-3-8-1-2-4

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CORELAP – Example 1 A=4, E=3, I=2, O=1, U=0, X=-1

Entering department: 9

PR = E[6,9] = 3

PR = E[6,9] + O[5,9] = 3 + 1 = 4

The placement sequence: 5-6-7-9-3-8-1-2-4

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CORELAP – Example 1 A=4, E=3, I=2, O=1, U=0, X=-1

Entering department: 3

PR = I[3,5] + O[3,7] + U[3,9]

=2+1+0=3

Entering department: 8

PR = E[3,8] + I[8,9]
=3+2=5

The placement sequence: 5-6-7-9-3-8-1-2-4

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CORELAP – Example 1 A=4, E=3, I=2, O=1, U=0, X=-1

Entering department: 1

PR = I[1,3] + U[1,7]
=2+0=2

Entering department: 2

PR = I[1,2] + O[2,3]
=2+1=3

Continue with Department 4.

The placement sequence: 5-6-7-9-3-8-1-2-4
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CORELAP – Example 1

Artistic Side of the Layout Planning

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CORELAP – Example 2
• Given the relationship chart below, determine the sequence of the placement of the
departments and find the best layout with CORELAP algorithm assuming that all the
departments have the same size.
• Use these closeness values: A=125, E=25, I=5, O=1, U=0, X=-125 and consider half weight if
the departments are only touching by one point.

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CORELAP – Example 2
• Table of TCR values:

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CORELAP – Example 2
• 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.).
• Any X? Yes, X with 8.

The placement sequence: 7

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CORELAP – Example 2
• 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.

The placement sequence: 7 8

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CORELAP – Example 2
• 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.
• Any X?

The placement sequence: 7-5 8

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CORELAP – Example 2
• The next department is the one with an A (E, I, etc.) relationship with the already placed
departments. If a tie exists, choose the one with the greatest TCR value.
• Any X? Yes, X with 8.

The placement sequence: 7-5-9 8

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CORELAP – Example 2
• The next department is the one with an A (E, I, etc.) relationship with the already placed
departments. If a tie exists, choose the one with the greatest TCR value.
• Any X?

The placement sequence: 7-5-9-3 8

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CORELAP – Example 2
• The next department is the one with an A (E, I, etc.) relationship with the already placed
departments. If a tie exists, choose the one with the greatest TCR value.
• Any X?

The placement sequence: 7-5-9-3-1 8

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CORELAP – Example 2
• The next department is the one with an A (E, I, etc.) relationship with the already placed
departments. If a tie exists, choose the one with the greatest TCR value.
• Any X?

The placement sequence: 7-5-9-3-1-4 8

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CORELAP – Example 2
• The next department is the one with an A (E, I, etc.) relationship with the already placed
departments. If a tie exists, choose the one with the greatest TCR value.
• Any X?

The placement sequence: 7-5-9-3-1-4-2-6-8

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CORELAP – Example 2
• Final table of TCR values with the placement sequence:

The placement sequence: 7-5-9-3-1-4-2-6-8

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CORELAP – Example 2

Department 5? Department 9? Department 3?

62.5 125 62.5 62.5 187.5 187.5 62.5 62.5 125 62.5 0

125 7 125 125 5 7 125 187.5 5 7 0

62.5 125 62.5 62.5 187.5 187.5 62.5 187.5 9 187.5 0

62.5 125 62.5

7-5…A = 125 7-9…A = 125
5-9…A = 125
3-5…A = 125
3-7…U = 0
3-9…A = 125

The placement sequence: 7-5-9-3-1-4-2-6-8

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CORELAP – Example 2

Department 1? Department 4? Department 2?

62.5 125.5 63.5 1 0 12.5 37.5 100 137.5 62.5 12.5 25 12.5 0 0

125 3 5 7 0 37.5 3 5 7 125 87.5 3 5 7 62.5

62.5 126.5 9 1.5 0 37.5 1 9 137.5 62.5 137.5 1 9 4 125

0.5 1 0.5 12.5 25 12.5 0 62.5 125 125 125 62.5

1-3…A = 125 7-4…A = 125 2-1…A = 125

1-7…U = 0 9-4…U = 0 2-4…A = 125
1-5…O = 1 3-4…E = 25 2-3…E = 25
1-9…O = 1 1-4…E = 25 2-5…U = 0
5-4…E = 25 2-7…U = 0
2-9…U = 0
The placement sequence: 7-5-9-3-1-4-2-6-8
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CORELAP – Example 2
Department 6? Department 8?

0 62.5 125 188 62.5 0.5 1 0.5

0.5 1 3 5 7 125 12.5 25.5 -60.5 6 -61.5

1 2 1 9 4 63.5 12.5 112.5 3 5 7 -112

0.5 1 1 1.5 1.5 0.5 25 2 1 9 4 -37.5

12.5 87.5 75 -62.5 -37.5 12.5 9-8…A = 125

5-6…A = 125
1-8…A = 125
7-6…A = 125
3-8…E = 25
2-6…O = 1
2-8…E = 25
9-6…O = 1
4-8…E = 25
4-6…O = 1
5-8…O = 1
3-6…U = 0
6-8…O = 1
1-6…U = 0
7-8…X = -125

The placement sequence: 7-5-9-3-1-4-2-6-8

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CORELAP – Example 2

The final layout

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CORELAP – Comments
• The final layouts are evaluated by the distance-based layout score
• CORELAP uses the shortest rectilinear path between the departments
(receiving/dispatch areas are assumed to be on the side of the
departments nearest its neighbor)

• The layouts often result in irregular building shapes

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Algorithm Classification

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ALDEP – Automated Layout Design Program
• Similar to CORELAP (objectives, requirements)
• Adjacency-based method

• The main differences:

• Randomness
• Multi-floor capability
• CORELAP attempts to produce the best layout, ALDEP produces many
layouts

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ALDEP – Procedure
• Department selection
• Randomly selects the first department
• Out of those departments which have “A” relationship with the first one (or “E”, “I”, etc. –min level of
importance is determined by the user) it selects randomly the second department
• If no such department exists it selects the second one completely randomly
• The selection procedure is repeated until all the departments are selected (Always search for the
departments having relationships with the last one placed in the layout – not all)
• Department placement
• Starts from upper left corner and extends it downward
• Vertical sweep pattern
• Sweep width is determined by the user
• Adjacency-based evaluation
• If minimum requirements met, it prints out the layout and the scores
• Repeats the procedure (max 20 layouts per run)
• User evaluation
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ALDEP
• Vertical sweep pattern

• Sweep width

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ALDEP – Example
• Use ALDEP procedure to (a) determine the layout vector, (b) construct and evaluate
the layout for the facility based on the relationship chart and the departmental
dimensions given below.
• The dimensions of the facility are 10x18. Use the sweep width of 2 and the minimum
acceptable level of importance “E”. The closeness values: A=64, E=16, I=4, O=1,
U=0, X=-1024

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ALDEP – Example
• Department selection

• Layout vector
• 4-2-1-6-5-7-3
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ALDEP – Example
• Layout construction
• Layout vector: 4-2-1-6-5-7-3
• Sweep width: 2

• Final layout

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ALDEP – Example
• Adjacency score

A=64,E=16,I=4,O=1,U=0,X=-1024

Total adjacency score 120

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ALDEP – Example
Alternative Solution
• Department selection

• Layout vector
• 2-1-4-5-6-7-3
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ALDEP – Example
Alternative Solution
• Layout construction
• Layout vector: 2-1-4-5-6-7-3
• Sweep width: 2
• Final layout • Adjacency score
A=64,E=16,I=4,O=1,U=0,X=-1024

Total adjacency score 104

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ALDEP Example – Solution Comparison
• Final layouts

• Adjacency scores
120 104

• The final decision depends on the facility planner

• It is necessary to consider many alternatives
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Algorithm Classification

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MULTIPLE – Multi-floor Plant Layout Evaluation
• Construction and improvement algorithm
• Distance-based algorithm

• Similar to CRAFT (departments not restricted to rectangular shapes, discrete

presentation, two-way exchanges)
• But MULTIPLE can exchange non-adjacent departments

• Uses space filling curves to reconstruct a new layout after each iteration

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MULTIPLE – Space Filling Curves (SFC)
• Space filling curve connects all the grids in a layout
• Each grid is visited exactly once
• Next grid visited is always adjacent to the current grid (only
horizontal or vertical moves)
• SFC is generated by the computer
• SFC allows MULTIPLE to map a layout vector into a two-dimensional
layout

Procedure:
• The departments are placed based on the layout vector (similar as
MCRAFT)
• The SFC is followed until the required number of grid for each
department is reached

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MULTIPLE – Improvement Algorithm
Example
• Create a MULTIPLE layout for the departments below based on the layout vector 1-2-
3-4-5-6.
• Then build a new layout by exchanging the departments 1 and 5.
• The facility and SFC are given below.

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 1-2-3-4-5-6

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 1-2-3-4-5-6

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 1-2-3-4-5-6

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 1-2-3-4-5-6

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 1-2-3-4-5-6

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 1-2-3-4-5-6

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 1-2-3-4-5-6

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 1-2-3-4-5-6

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MULTIPLE – Improvement Algorithm
Example
• Exchange 1 and 5 – Layout vector 5-2-3-4-1-6

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MULTIPLE – Improvement Algorithm
Example
• Layout vector 5-2-3-4-1-6

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MULTIPLE – Improvement Algorithm
Example

• Initial layout →

• Layout after the exchange →

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MULTIPLE – Conforming Curves
• Conforming curves are hand-generated curves

• They are used:

• If the building shape is irregular
• If we want to capture the initial layout exactly
• If there are numerous obstacles (walls)
• If there are fixed departments

Procedure:
• May start and end at any grid
• The curve visits all the grids assigned to a particular department before visiting other
department
• The fixed departments and obstacles are not visited
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MULTIPLE – Conforming Curves

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MULTIPLE – Improvement Algorithm
• Final MULTIPLE layout for the CRAFT example

• The cost is lower than for the final layout found by CRAFT!
• MULTIPLE is very likely to obtain lower-cost solutions than CRAFT, since it considers
a larger set of possible solutions at each iteration

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MULTIPLE – Improvement Algorithm
• Final MULTIPLE layout for the CRAFT example may also need massaging to smooth
the department border

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MULTIPLE – Improvement Algorithm
• Any SFC or conforming curves could be used to fill the vacant building
• Any vector can be used as the initial layout vector
• Alternative layouts can be generated by trying different SFC
• The cost may not be much different

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MULTIPLE – Improvement Algorithm

Alternative layout vector:

D-E-F-B-C-H
Final layout cost z=54,900

Alternative layout vector:

Original layout vector: D-E-F-H-B-C
D-B-H-C-F-E Final layout cost z=54,540
Final layout cost z=54,200

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Algorithm Classification

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PLANET

A Computerized Plant Layout Analysis and Evaluation Technique (PLANET)

• Deisenroth, M. P., and Apple, J. M., “A Computerized Plant Layout Analysis and Evaluation
Technique (PLANET),” Technical Papers 1962, American Institute of Industrial Engineers,
Norcross, GA, 1972.

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Layout Generation Algorithms – Conclusion
• Each layout algorithm has certain strengths and weaknesses
• Capturing well the initial layout, the building shape, fixed departments → CRAFT,
MULTIPLE
• Generating acceptable shapes (rectangular) → BLOCPLAN, LOGIC
• Generating many alternatives → ALDEP, MULTIPLE

• No algorithm generates an optimal layout

• No computer-based algorithm can capture all the significant aspects of a facility
layout problem
• Human layout planner will continue to play a key role in developing and evaluating the
facility layout

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Algorithm Classification

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Next Lecture

• MIP

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