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Algoritma Untuk Tataletak Fasilitas

This document discusses algorithms for facility layout problems. It introduces heuristic algorithms like construction algorithms (MST, CORELAP, PLANET), improvement algorithms (2-OPT, 3-OPT, CRAFT), and hybrid algorithms (BLOCPLAN). It also discusses software for layout modeling and issues with layouts in modern manufacturing systems, such as the need to consider dynamic layout changes and 3D layout optimization.

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446 views53 pages

Algoritma Untuk Tataletak Fasilitas

This document discusses algorithms for facility layout problems. It introduces heuristic algorithms like construction algorithms (MST, CORELAP, PLANET), improvement algorithms (2-OPT, 3-OPT, CRAFT), and hybrid algorithms (BLOCPLAN). It also discusses software for layout modeling and issues with layouts in modern manufacturing systems, such as the need to consider dynamic layout changes and 3D layout optimization.

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© Attribution Non-Commercial (BY-NC)
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ALGORITMA UNTUK

TATALETAK FASILITAS
Adaptasi dari materi kuliah TI ITB
OUTLINE
• Introduction
• Heuristic Algorithms
• Software for layout modelling
• Layout issues in modern manufacturing
systems
INTRODUCTION
• A model itself does not provide a solution to a
problem
• Algorithms or solution techniques have to be
developed to solve a model. An algorithm is a
step-by-step procedure that finds a solution to a
model and hence to the problem, in a finite
number of steps.
• We introduce algorithms that have been
developed for the layout problem
INTRODUCTION
• Algorithms developed can be divided into two
categories:
– Optimal Algorithms (discussed in Ch. 5)
– Heuristic Algorithms
• All optimal algorithms developed suffer from
disadvantages: the memory and computational
time requirements are extremely high increase
exponentially as the problem size increases.
• Hence, there are many more heuristic algorithms
for solving the layout problem
Heuristic Algorithms

Can be classified into 3 categories:


• Construction Algorithms
• Improvement Algorithms
• Hybrid Algorithms
Construction Algorithms
• MST
• CORELAP
• PLANET
MST ALGORITHM
Example:[MST]
Example:[MST]
Example:[Output]
CORELAP
• First construction algorithm
• Developed by Lee and Moore (1967)
• It converts qualitative input data (obtained
from ARC) into quantitative data
• CORELAP calculates the total closeness rating
(TCR) for each facility
• Facility with the highest TCR is selected and
placed in the centre of the layout
CORELAP
• If two or more facilities share the highest TCR,
select one with the highest area (if there is
still a tie, select the first such facility).
• Selection of the second facility depends on
the interaction with the permanent facility
(placed in the layout).
• The temporary facility (unselected facility)
with highest adjacency relationship (A, E, I,
etc.) with the permanent facility is selected
CORELAP
• The third and subsequent facilities are
selected on the basis of their relationship with
the permanent facilities.
• The entering facility is placed in the location
that maximizes the PR (placement rating) –For
an example, see Fig. 6.4
CORELAP
EXAMPLE 2: [ADJACENCY REL]
CORELAP: TCR
CORELAP
Improvement Algorithms
• 2-OPT and 3-OPT
• CRAFT
• SA-CRAFT (Mulyono dan Iskandar, 1994)
2-Opt Algorithm
Facilities and Sites
Example:[2-Opt Algorithm]
SOLUTION
SOLUTION
SOLUTION
3-Opt Algorithm
CRAFT
• Computerized Relative Allocation of Facility Technique
(Armour and Buffa, 1963)
• Up till now, It is still popular and widely used in practice
• CRAFT requires the input data:
– Dimension of the building
– Dimension of facilities
– Flow of material and cost per unit load per unit distance
– An initial layout
– Restriction on location of facilities (fixed facilities)
Departemen Dummy
• Mengisi bagian yang bersifat umum atau tidak
beraturan.
• Menggambarkan area yang tetap di dalam
fasilitas dimana departemen tidak. dapat
dialokasikan, yaitu tangga elevator, ruang
istirahat, tempat alat-alat service, dan lain-lain.
• Menyatakan ruang ekstra dalam fasilitas.
• Membantu dalam mengevaluasi lokasi Gang
dalam tata letak.
CRAFT
• Given the initial layout, CRAFT computes the
distance between centres of each pair facility
and determine the cost of the initial layout.
• CRAFT considers exchanging the location of
certain pair of facilities
• The facility pairs considered either have the
same area or are adjacent (See Fig. 6.13)
CRAFT:[Estimated Cost]
CRAFT
• Each iteration, CRAFT can examine a
maximum n(n-1) possible exchanges, (n=#of
facilities)
• The location exchange that result in the
greatest estimated cost reduction is made
• The algorithm is stopped if no two-way
exchange results in a lower cost.
CRAFT:[Exchange facilities]
CRAFT is also capable of performing:
• Three way exchanges
• Two-way exchanges followed by three way
exchanges
• Three way exchanges followed by two-way
exchanges
CRAFT
• The original version was capable of handling
only 40 facilities (Please check the capability
of CRAFT in the QSB).
• In general, better the starting solution, the
better the final solution.
• This is true with CRAFT also.
Example: [CRAFT]
Example: [CRAFT]
Data Input
CRAFT
OUTPUT: [CRAFT]
OUTPUT: [CRAFT]
OUTPUT: [CRAFT]
OUTPUT: [CRAFT]
OUTPUT: [CRAFT]
OUTPUT: [CRAFT]
OUTPUT: [CRAFT]
Hybrid Algorithms
• All improvement algorithms require an initial
layout
• The better the starting solution, the better the
final solution
• A hybrid algorithm uses a construction
algorithm to produce an initial layout and then
improve it by an improvement algorithm.
• BLOCPLAN is a hybrid algorithm.
• R-MAT (Iskandar, 1985)
BLOCPLAN
• Can develop a single-story or multi-story layout
• Can handle quantitative or qualitative data
• Can handle a maximum of 18 facilities
• Three ways of providing flow data:
– ARC
– From-To-Chart
– Product-Routing data
• BLOCPLAN converts flow matrix into an equivalent
relationship chart by dividing the maximum flow element by 5
(See Table 6.2).
• Then rel chart is used to develop a layout
TABLE 6.2
BLOCPLAN
• BLOCPLAN can develop a layout:
– Randomly using a construction algorithm;
– Using an embedded improvement algorithm; or
– Using an automatic search algorithm
• The improvement algorithm executes an
exchange and calculates the adjacency score
and the rel-dist score of the new layout.
Adjacency score and Rel-Dist score
BLOCPLAN
• The Criterion used is R-score
• R-score=1 – (rel-dist score-LB)/(UB-LB)
• UB: Upper Bound LB: Lower Bound
• R-score =1 means that the solution is optimal
• Hence, BLOCPLAN is trying to develop the
layout with R-score being close to one.
Software for layout modelling

• CORELAP
• CRAFT
• BLOCPLAN
• FactoryCAD
• FactoryPLAN
• FactoryFLOW
(See more in IE Solutions magazine, August 1995)
Layout issues
in modern manufacturing systems
• The layout problem discussed has been based on
three assumptions:
1. The layout problem is two-dimensional
2. Information on future manufacturing activities is
known at the time facility design decisions are
made
3. The product mix and volume remain fairly constant
• These may have been justified in traditional
manufacturing systems but they no longer hold in
modern systems
Layout Issues in modern manufacturing
•
systems
A stable business environment –the traditional manufacturing
systems
• A high level of volatility and uncertainty in the current
industrial climate
• Effective lifetime of a layout is two years (Nicol and Hollier,
1983)
• The lifetime has decreased further say to one year or less in
the past decade
• Due to the high rate of technological innovations as well as the
frequent changes in product design and functional demanded
by customers
• Re-layout will become more common that layout of new
facilities in the future systems (the Dynamic layout problem)
Layout issues
• The layout problem is two-dimensional (This is
hold for a manufacturing system)
• It does not apply in an office layout problem –
where facilities are usually located in several floors
• Manufacturing systems in the future may have to
deal with three-dimensional layout problems –
land prices become to high; building a new plant
costs ten times more than refurbishing an existing
one
Layout issues
• Hence, the manufacturer needs to consider
expansion in vertical dimension –transforming
a 2-D layout problem into a 3-D layout one.
• The distance between facilities situated in
different floors may be nonlinear.
• Many algorithms are available the multifloor
problem (e.g. BLOCPLAN, SPACECRAFT, CRAFT
3-D, MULTIPLE)

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