CHAPTER 5

MODELS FOR THE LAYOUT PROBLEM

INTRODUCTION
There are several objectives in developing a layout, the primary goal is
to minimize the cost or time involved in transportation
The focus of this subject is on mathematical models used for the facility
layout problem.
For purposes of modeling, we classify the layout problem into two
types:
Single row layout problem
Multi row layout problem

Single row layout

Multi row layout

ABSMODEL 1
SINGLE ROW LAYOUT PROBLEM

ABSMODEL 1 :
Assumptions
1. The facilities are square or rectangular and their shapes are known a
priori

ABSMODEL 1 :
Assumptions
2. The facilities are arranged along a straight line.

ABSMODEL 1 :
Assumptions
3. the orientation of facilities is known a priori

4. there is no restriction on the shape of the building in which the

facilities are to be housed

ABSMODEL 1 :
Parameters
Parameters:
n

number of departments in the problem

cij

cost of moving a unit load by a unit distance between

departments i and j

fij

number of unit loads between departments i and j

li

length of the horizontal side of department i

dij

minimum distance by which departments i and j are to be

separated horizontally

horizontal dimension of the floor plan

Decision Variable:
xi

distance between center of department i and vertical

reference line (VRL)

ABSMODEL 1: Formulation
n 1

Minimize

i 1 j i 1

Subject to

ij

f ij xi x j

xi x j 0.5 li l j dij

i 1,2,..., n 1

H
lj

li

...

Facility j

VRL

Facility i

xi
xj

H 0.5 li xi 0.5 li

i 1,2,..., n

ABSMODEL 1: Example
TVCR repair shop current layout

Customer
service

15 ft.

General repair
area
Parts display
area

75 ft.

ABSMODEL 1: Example

[fij]=

Room
Number

Room Name

Dimensions
(in feet)

12

20

TV/VCR

20 x 10

12

Audio

10 x 10

10

Microwave

10 x 10

20

10

Computer

20 x 10

Parts

15 x 10

ABSMODEL 1: Example
Solution
DECISION VARIABLES
X1 = Distance between the center of facility 1 and the VRL
X2 = Distance between the center of facility 2 and the VRL
X3 = Distance between the center of facility 3 and the VRL
X4 = Distance between the center of facility 4 and the VRL
X5 = Distance between the center of facility 5 and the VRL
FINAL MODEL
Minimize = 12 * ABS( X1 - X2 ) + 8 * ABS( X1 - X3 ) + 20 * ABS ( X1 - X3 ) +
4 * ABS ( X2 - X3 ) + 6 * ABS( X2 - X4 ) + 2 * ABS( X2 - X5 ) + 10 * ABS( X3
- X4 ) + 3 * ABS( X4 - X5 )

ABSMODEL 1: Example
Solution
SUBJECT TO:

ABS( X1 - X2 ) > 15 ;

X1 > 10 ;

ABS( X1 - X3 ) > 15 ;

X2 > 5 ;

ABS( X1 - X4 ) > 20 ;

X3 > 5 ;

ABS( X1 - X5 ) > 17.5 ;

X4 > 10 ;

ABS( X2 - X3 ) > 10 ;

X5 > 7.5 ;

ABS( X2 - X4 ) > 15 ;

X1 < 65 ;

ABS( X2 - X5 ) > 12.5 ;

X2 < 70 ;

ABS( X3 - X4 ) > 15 ;

X3 < 70 ;

ABS( X3 - X5 ) > 12.5 ;

X4 < 65 ;

ABS( X4 - X5 ) > 17.5

X5 < 67.5 ;

ABSMODEL 1: Example
Sol
OPTIMAL SOLUTION USING GINO OPTIMIZATION SOFTWARE
MIN = 1657.50

VARIABLES

X5 = 67.5

X1 = 10.00

X3 = 35.00
X4 = 50.00
X5 = 67.50

Vertical Reference Line (VRL)

X2 = 25.00

X4 = 50
X3 = 35
X2 = 25

X1 = 10

ABSMODEL 1: Example
Sol
X5 = 67.5

Vertical Reference Line (VRL)

X4 = 50
X3 = 35
X2 = 25
X1 = 10

TV/VCR

Audio

Microwave

Computer

Current Layout

General repair
area

Customer
service
Parts display
area

Final Layout

TV/VCR

Audio

Microwave

Computer

Parts
Display
Area

THE
MULTIROW
LAYOUT
PROBLEM
WITH FACILITIES OF EQUAL AREA

MODELS FOR THE MULTIROW

LAYOUT PROBLEM (with facilities of
equal area)
Facility 1

Facility 2

Facility 3

Facility 4

1.

Quadratic Assignment Problem (QAP)

2.

Linear Mixed-Integer Programming (LMIP)

3.

Quadratic set covering model

4.

Non-linear model with absolute terms with OF and constraints

Quadratic Assignment
Problem (Multi-row Problem)
Facility 1

Facility 2

Location 1

Location 2

Facility 3

Facility 4

Location 3

Location 4

The QAP formulations requires equal number of facilities and location.

If there are fewer facilities to be assigned to locations, create dummy
facilities.

If there are fewer locations than to locations, the problem is infeasible.

QAP Parameters
Parameters:
n total number of departments and locations
aij net revenue from operating department i at location j
fik flow of material from department i to k
cjl cost of transporting unit load of material from location j to l

Decision Variable:

1 if department i is assigned to location j

xij
0 otherwise

QAP Formulation
n

Maximize

a x

ij ij

i 1 j 1
n

Minimize

a x

ij ij

i 1 j 1

Minimize

j 1
n

ij

x
i 1

ij

i 1 j 1 k 1 l 1
i k j l
n
n
n
n

ik

i 1 j 1 k 1 l 1
i k j l

ik

c jl xij xkl
c jl xij xkl

i 1 j 1 k 1 l 1
n i k j l

Subject to

ik

c jl xij xkl

i=1,2,...,n

j=1,2,...,n

xij 0 or 1

i, j=1,2,...,n

Ensures each
facility assigned to
one location. And
guarantee that
each location has
one facility.

QAP Example
LonBank Inc,.
Trip Matrix( trips between each offices)
1

Sites Matrix (dist between each sites)

1

[fNij]=

17

12

11

17

12

12

12

11

[dij]=

QAP Example Solution

Objective Function

Subject to

QAP Example Solution: FINAL MODEL

Objective Function

Subject to
Decision Variables
X22 = 1 if Room 2 assigned to Site 2, 0 if not
X23 = 1 if Room 2 assigned to Site 3, 0 if not
X24 = 1 if Room 2 assigned to Site 4, 0 if not
X32 = 1 if Room 2 assigned to Site 2, 0 if not
X33 = 1 if Room 2 assigned to Site 3, 0 if not
X34 = 1 if Room 2 assigned to Site 4, 0 if not
X42 = 1 if Room 2 assigned to Site 2, 0 if not
X43 = 1 if Room 2 assigned to Site 3, 0 if not
X44 = 1 if Room 2 assigned to Site 4, 0 if not

QAP Example Solution: OPTIMAL SOLUTION using GINO OPTIMIZATION SOFTWARE

Decision Variables
X22 = 1 if Room 2 assigned to Site 2, 0 if not
X23 = 1 if Room 2 assigned to Site 3, 0 if not
X24 = 1 if Room 2 assigned to Site 4, 0 if not
X32 = 1 if Room 2 assigned to Site 2, 0 if not
X33 = 1 if Room 2 assigned to Site 3, 0 if not
X34 = 1 if Room 2 assigned to Site 4, 0 if not
X42 = 1 if Room 2 assigned to Site 2, 0 if not
X43 = 1 if Room 2 assigned to Site 3, 0 if not
X44 = 1 if Room 2 assigned to Site 4, 0 if not

Objective Function
MIN C = 152.00
Variables Value
X22 = 0
X23 = 1
X24 = 0
X32 = 0
X33 = 0
X34 = 1
X42 = 1
X43 = 0
X44 = 0

Final Layout
Room 1

Room 2

Site 1

Site 2

R1, S1

R4, S2

Room 3

Room 4

Site 3

Site 4

R2, S3

R3, S4

ABSMODEL 2
n 1

Minimize

c
i 1 j i 1

ij

f ij xi x j yi y j

Subject to

|xi xj| + |yi yj| > 1 i=1,2,...,n1; j=i+1,...,n

xi, yi = integer
i=1,...,n

Parameters:
Use the ABSMODEL 1 parameters

H
xi

Decision Variables
x horizontal distance between
center of facility I and vertical
reference line
y - Vertical distance between
center of facility I and horizontal
reference line

Facility i

V
yi
Facility j
yj
xj
HRL
VRL

ABSMODEL 2 Example(
using the previous
example)
LonBank Inc,.
Dimension: 2 X 2
Trip Matrix( trips between each offices)

ABSMODEL 2 Example(
using the previous example)
Solution: Model
Objective Function

Subject to

ABSMODEL 2 Example(
using the previous
example)
OPTIMAL SOLUTION

Variables (ft)
X1 = 1
Y1 = 1
X2 = 2
Y2 = 1
X3 = 1
Y3 = 2
X4 = 2
Y4 = 2

Vertical Reference Line (VRL)

Objective Function
Min = 83.00

1
2
1
2 1

Horizontal Reference Line (HRL)

THE
MULTIROW
LAYOUT
PROBLEM
WITH FACILITIES OF UNEQUAL AREA

ABSMODEL 3
Parameters:
n

number of departments in the problem

cij

cost of moving a unit load by a unit distance between

departments i and j

fij

number of unit loads between departments i and j

li

length of the horizontal side of department i

dij

minimum distance by which departments i and j are to be

separated horizontally

horizontal dimension of the floor plan

li length of the horizontal side of facility i

bi length of the vertical side of facility i
dhij horizontal clearance betweenfacilities i and j
dvij vertical clearance betweenfacilities i and j

ABSMODEL 3
c f x
n 1

Minimize

i 1 j i 1

Subject to

ij

ij

x j yi y j

|xi xj| +Mzij> 0.5(li+lj)+dhij

|yi yj| +M(1-zij)> 0.5(bi+bj)+dvij
zij(1-zij) = 0
xi, yi > 0

i=1,2,...,n1; j=i+1,...,n
i=1,2,...,n1; j=i+1,...,n
i=1,2,...,n1; j=i+1,...,n
i=1,...,n

xj

bj

Facility j

dhij

lj

dvij
li

bi
xi
VRL

yj

Facility i
yi
HRL

ABSMODEL 3 Example
Insurance Company
Office
O

[fij] =

Trips Matrix

Office

Dimensions (in feet)

10

15

20

25 x 2

10

30

35

10

25 x 20

15

30

10

20

35 x 30

20

35

10

15

30 x 20

10

20

15

35 x 20

LINEAR
MIXEDINTEGER
MODELS
FOR THE SINGLE-ROW LAYOUT PROBLEM

LMIP 1
Minimize

n 1

i 1 j i 1

Subject to

cij f ij xij xij

xi x j Mzij 0.5 li l j dij , i 1, 2,...n 1; j i 1,..., n

x j xi M (1 zij ) 0.5 li l j dij i 1, 2,..., n 1; j i 1,..., n

xi x j xij xij i 1, 2,..., n -1; j i 1,...n

xij , xij i 1, 2,..., n -1; j i 1,...n

zij 0 or 1

xi 0

i=1, 2,..., n -1; j i 1,...n

i=1, 2,..., n

LMIP 1 Example
Furniture Manufacturer
Machine Dimensions Horizontal Clearance Matrix
1

Flow Matrix
1

25x20

3.5

5.0

5.0

5.0

25

35

50

35x20

3.5

5.0

3.0

5.0

25

10

15

20

30x30

5.0

5.0

5.0

5.0

35

10

50

10

40x20

5.0

3.0

5.0

5.0

50

15

50

15

35x35

5.0

5.0

5.0

5.0

5.0

20

10

15

LMIP 1 Example Solution

Objective Function

Subject to

LMIP 1 Example Solution