Plant Layout Optimization

Figure 6.8. Initial Layout of Cell 1
The optimum sequence method starts with an arbitrary initial solution and tries to improve the layout by switching two departments in the sequence. At each step the method computes the cost changes for all possible switches of two departments and chooses the most effective pair. The two departments are switched in sequence and the method repeats. The process stops when no switch results in a reduced cost. The optimized facility information and layout have been shown below.
Table 6.7 Optimized Facility Information of Cell 1
Department
Color
Area-required
Area-defined x-centroid y-centroid
Sequence
M41
1
11
11
9.13636398
8.77272701
1
M4
2
6
6
9
10.166667
2
M2
3
6
6
3
0.5
3
M31
4
14
14
8.71428585
11.7857141
4
M25
5
84
84
3.42857146
7.92857122
5
M7
6
6
6
9
7.33333349
6

Figure 6.9. Optimized Layout of Cell 1
The initial material handling cost of the layout was Rs.10550. The CRAFT algorithm is used for the optimization of machines in the Cell 1 layout. After performing six iterations the cost has been reduced to Rs. 5950 and the layout has been optimized. In the optimized layout the machines 25 and 7 needs to be switched/interchanged.
1.1.1. Machine Optimization in Cell 2 The procedure for doing the optimization is discussed in 6.7.1. The facility information, machine information, flow matrix, cost matrix, initial facility information and optimized facility information for Cell 2 is shown in Appendix F. The procedure for optimization of Cell 2 is same as that of Cell 1 and the results of the optimized layout is shown below. The result of the optimized layout is shown in the figure below.

Initial layout of Cell 2
Optimized Layout of Cell 2

Figure 6.10. Initial and optimized layouts of Cell 2
The initial material handling cost of Cell 2 layout was Rs. 6100. The iterations performed is only one and the cost has been reduced to Rs. 5600. The machines 9 and 38 needs to