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Computer‐based models for the automatic generation of facility layouts have been shown to provide significant benefits to the industrial community for the planning and development of facilities. In a manufacturing environment, layouts are often needed for the manufacture, storage and shipment of specific product types within specific time periods. This is especially true in metal fabrication plants, as the dynamic nature of product storage and manufacture dictates the need for effective layout generation to achieve cost reductions. The system described in this paper integrates raw material storage, inventory management, scheduling and rack system design with facility layout development for the most satisfactory dynamic response. The research addressed in this paper has resulted in the development of a computer‐based model that focuses on the concept of integrating the domains of plant layout, material handling and warehousing in terms of raising overall effectiveness.

A plant layout in the context of manufacturing facilities design consists of the production areas, manufacturing support areas and personnel areas. In facilities design, plant layout has been determined to be one of the most important elements in the effectiveness of systematic manufacturing operability. This paper describes the development of a split departmental plant layout generation system (LAYSPLIT) in the domain of facilities design to develop layouts that will minimize the material handling costs. The plant layout generation system consists of a data acquisition module, a pair‐wise departmental exchange module, a layout development module, and a graphical representation module. The approach used to develop the system using a split departmental method, and the characteristics of the system are outlined. The advantages of the developed system in terms of facilitating effective operations and increasing productivity in manufacturing environments are discussed. The results obtained from LAYSPLIT are compared with that produced by the MCRAFT system and discussed.

The purpose of this paper is to review, evaluate and classify the academic research that has been published in facility layout problems (FLPs) and to analyse how researches and practices on FLPs are.

The review is based on 166 papers published from 1953 to 2021 in international peer-reviewed journals. The literature review on FLPs is presented under broader headings of discrete space and continuous space FLPs. The important formulations of FLPs under static and dynamic environments represented in the discrete and continuous space are presented. The articles reported in the literature on various representations of facilities for the continuous space Unequal Area Facility Layout Problems (UA-FLPs) are summarized. Discussed and commented on adaptive and robust approaches for dynamic environment FLPs. Highlighted the application of meta-heuristic solution methods for FLPs of a larger size.

It is found that most of the earlier research adopted the discrete space for the formulation of FLPs. This type of space representation for FLPs mostly assumes an equal area for all facilities. UA-FLPs represented in discrete space yield irregular shape facilities. It is also observed that the recent works consider the UA-FLPs in continuous space. The solution of continuous space UA-FLPs is more accurate and realistic. Some of the recent works on UA-FLPs consider the flexible bay structure (FBS) due to its advantages over the other representations. FBS helps the proper design of aisle structure in the detailed layout plan. Further, the recent articles reported in the literature consider the dynamic environment for both equal and unequal area FLPs to cope with the changing market environment. It is also found that FLPs are Non-deterministic Polynomial-complete problems, and hence, they set the challenges to researchers to develop efficient meta-heuristic methods to solve the bigger size FLPs in a reasonable time.

Due to the extremely large number of papers on FLPs, a few papers may have inadvertently been missed. The facility layout design research domain is extremely vast which covers other areas such as cellular layouts, pick and drop points and aisle structure design. This research review on FLPs did not consider the papers published on cellular layouts, pick and drop points and aisle structure design. Despite the possibility of not being all-inclusive, the authors firmly believe that most of the papers published on FLPs are covered and the general picture presented on various approaches and parameters of FLPs in this paper are precise and trustworthy.

To the best of the authors’ knowledge, this paper reviews and classifies the literature on FLPs for the first time under the broader headings of discrete space and continuous space representations. Many important formulations of FLPs under static and dynamic environments represented in the discrete and continuous space are presented. This paper also provides the observations from the literature review and identifies the prospective future directions.

The purpose of this paper is to develop a mathematical model for the design of robust layout for unequal area-dynamic facility layout problem with flexible bay structure (UA-DFLP with FBS) and test the suitability of generated robust layout in a dynamic environment.

This research adopts formulation of a mathematical model for generating a single layout for unequal area facility layout problems with flexible bay structure under dynamic environment. The formulated model for the robust layout formation is solved by developing a simulated annealing algorithm. The proposed robust approach model for UA-DFLP with FBS is validated by conducting numerical experiments on standard UA-DFLPs reported in the literature. The suitability of the generated robust layout in a dynamic environment is tested with total penalty cost criteria.

The proposed model has given a better solution for some UA-DFLPs with FBS in comparison with the adaptive approach’s solution reported in the literature. The total penalty cost is within the specified limit given in the literature, for most of the layouts generated for UA-DFLPs with FBS. In the proposed model, there is no rearrangement of facilities in various periods of planning horizon and thus no disruptions in operations.

The present work has limitations that when the area and aspect ratio of the facilities are required to change from one period to another, then it is not possible to make application of the robust approach-based formulation to the dynamic environment facility layout problems.

Rearrangement of facilities in adaptive approach disrupts the operations whereas in the proposed approach no disruption of production. The FBS approach is more suitable for layout planning where proper aisle structure is required. The solution of the proposed approach helps to create a proper aisle structure in the detailed layout plan. Thus, easy interaction of the material handling equipment, men and materials is possible.

This paper proposes a mathematical formulation for the design of robust layout for UA-FLPs with FBS in a dynamic environment and an efficient simulated annealing algorithm as its solution procedure. The proposed robust approach generates a single layout for the entire planning horizon. This approach is more useful for facilities which are difficult/sensitive to relocate in various periods of the planning horizon.

A bay configuration arranged along a central spine and served by an automated monorail material‐handling system are common designs for the layout and material‐handling system in new semiconductor wafer fabrication facilities. Investigates the facility design problem in semiconductor fabrication facilities and proposes a procedure to determine the optimal spine layout design, given a design of the material‐handling system. Explains and tests the procedure to demonstrate the use of the model for solving semiconductor facility design problems. The procedure is applicable for the important semicondutor industry as well as in other facilities that use a central spine layout configuration.

The purpose of this article is to develop a bi-directional relaxed flexible bay structure (BRFBS) in the layout for the unequal area facility layout problems (UA-FLPs) and test the suitability of the proposed approach using literature data.

This research adopts a two-stage solution approach for UA-FLPs to form BRFBS in the layout. The solution to UA-FLPs is carried out in discrete space. The proposed heuristic method optimises the layout plan for minimising the material handling cost (MHC), and also, it indirectly optimises the space utilisation by reducing the empty space in the layout. The first stage of layout design assumes that all facilities are equal in size and uses quadratic assignment problem (QAP) model. QAP is solved with a simulated annealing heuristic method. In the second stage, a heuristic method is proposed to find the optimum width for each bay and the dimension for facilities. The proposed heuristic method is tested with numerical data available in the literature. Results are compared with the results obtained by layout planning software, and with the simulated annealing algorithm for flexible bay structure (SA-FBS) heuristic procedure for continuous space UA-FLPs.

The proposed two-stage solution approach gives the BRFBS for the UA-FLPs. BRFBS helps to create proper aisle structure in the layout plan. The layout configuration and solution of the proposed method is better than the layout planning software solution and SA-FBS solution. The application of the proposed heuristic method to case data gave lesser MHC, better space utilisation and better aisle formation than the existing layout.

The proposed approach has the limitation that it can be applied only to UA-FLPs solved in discrete space. When the UA-FLPs are solved in continuous space, then it is not possible to make application of this approach to form bi-directional relaxed flexible bays in the layout plan.

Most of the modern industries are automated, and they use material handling equipment (MHE) like automated guided vehicles (AGVs). Design of layout plans that help to create proper aisle structure for AGV’s in the layout plan is a challenging to the researchers. The BRFBS configuration is more suitable in the flexible manufacturing system where AGVs are used for material transportation.

This paper proposes a novel two-stage heuristic method for solving the UA-FLPs in discrete space. The proposed approach generates a BRFBS in the layout plan. The BRFBS helps to create a proper aisle structure suitable for better material handling operations. Hence, this type of layout helps in easy interaction of the MHE (e.g. AGVs) with the boundaries of the facilities touching the aisle.

This paper seeks to apply a heuristic approach to solve the facility layout problem and the description of a new computer‐aided layout design system.

The system utilizes a new approach for computing the adjacency scores, stacking of departments, and reserving or changing the department's shapes and dimensions. The system algorithms are based on calculating the minimal distance between departments and modified departmental closeness rating.

The research addressed in this paper has resulted in developing FLASP (Facility LAyout Support Program) software. FLASP could reduce the number of iterations needed to reach the optimal solution of the layout problems by restricting the location for each department depending on the relationships between them.

The system is built on a set of algorithms that are concerned with stacking, calculating the shortest rectilinear distances between departments, adjacency matrix system, modifications capabilities, and plans main aisles surrounding each department.

The program gathers the importance of both the adjacency relationships and the distances between departments in a way that depends on the concept that the adjacency score should not be nullified just because the two departments are no longer strictly adjacent. It rather considers that the adjacency score fades away gradually with the increase of distance between the two departments which leads to a main difference in distance consideration.

Real flight is cognitively demanding; accordingly, both indicators and display panel layout should be user-friendly to improve pilot-aircraft interaction. Poor pilot-interface interactions in aircrafts could result in accidents. Although a general reason of accidents is improper displays, relatively few studies were conducted on interfaces. This study aims to present an optimization model to create intuitively integrated user-friendly cockpit interfaces.

Subjectivity within most usability evaluation techniques could bring about interface design problems. A priori information about indicator’s possible locations may be available or unavailable. Thus different analytical approaches must be applied for modifications and new interface designs. Relative layout design (RLD) model was developed and used in new interface designs to optimize locations of indicators. This model was based on layout optimization and constructed in accordance with design requirements, ergonomic considerations with the pilot preferences. RLD model optimizes interface design by deploying indicators to the best locations to improve usability of display panel, pilot-aircraft interaction and flight safety.

Optimum interfaces for two problem instances were gathered by RLD model in 15.77 CPU(s) with 10 indicators and 542.51 CPU(s) with 19 indicators. A comparison between relative and existing cockpit interfaces reveals that locations of six navigation and four mechanical system indicators are different. The differences may stem from pilots’ preferences and relativity constraints. Both interfaces are more similar for the central part of the display panel. The objective function value of relative interface design (Opt: 527938) is far better than existing interface (737100). The RLD model improved usability of existing interface (28.61 per cent considering decrease in the objective function values from 737100 to 527938.

Future cockpit and new helicopter interface designs may involve RLD model as an alternative interface design tool. Furthermore, other layout optimization problems, e.g. circuit boards, microchips and engines, etc. could be handled in a more realistic manner by RLD model.

Originality and impact of this study related to development and employment of a new optimization model (RLD) on cockpit interface design for the first time. Engineering requirements, human factors, ergonomics and pilots’ preferences are simultaneously considered in the RLD model. The subjectivity within usability evaluation techniques could be diminished in this way. The contributions of RLD model to classical facility layout models are relativity constraints with the physical constrictions and ergonomic objective function weights. Novelty of this paper is the development and employment of a new optimization model (RLD) to locate indicators.

The purpose of this study is to explore the influence of an office canteen layout on operations, specifically on customer behaviour before checkout, waiting times, and congestion.

The current study was made in the context of discovery and exemplification. The sample was not randomly obtained: the method of recruitment was purposive and convenient. Two Dutch office canteens were selected based on their motivation to participate in the study. A small exploratory study aiming to report on current practices and to inform on possibilities for future research and intervention. With direct observations the behaviour, waiting times, and congestion of 47 customers were analyzed. Customer behaviour was reported qualitatively, waiting times and congestion were reported quantitatively.

Canteens where customers can move freely before checkout queue, allow them to move away from congestion towards food products and to have more favourable waiting times than customers in canteens with layouts requiring a strict order and line‐up for self‐service and checkout.

The results contribute to the managerial repertoire of facilities managers by illuminating latent positive influences of facility layout on operations, which can stimulate the design of better facilities.

This paper contributes to the understanding of how facilities are interwoven with operations. It also informs on possibilities for future research in this area, for instance, combining approaches that originate from facilities management and operations management. This may lead to future research to recommend specific designs or behaviour‐inducing layouts for increased operational enhancements.

The purpose of this paper is to show how the successful implementation of the just‐in‐time (JIT) philosophy in the manufacturing industry has helped to reduce cost and time and increase quality of products. Existing studies on JIT principles in the building industry were predominantly focused on the construction stage.

The empirical part consisted of pilot interviews with architects who designed ramp‐up light factories and a survey of tenants operating out of these factories.

The findings from the survey of tenants suggest that architectural designs, in terms of space and layout, have met the tenants' operational facilities needs. The tenants were generally satisfied with the ramp‐up light factory facilities design features, in relation to the relevant JIT principles.

The empirical findings were based on the user's perceptions and not on analyzing the actual physical facilities design of the ramp‐up factories with respect to JIT principles. This area is recommended for future research.

The application of JIT principles to further improve the facilities design of ramp‐up light factories would help to reduce waiting time and double handling of goods during transportation. In addition, the application of JIT principles also enhances the smooth flow of delivery to every unit with less damage to the quality of the goods being delivered.

This exploratory study is not about how the management of the design process can be improved. Rather, it examines, for the first time, whether the application of JIT principles to improving the facilities design of ramp‐up light factories would effectively meet the tenants' operational facilities needs and improve their productivity after they have moved into the premises.