The aperiodic facility layout problem with time-varying demands and an optimal master-slave solution approach

In many seasonal industries, customer demands are constantly changing over time, and accordingly the facility layout should be re-optimized in a timely manner to adapt to changing material handling patterns among manufacturing departments. This paper investigates the aperiodic facility layout problem (AFLP) that involves arranging facilities layout and re-layout aperiodically in a dynamic manufacturing environment during a given planning horizon. The AFLP is decomposed into a master problem and a combination set of static facility layout problems (FLPs, the slave problems) without loss of optimality, and all problems are formulated as mixed-integer linear programming (MILP) models that can be solved by MIP solvers for small-sized problems. An exact backward dynamic programming (BDP) algorithm with a computational complexity of O(n 2) is developed for the master problem, and an improved linear programming based problem evolution algorithm (PEA-LP) is developed for the traditional static FLP. Computational experiments are conducted on two new problems and twelve well-known benchmark problems from the literature, and the experimental results show that the proposed solution approach is promising for solving the AFLP with practical sizes of problem instances. In addition, the improved PEA-LP found new best solutions for five benchmark problems

A Semidefinite Programming Model for the Facility Layout Problem

The continuous facility layout problem consists of arranging a set of facilities so that no pair overlaps and the total sum of the pairwise connection costs (proportional to the center-to-center rectilinear distance) is minimized. This thesis presents a completely mixed integer semidefinite programming (MISDP) model for the continuous facility layout problem. To begin we describe the problem in detail; discuss the conditions required for a feasible layout; and define quaternary variables. These variables are the basis of the MISDP model. We prove that the model is an exact formulation and a distinction is made between the constraints that semidefinite programming (SDP) optimization software can solve and those that must be relaxed. The latter are called exactness constraints and three possible exactness constraints are shown to be equivalent. The main contribution of this thesis is the theoretical development of a MISDP model that is based on quaternary, as oppose to binary, variables; nevertheless preliminary computational results will be presented for problems with 5 to 20 facilities. The optimal solution is found for problems with 5 and 6 facilities, confirming the validity of the model; and the potential of the model is revealed as a new upper bound is found for an 11-facility problem

Heuristics for the dynamic facility layout problem with unequal area departments

The facility layout problem (FLP) is a well researched problem of finding positions of departments on a plant floor such that departments do not overlap and some objective(s) is (are) optimized. In this dissertation, the FLP with unequal area rectangular shaped departments is considered, when material flows between departments change during the planning horizon. This problem is known as the dynamic FLP. The change in material flows between pairs of departments in consecutive periods may require rearrangements of departments during the planning horizon in order to keep material handling costs low. The objective of our problem is to minimize the sum of the material handling and rearrangement costs. Because of the combinatorial structure of the problem, only small sized problems can be solved in reasonable time using exact techniques. As a result, construction and improvement heuristics are developed for the proposed problem. The construction algorithms are boundary search heuristics as well as a dual simplex method, and the improvement heuristics are tabu search and memetic heuristics with boundary search and dual simplex (linear programming model) techniques. The heuristics were tested on a generated data set as well as some instances from the literature. In summary, the memetic heuristic with the boundary search technique out-performed the other techniques with respect to solution quality

Facility layout problem: Bibliometric and benchmarking analysis

Facility layout problem is related to the location of departments in a facility area, with the aim of determining the most effective configuration. Researches based on different approaches have been published in the last six decades and, to prove the effectiveness of the results obtained, several instances have been developed. This paper presents a general overview on the extant literature on facility layout problems in order to identify the main research trends and propose future research questions. Firstly, in order to give the reader an overview of the literature, a bibliometric analysis is presented. Then, a clusterization of the papers referred to the main instances reported in literature was carried out in order to create a database that can be a useful tool in the benchmarking procedure for researchers that would approach this kind of problems

The Single Row Facility Layout Problem: State of the Art

The single row facility layout problem (SRFLP) is a NP-hard problem concerned with the arrangement of facilities of given lenghs on a line so as to minimize the weighted sum of the distances between all the pairs of facilities. The SRFLP and its special cases often arise while modeling a large variety of applications. It was actively researched until the mid-nineties. It has again been actively studied since 2005. Interestingly, research on many aspects of this problem is still in the initial stages, and hence the SRFLP is an interesting problem to work on. In this paper, we review the literature on the SRFLP and comment on its relationship with other location problems. We then provide an overview of different formulations of the problem that appear in the literature. We provide exact and heuristic approaches that have been used to solve SRFLPs, and finally point out research gaps and promising directions for future research on this problem.

A Lin-Kernighan Heuristic for Single Row Facility Layout

The single row facility layout problem (SRFLP) is the problem of arranging facilities with given lengths on a line, while minimizing the weighted sum of the distances between all pairs of facilities. The problem is known to be NP-hard. In this paper, we present a neighborhood search heuristic called LK-INSERT which uses a Lin-Kernighan neighborhood structure built on insertion neighborhoods. To the best of our knowledge this is the first such heuristic for the SRFLP. Our computational experiments show that LK-INSERT is competitive and improves the best known solutions for several large sized benchmark SRFLP instances.

An Exponential Neighborhood Local Search Algorithm for the Single Row Facility Location Problem

In this work we present a local search algorithm for the single row facility location problem. In contrast to other local search algorithms for the problem, our algorithm uses an exponential neighborhood structure. Our computations indicate that our local search algorithm generates solutions to benchmark instances of the problem whose costs are on average within 2% of costs of optimal solutions within reasonable execution time.

Tabu Search for the Single Row Facility Layout Problem in FMS using a 3-opt Neighborhood

Since material handling agents in a FMS are most efficient when moving in straight lines, a common layout of machines in a FMS is a single row layout. This allows a floor designer to model the problem of generating an optimal machine layout in a FMS as a single row facility layout problem (SRFLP). Due to the computational complexity involved in solving the SRFLP, researchers have developed several heuristics to solve large instances of the problem. In this paper, we present a tabu search implementation based on a 3-opt neighborhood search scheme. We also present a technique to speed up the exhaustive 3-opt neighborhood search process significantly. Our computational experiments show that speed up of the 3-opt search is effective, and our tabu search implementation is competitive. The results we present here are better than the currently known best layouts for several large sized benchmark SRFLP instances, and competitive for other benchmark instances.

A Competitive Genetic Algorithm for Single Row Facility Layout

The single row facility layout is the NP-Hard problem of arranging facilities with given lengths on a line, so as to minimize the weighted sum of the distances between all pairs of facilities. Owing to the computational complexity of the problem, researchers have developed several heuristics to obtain good quality solutions. In this paper, we present a genetic algorithm to solve large SRFLP instances. Our computational experiments show that an appropriate selection of genetic operators can yield high quality solutions in spite of starting with an initial population that is largely randomly generated. Our algorithm improves the previously best known solutions for several benchmark instances and is competitive for the remaining ones.