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Simulation and Genetic to FLP

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    INT. J. PROD.RES.,2000, VOL. 38, NO. 17, 43694383

    Facility layout optimization using simulation and genetic algorithms

    FARHAD AZADIVAR{* and JOHN (JIAN) WANG{

    Traditionally, t he objective of a facility layout problem has been to minimize thematerial handling cost of the manufacturing system. While it is important toreduce the amount of material handling, the traditional methods do not addressthe actual time at which the material is transported. In todays short cycle timeproduction environments, the timing of material movement may have a biggerimpact on the productivity of the system than its cost. In this paper, a facilitylayout optimization technique is presented that takes into consideration the

    dynamic characteristics and operational constraints of the system as a whole,and is able to solve the facility layout design problem based on a systems per-formance measures, such as the cycle time and productivity. Each layout solutionis presented in the form of a string that is suitable for analysis by a geneticalgorithm technique. These solutions are then translated into simulation modelsby a specially designed automated simulation model generator. Geneticalgorithms are used to optimize the layout for manufacturing eectivenesswhile simulation serves as a system performance evaluation tool. Combinedwith a statistical comparison technique to reduce the simulation burden, thetest results demonstrate that the proposed approach overcomes the limitations

    of traditional layout optimization methods and is capable of nding optimal ornear optimal solutions.

    1. Introduction

    The facility layout problem in a manufacturing setting is dened as the

    determination of the relative locations for, and allocation of, the available space

    among a given number of workstations. Although most facility layout solutions

    have, in the past, focused on minimizing the amount of transportation, the eect

    of a given layout design on the production function of a manufacturing system is

    much more than just the cost of material handling. While material handling cost

    remains critical, shorter cycle times have become much more important in todays

    manufacturing systems. In other words, when a certain material is moved is as

    important, if not more important, as how much it costs to move it. Rapid develop-

    ment of new products, coupled with short delivery times demanded by customers,

    are the bases of the time-based competitive strategies rapidly being adopted by

    leading rms in many industries. Responsive delivery without inecient excess

    inventory and short manufacturing cycle times are the practical considerationsthat have strong impacts on the layout design and should be incorporated into the

    layout design process as genuine concerns.

    International Journal of Production Research ISSN 00207543 print/ISSN 1366588X online # 2000 Taylor & Francis Ltd

    http://www.tand f.co.uk/journals

    {Department of Industrial and Manufacturing Systems Engineering, Kansas StateUniversity, Manhattan, KA 66506, USA.

    {Talus Solutions Inc., Waterstone, Suite 300, 4751 Best Road, Atlanta, GA 30337-5609,USA.

    * To whom correspondence should be addressed. Present address: College of Engineering,University of Massachusetts, Dartmouth, MA 02747-2300, USA. e-mail: [email protected]

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    Because of complexity of the manufacturing systems, usually closed-form

    analytical expressions for objective functions do not exist. During the past three

    decades, a variety of approaches have been proposed to deal with facility layout

    optimization problems. In order to come up with analytical objective functions, most

    of these approaches limited themselves within the assumption that the volume ofmaterial ow between workstation pairs is xed and resources are always available.

    In some cases, there have been a few attempts to take the dynamic characteristics of

    systems into considerations as well. Techniques such as dynamic programming

    (Rosenblatt 1986), and fuzzy logic theory (Cheng and Gen 1996) have been used

    to model such uncertainties.

    However, we believe that, in order to account for all the impacts a layout design

    has on the performance of a system, a more detailed model of the system needs to be

    considered for evaluation of the performance measures. To accomplish this, we use

    computer simulation. The problem with computer simulation models is that they do

    not yield themselves easily to optimization processes. In this paper, it is proposed to

    use an integrated solution procedure that optimizes facility layout designs using

    simulation as the means of evaluating the objective function. This provides an addi-

    tional exibility in optimization because, in addition to the usual quantitative vari-

    ables, evaluation by simulation allows consideration of qualitative decision variables

    that analytical objective functions are not equipped to incorporate.

    One of the promising methods of optimizing problems whose performances are

    evaluated by a simulation model, especially when qualitative variables are involved,is the use of Genetic Algorithms (GA). Azadivar and Tompkins (1999) proposed a

    simulation model generator with a GA-based optimum seeking algorithm capable of

    optimizing simulation models whose performances are functions of qualitative and

    structural decision variables of the system. Zhang (1997) extended the technique to

    more general exible manufacturing systems. The work presented here is a method-

    ology that is based on this approach for facility layout design where the objective

    function is a measure of an actual system performance rather than just the volume of

    materials handled.

    2. Problem statement

    Consider a manufacturing system consisting ofm workstations in which n types

    of parts, each requiring a set of tasks (operations), are to be processed. A work-

    station may consist of a single machine, a cell of several machines, an inspection

    centre, a paint booth, etc. The parts require processing on dierent subsets of the m

    workstations and have dierent processing times in each workstation. Each work-

    station has its own queuing discipline and breakdown distribution. The system iseither a pull or a push type. In addition, let the area of the shop oor, the area

    required by each workstation, the time delay in each workstation, capacity and speed

    of the material handling devices, and the precedence constraints of tasks be given. A

    desired design for the system requires an arrangement of these workstations into the

    shop oor such that a certain measure of performance is optimized.

    The main assumptions for this problem are as follows.

    . The work areas of workstations are rectangular in shape and their orientations

    are known.. Every workstation works only one part at a time.. Every transporter carries only one type of part at a time.

    4370 F. Azadivar and J. Wang

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    . The operations are not pre-emptable.

    . The operating sequences of tasks are the same for the same part types.

    . The objective of the facility layout design is to minimize some measure of the

    system performance (e.g. production completion time of the parts produced in

    the system, while preserving the stated constraints).Although the procedure being described in this paper is suitable for all types of

    layouts, here we describe the procedure for free layout problems, which are the

    most general (and the most dicult) facility layout systems. A free layout is dened

    as follows.

    There is a set ofm workstations, denoted byfMig, i 1; 2;. . . ; m. The area thateach workstation occupies is restricted to be rectangular and is characterized by its

    length li, width wi and length and width clearances of cli and cwi, respectively. A

    facility layout solution for a given m-workstation plant consists of a boundedrectangle, R, partitioned by horizontal and vertical line segments into m non-over-

    lapping rectangular regions, denoted by fri, i1; 2;. . . ; m. Each region ri, withwidthxiand length yi, must be large enough to accommodate one workstation Mi

    plus its clearances.

    3. Use of genetic algorithm in facility layout design

    Genetic Algorithms (GA), proposed by Holland (1975), are heuristic search and

    optimization techniques that imitate the natural selection and biological evolution-ary process. In a GA approach to optimization, feasible solutions to the problem are

    encoded in data structures in the form of a string of decision choices that resemble

    chromosomes. The algorithm maintains a population of individuals or chromosomes

    (solutions) that evolve as chromosomes are created and discarded. Each chromo-

    some comprises a number of genes (decision choices), that describe various aspects of

    a particular solution. The layout design corresponding to each chromosome is char-

    acterized by its tness, which is measured by its objective function value. A genera-

    tion consisting of surviving individuals of the previous population and new

    individuals or ospring is generated through reproduction by means of crossover,

    mutation, and selection of their parents chromosomes.

    An eective layout of workstations can signicantly cut down manufacturing

    lead times. Unfortunately, the complexity of this task increases exponentially as

    the number of workstations increases. There are n! dierent ways of arranging n

    workstations into n locations. If all workstations are of equal area, or can be physi-

    cally interchanged without altering the overall adjacency or distance relationships

    among the remaining workstations, it is easy to specify, in advance, a nite number

    of potential sites for these workstations to occupy. Given this, the layout problemcan be modelled as a quadratic assignment problem (QAP). If we allow workstations

    unequal areas, their respective dimensions and the clearance requirements between

    them will determine the distance between two workstations. In such a case, since

    distances between locations are not equal and cannot be predetermined, it becomes

    extremely dicult even to describe feasible solutions.

    During the past three decades, numerous heuristic methods have been developed

    to obtain some good, rather than optimal, solutions for layout problems. The pri-

    mary diculties associated with these problems are the vast number of possible

    physical layouts, and the existence of many relatively poor local optima. For such

    a problem, one might expect parallel search methods to perform better than strictly

    4371Facility layout optimization

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    serial searches, and randomized search methods to perform better than greedy or

    enumerative searches. Genetic algorithms combine both of these attributes in a

    parallel, stochastic heuristic.

    As a powerful and broadly applicable stochastic search and optimization tech-

    nique, genetic algorithms have successfully been applied in various areas of industrialengineering, such as production scheduling and sequencing, reliability design, vehicle

    routing and scheduling, group technology, transportation, and many others. The

    technique has also been applied to the facility layout problem (Tate and Smith 1995,

    Cheng and Gen 1996, Meller and Gau 1996, Tam 1992). However, these published

    works are mostly material handling cost driven and do not put enough emphasis on

    the performance measures that are time driven and are complex functions of the

    layout design (e.g. production rate, cycle time). To evaluate these complex measures,

    simulation modelling is often the only feasible method. The approach proposed here,

    which combines simulation modelling and a genetic algorithm, provides a unique

    opportunity to address this issue.

    3.1. String representation of a layout design

    Most of the concepts in modelling layout problems for application of genetic

    algorithms in this work have been adopted from Cheng and Gen (1996). A brief

    description of their approach in representing these problems and using genetic

    algorithm operators is presented here.

    A free layout type facility design can be represented as a slicing structure. Slicingis the process of cutting a rectangular region into two smaller rectangular regions by

    either a horizontal or a vertical line segment (gure 1(a)). The line segment is called

    the cut-line. The slicing operations are repeated for each newly formed rectangle,

    with the slice-line direction chosen to be perpendicular to the previous slice line. A

    slicing structure is constructed by recursively partitioning a rectangle R(i.e. the oor

    plan) in such a way that each rectangular partition in the slicing structure cor-

    responds to the space allocated to a workstation.

    An equivalent representation of a slicing structure is a slicing tree. A slicing tree is

    a binary tree, which shows the recursive partitioning process that generates a slicing

    4372 F. Azadivar and J. Wang

    *

    1

    * + +

    111 2

    1222

    11

    1

    1

    2

    22 2

    12* 21* 12+ 21+

    (a) Slicing Structure

    (b) Slicing Tree

    (c) Reverse Polish Expression

    Figure 1. Slicing structure, slicing tree and reverse Polish expression.

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    structure. Let the operation of a horizontal cut and a vertical cut be denoted by the

    position symbols * and, respectively. Each symbol is explained pictorially in gure1(b). Each internal node represents the way a rectangular partition is cut. Partitions

    reserved for workstations reside in the leaves of the tree. Each leaf is assigned a

    unique integer corresponding to the identier (id) of a workstation. If we recursivelyprint out the left subtree and the right subtree, then the position symbol of a slicing

    tree, a postx expression called Reverse Polish Expression, is obtained (gure1(c)).

    This representation method yields itself very well to the coding scheme of chro-

    mosomes in genetic algorithms. A chromosome will then have m dierent work-

    station numbers and m1 position symbols where m is the number ofworkstations. Slicing structures comprising mgiven workstations can be represented

    by slicing trees or Reverse Polish Expressions over the symbol setP f1; 2;. . . ; m; *; g (Gen and Chen 1997). Figure 2 demonstrates the process

    of constructing a layout from its Reverse Polish Expression for a 6-station facility

    layout problem.

    3.2. Crossover

    We employed a special form of crossover operation as suggested by Cheng and

    Gen (1996) to preserve the feasibility of solutions. In this operation, an ospring

    chromosome is generated by adopting workstation numbers from one parent and

    position symbols from the other. An example of crossover operation is shown in

    gures 3 and 4. Suppose we have two parents, p1 and p2. The crossover operatorcopies the workstation numbers from parents p1 into the corresponding positions in

    an ospring o. Then it copies position symbols from p2, by scanning from left to

    right, to complete the ospring o.

    3.3. Mutation

    Random altering, inverting and swapping are used as a mutation operation

    (that is, altering a position symbol to the opposite one (gure 5), inverting a

    sequence of adjacent position symbols or a sequence of adjacent facility numbers

    (gure 6), swapping two adjacent position symbols or two adjacent facility numbers

    (gure 7). Mutation performed in this way can also guarantee to generate legal

    ospring.

    3.4. Selection

    The task of selection in the genetic algorithms is to allocate the reproductive

    opportunities to each chromosome such that the chromosomes with higher tness

    value are more likely to survive to the next generation. Selection directs a genetic

    algorithm search toward promising regions in the search space. The degree to whichthe better chromosomes are favoured is dened as the selection pressure. Typically,

    higher selection pressure indicates that more of the high tness chromosomes are

    selected.

    Tournament selection (Brindle 1981, Goldberg 1989) is a selection approach with

    both random and deterministic sampling features. This method randomly chooses a

    set of chromosomes and picks out the one with the highest tness value (the winner)

    for reproduction. The number of chromosomes in the set is called tournament size.

    Usually, tournaments are held between pairs of chromosomes (tournament size 2),and the selection process is repeated until a desired size of reproduction set has been

    formed. The tournament selection is ecient, simple to code, has no scaling problem,

    4373Facility layout optimization

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    and is capable of adjusting its selection pressure. This selection method has been

    employed in this work.

    In a facility layout design process based on simulation and genetic algorithm, the

    tness functions are almost always stochastic. The tness value of the chromosome,

    which is the output of a simulation experiment, could be viewed as one realization of

    a random variable whose mean corresponds to the presumed true response. Since the

    selection process is based on tness values, random tness functions cause the selec-

    tion process itself to be random as well. However, the precision of the tness values

    can be improved by replicating the simulation experiment and obtaining a narrower

    4374 F. Azadivar and J. Wang

    +

    +

    + *

    *1 2 3

    54

    6

    cut-point

    12+345+6**+

    +

    + *

    *1 2 3

    54

    6

    (12+) 345+6**

    +

    *

    54

    6

    +

    54

    1 2

    3

    45+6*

    1 2

    3

    45+

    6

    1

    6

    54

    3

    2

    Figure 2. Constructing a layout from its reverse Polish expression.

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    condence interval. The more replications are performed the better will be the accu-

    racy of the solution obtained. Welshs (1938) statistical comparison was employed

    for determining the winners of the tournaments.

    Since simulation experiments are usually very time consuming, a variable number

    of replications per solution are used. This allows us to make fewer replications when

    the dierence in the tness values is relatively large, and to save a larger number of

    replications for points where the signal-to-noise ratio is small. The process for using

    a variable sample size is as follows.

    4375Facility layout optimization

    1 2 * 3 4 5 * 6 + + *

    1 2 + 3 4 5 * 6 * * +

    3 6 1 + 2 5 4 * * * +

    P1

    o

    P2

    Figure 3. Crossover operation.

    m2

    m3m4

    m5

    m6

    *

    *

    *

    +

    +

    1

    2

    3

    5

    4

    6

    m1

    1 (b) Parent 2 p2

    m1 m2

    m3

    m4

    m5

    m6

    *

    *

    *

    +

    +

    1 2 3

    54

    6

    *

    (c) Offspring

    m1

    m2

    m3m4

    m5

    m6

    *

    *

    * +

    +1 2 3

    54

    6

    (a) Parent 1 p1

    Figure 4. Layout after crossover.

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    4376 F. Azadivar and J. Wang

    1

    6

    54

    3

    2

    +

    +

    + *

    *1 2 3

    54

    6

    Parent p1 (12+345+6**+)

    1 2 + 3 4 5 + 6 * * +

    1 2 * 3 4 5 + 6 * * +(a) Altering operation

    4 5

    3

    6

    1

    2

    +

    +

    * *

    *1 2 3

    54

    6

    (b) Offspring o1 after altering

    Figure 5. Altering operation.

    1 2 + 3 4 5 + 6 * * +

    1 2 + 5 4 3 + 6 * * +(a) Inverting operation

    1 2

    5

    4 3

    6

    (b) Offspring o2 after inverting

    +

    +

    + *

    *1 2

    3

    5

    4

    6

    Figure 6. Inverting operation.

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    . The tness values of two chromosomes are rst compared based on ve repli-

    cations of their corresponding simulation models. A test of signicance is

    performed to make sure the dierence between tness values is signicant. Ifso, the chromosome with the inferior tness value is considered the loser and

    does not move on to the next generation.

    . If the dierence is not signicant, one more replication is made for each

    chromosome and the comparison is repeated. This process continues until

    either the dierence becomes signicant (as a result of a reduction in the con-

    dence interval due to the larger number of replications) or a limit of 20

    replications per point is reached.

    3.5. System owchart

    The general owchart of the algorithm is given in gure 8. In the algorithm,

    simulation is considered as a function evaluator, and its output is regarded as the

    tness of the chromosome. The algorithm starts with an initial set of random

    solutions generated by the optimization module. A new generation is formed by

    selecting parent chromosomes from the current generation and modifying them

    with crossover and mutation operators. Then, chromosomes in the new genera-tion are evaluated by simulation, their representation strings and tness are stored

    in a standard data structure called a hashing table, which is very ecient in

    searching for identical elements. In each evaluation process, the hashing table is

    rst probed to nd out if the same chromosome has been tested in previous

    generations; if not, a simulation experiment is run to get the tness value.

    Otherwise, the tness value found in the tness hashing table is simply assigned

    to the chromosome. A similar approach has been employed by Zhang (1997) and

    has shown a signicant reduction in simulation runs resulting in savings of up to

    45% 70% of expensive CPU time. Such benets have been also observed in thisimplementation.

    4377Facility layout optimization

    1 2 + 3 4 5 + 6 * * +

    1 2 + 3 4 5 + 6 * + *(a) Swapping operation

    1 2

    3

    4 5

    6

    *

    +

    + +

    *1 2 3

    54

    6

    (b) Offspring o3 after swapping

    Figure 7. Swapping operation.

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    4. System architecture

    The system consists of a GA package, a simulation package, an automatic

    simulation model generator, and a graphical user interface. The graphical user inter-

    face is used to input the information on workstations and parts, dimensional

    constraints of the shop oor and GA parameters. The simulation is considered a

    function evaluator (objective function). The genetic algorithm systematicallysearches and generates alternative layout designs according to the decision criterion

    specied by the user. The simulation model generator then creates and executes

    simulation models recommended by the GA and returns the results to the GA.

    This iteration between the generator and GA continues until all the chromosomes

    in the generation converge to one structure, or the limit on the number of genera-

    tions to consider (set according to the available time and resources) is reached.

    5. Numerical exampleThe test problem is described as follows: A manufacturing system consists of

    eight workstations, and two lift trucks. Four dierent types of parts come into the

    system randomly with an inter-arrival time following a certain distribution. The

    parts require processing on dierent subsets of eight workstations and have dierent

    distributions of processing times on each operation. Lift trucks are used to move

    parts from one workstation to another according to the pre-dened processing

    sequences for each part type. The area requirements of each workstation are given

    in table 1. Tables 2, 3 and 4 provide more information about the manufacturing

    system. The shop oor is a 90 90 (m) square area. The objective is to nd a freelayout design for the system to result in an overall shorter average cycle time for all

    4378 F. Azadivar and J. Wang

    start

    initial

    population

    converged ?

    end

    yes

    no

    selectionadd one more

    replication

    comparing

    chromosomes

    crossover

    mutation

    update fitness

    table

    evaluation

    significant?

    yes

    no

    search in

    fitness table

    find?

    run simulation

    no

    get fitness

    yes

    Figure 8. Computation owchart of the algorithm.

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    4379Facility layout optimization

    Workstation Length Width Clearance Clearance Total areaidentication (X-axis) (Y-axis) in X-direction in Y-direction required

    1 9 17 1 3 10202 18 18 2 2 2020

    3 26 16 4 4 30204 32 9 8 1 40105 45 28 5 2 50306 16 8 4 2 20107 36 17 4 3 40208 16 9 4 1 2010

    Table 1. Geometric constraints on workstations.

    SpeedNumber (m/min) Policy Capacity

    2 10.0 FCFS 1

    Table 2. Transporter information.

    Part Inter-arrival Batch Maximum Start Total numberidentication distribution (min) size batch time of processes

    1 EXPONENTIAL(12) 1 100 0 42 EXPONENTIAL(14) 1 100 0 43 CONSTANT(8) 1 100 0 34 EXPONENTIAL(14) 1 100 0 4

    Table 3. Parts information.

    Part Part Routing Processing timeidentication name sequences distribution

    1 Part 1 Machine 1 NORM(1,0.5)Machine 4 NORM(1,0.2)Machine 6 NORM(1,0.2)Machine 7 NORM(6,1)

    2 Part 2 Machine 4 NORM(1,0.5)

    Machine 1 CONSTANT(1)Machine 3 NORM(0.5,0.1)Machine 5 CONSTANT(1)

    3 Part 3 Machine 7 NORM(1,0.2)Machine 4 NORM(1.5,0.5)Machine 8 NORM(4,1)

    4 Part 4 Machine 5 CONSTANT(1)Machine 6 NORM(2,0.5)Machine 2 NORM(2,0.5)

    Machine 3 CONSTANT(4)

    Table 4. Routing information.

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    parts. The evolutionary environment for this GA experiment is given as follows. The

    population size is 30, the crossover rate is 0.60, the mutation rate is 0.008, and the

    maximum number of generations allowed is 50. A typical solution (the best chromo-

    some obtained from one pass of the genetic algorithm) is shown as follows:

    2; 1; *; 3; *; 7; 6; *; 4; *; 8; ; 5; *;

    which has an average cycle time of 940.88 minutes.

    This best layout is depicted in gure 9. The evolutionary process is shown in

    gure 10.

    4380 F. Azadivar and J. Wang

    Width90

    Length 90

    80

    80

    m5

    m8

    m4

    m6

    m7

    m3

    m1

    m2

    Figure 9. The llayout of the Example

    Evolutionary Process

    0

    200

    400

    600

    800

    1000

    1200

    1400

    1600

    1800

    1 611

    16

    21

    26

    31

    36

    41

    46

    generation

    cycletim

    e

    averagecycle time

    minimum

    cycle time

    Figure 10. Evolutionary process of GA in obtaining the optimum layout.

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    From the evolutionary process, we can see that before the 11th generation, the

    solution with the minimum cycle time still has a cycle time greater than the nal

    minimum and the whole generation has an average cycle time of above 1200 minutes.

    The worst cycle time found during this period has an average cycle time of 2101.53

    minutes. Under pressure of selection, chromosomes evolve gradually while under theguidance of genetic algorithm the solutions in the search process move slowly to

    some promising regions. The average cycle time improves from the initial value of

    1665.81 to 948.67 in the 20th generation. The solutions in the set converge gradually

    and, after the 25th generation, the variation among the chromosomes in the set

    diminishes and all the solutions converge to only one alternative. As shown in the

    history of the best tness values, the best chromosome is found in the 21st genera-

    tion, with an average cycle time of 940.88, which is less than half of the average cycle

    time that resulted from the worst system.

    6. Comparison of proposed and traditional methods

    As mentioned earlier, in traditional facility layouts, material handling cost is the

    major concern of the layout design. Eort is spent to reduce unnecessary part move-

    ments between workstations. In todays rapidly changing global market, while

    material handling cost remains critical, the development of new products and

    quick customer delivery are playing a key role when competing with other factors.

    Responsive delivery without inecient excess inventory, short manufacturing cycletime, and other practical considerations have strong impacts on the layout design

    and should be incorporated into the layout design process. Since traditional methods

    only consider the volume of materials handled, changing other factors such as the

    number of transporters or processing time on various machines does not aect the

    solution. If the optimum layout does indeed change with the change in these par-

    ameters, it will be an indication of the need for considering the actual performance of

    interest rather than just the volume of material handling. To assess this, experiments

    were conducted to investigate the eects of varying factors, such as the number of

    material handling units and machines capacities, and the changes in the results were

    observed.

    A stable manufacturing system with eight workstations is chosen as a base model,

    in which each workstation has a medium level work loading (utilization between

    30% 70% ). In the rst experiment, the eect of machine performance on layout

    design was studied. The processing speed of a machine was changed while keeping all

    other factors the same. In the second set of experiments, the eect of the number of

    material handling resources on the layout design was investigated by varying the

    number of available lift trucks with all other settings of the manufacturing systemkept unchanged.

    To examine the eect of machines capacities, two slightly dierent manufactur-

    ing systems were chosen and the objective of the optimization process was set as a

    minimization of the average cycle time. Basically, the two models are the same except

    that the processing speed of one of the machines in system 1 is lower than a similar

    machine in system 2. All the other parameter settings (number of simulation runs,

    population size, maximum generation, etc) were kept the same for both systems. The

    experiment showed that the results are dierent for these two systems. Figure 11( a)

    shows this evolutionary process. Obviously, with traditional methods the answer

    provided for both systems would have been the same.

    4381Facility layout optimization

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    Similar tests were conducted with material handling resources. This time the

    manufacturing system was tested with dierent numbers of material handling

    resources. In the two test cases, the number of transporters was varied while all

    other parameters were kept the same. The test results showed that, again the

    optimum layout changed with this change. The evolutionary process for this test

    is shown in gure 11(b).

    7. Conclusions

    This paper presented an approach for solving facility layout optimizationproblems for manufacturing systems with dynamic characteristics and qualitative

    and structural decision variables. The proposed approach integrates genetic algor-

    ithms, computer simulation and an automated simulation model generator with a

    user-friendly interface. Since GA is capable of solving the combinatorial optimiza-

    tion problems, and the simulation is capable of modelling and evaluating the per-

    formance of complex systems, this combination enables us to optimize eciently the

    facility layout design of such systems. The proposed method considers the opera-

    tional policies, resources and time requirements of all aspects of the process toovercome the limitations of traditional layout optimization methods.

    Although this method cannot guarantee an optimum solution, empirical tests indi-

    cate it is able to make considerable improvements in the value of the objective

    function.

    Additional work in this area can improve the performance of the process. In

    particular, to preserve the feasibility of a solution, the search proposed in this work

    uses a particular crossover strategy that allows only the position symbols to trade

    places. Other techniques can be investigated to take full advantage of all crossover

    methods that can still preserve feasibility. Furthermore, other methods of mutation

    can also be investigated.

    4382 F. Azadivar and J. Wang

    0

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    1 11 21 31 41Number of Generations

    (b)

    AverageCycleTimeofthePopulation

    Two Transporters

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    Figure 11. The eect of change in system parameters on the optimum layout.

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    4383Facility layout optimization