Systematic Layout Planning (SLP) for Facility Design

Systematic Layout Planning (SLP)

The Systematic Layout Planning (SLP) methodology provides a common framework for solving facility layout and implementation problems.

Core Elements of SLP

• Product (P): Characteristics of the product being manufactured.
• Quantity (Q): Volume of production.
• Tour (R): The path or flow of materials and products.
• Service (S): Support services required.
• Time (T): Time considerations for production and processes.

The SLP Sequence: Phases of Analysis

The SLP sequence involves a preliminary analysis of production, routes to be used, activity relationships, and more. It is structured into three distinct phases:

Phase I: PQ Analysis and Relational PQ Diagram

This phase involves an analysis of Product-Quantity (PQ) to generate a Relational PQ Diagram. This diagram considers space requirements and available space.

Phase II: Path Analysis and Relational Space Diagram

This phase focuses on a path analysis using the Relational Space Diagram. It evaluates influential factors versus practical limitations to derive potential solutions.

Phase III: Draft Implementation

The final phase involves drafting the implementation plan after selecting the optimal solution from the options generated in Phase II.

Key Concepts in SLP

Product Tour Analysis

Product tour analysis is a crucial aspect of plant layout, reflecting characteristic factors such as:

• Linking of activities
• Operating times
• Assembly flows

It is represented in diagrams illustrating the travel characteristics of each product. For multiple products, joint representations or matrices are often used.

A generic unit, called MAG, is utilized. It relates to the dimensions, cost, and form of the manufactured object, serving as a base value for each product:

MAG = ¼ A (B + C + D + E + F) + A >= ¼ A

• A: Original base value
• B: Volume, density
• C: Form
• D: Endangered
• E: Wear surface state

Relations Between Activities

This concept encompasses productive departments, utilities, and other significant elements. The more activities reflected, the better the analysis. Activities can be grouped into sets.

The primary aim is to link all activities, revealing:

• Whether two activities need to be similar (e.g., based on proximity codes like A, E, I, O, U, X, or color-coding).
• Reasons for proximity or separation (e.g., noise, travel distance, contact requirements).

These relationships are grouped and evaluated in the relational table.

Relational Diagram of Tours and/or Activities (DRA)

This diagram, known as a DRA (Diagrama Relacional de Actividades/Áreas), combines information on product tours and activity relationships. It is typically represented by flows of products.

Relational Space Diagram

This diagram determines the space allocated for each department, sector, or activity. Calculations are performed directly or through standard extrapolations. The DRA is derived by incorporating the allocated spaces for each activity.

Solutions in SLP

While the SLP methodology does not prescribe a specific problem-solving method, it provides a robust framework for evaluating, selecting, and implementing plant layouts. Various resolution techniques are employed, such as mathematical models (e.g., minimax). Commonly used approaches include construction methods, improvement methods, or hybrid strategies. Advanced techniques like general heuristics, graph theory, simulated annealing, and genetic algorithms are also utilized to find optimal solutions.