An integrated systematic layout planning, analytical hierarchy process and nonlinear programming approach to facility layout design

This study has three aims: 1) finding alternative layout designs through procedural approach of SLP of a large-scale auto component manufacturer; 2) examine optimality of identified alternatives by using both qualitative and quantitative criteria and ranking them by using AHP method by collecting data from decision-makers of similar 132 manufacturers; 3) identifying most optimal design by using mathematical optimisation model of NLP. Results of SLP provided three prominent quantitative criteria by comparing key performance indicators of four alternative designs with those of existing layout. Informal discussions extracted major qualitative criteria. Rating of all six criteria indicated distance and cost of change being primary influencers. Results of NLP were able to identify one most optimal alternative from feasible four derived from SLP. The study derives its originality by dealing with shortcoming of SLP approach of over emphasis on subjective criteria and of metaheuristic methods of assigning excessive importance to metaheuristic methods.