FACTORY LAYOUT PLANNER:

HOW TO SPEED UP THE FACTORY DESIGN PROCESS

IN A NATURAL AND COMFORTABLE WAY

Antonio Avai(a), Giovanni Dal Maso(b)

Paolo Pedrazzoli(c), Diego Rovere(d)
(a) (b)
Technology Transfer System s.r.l., Milano, Italy
(c) (d)
SUPSI-ICIMSI, Manno, Switzerland
(a)
avai@ttsnetwork.com, (b)dalmaso@ttsnetwork.com
(c)
paolo.pedrazzoli@icimsi.ch, (d)diego.rovere@icimsi.ch

ABSTRACT difficult, so it is best to get it right the first time (Meyers

This paper describes a new tool, named Factory Layout and Stephens, 2000).
Planner (FLP). The FLP is meant to speed up the Thus a need for a new factory planning tool, easy
factory design process and to facilitate the cooperation to use and understand for all the involved actors, is
of heterogeneous actors usually involved in the design, becoming more and more pressing. 3D technology is
simulation and analysis of future or existing layouts. mandatory for such a tool because 3D models look
The idea is to provide an innovative environment where realistic, provide a better understanding of space
people can perform the aforementioned activities in a requirements and can be animated to show the physical
natural, comfortable and creative way, without any flow of materials. Users can have a 360 degrees view of
constraints. In the vision of the authors, this the new factory layout and they can easily see how
requirement points to the massive use of 3D technology factory objects interact, to detect the weakness of the
supported by a new human-computer interaction layout and to reduce the interpretation errors.
solution based on the multi-touch paradigm. The FLP Another key feature is represented by the
provides both 3D and discrete event simulation simulation technology, both 3D and discrete event, that
capabilities, that are key enabling technologies in promotes more informed decisions, before any
speeding up the layout planning process and in finding equipment is installed (Boër et al., 1993).
out the desired solution. A simple test case is reported Last but not less important, the way to interact with
to demonstrate the industrial applicability of the FLP. this tool should be very intuitive, quick and natural
because several actors, with different skills, are
Keywords: layout planning, multi-touch system, 3D involved in this strategic process.
and discrete event simulation. Keeping in mind this context, the Factory Layout
Planner (FLP) was developed with the main aims:
1. INTRODUCTION
Manufacturing facilities are one of the most important 1. To accelerate and simplify the factory layout
strategic elements of a business enterprise. They are process by creating accurate factory 3D models.
expensive and their lifespan is some decades. A 2. To foster the effective collaboration between
properly designed plant layout is an important source of teams.
competitive advantage (Quartermann et al, 1996). 3. To facilitate the human computer interaction.
Planning a factory layout involves deciding where 4. To reduce the time to production of new layouts.
to put all the facilities, machines, equipment and staff in
the manufacturing operation and the way in which This paper describes the main modules and
materials and other inputs (like people and information) technologies used in developing the FLP. It is organized
flow through the operations. as follows: section 2 presents a state of the art about
Traditionally, factory design processes are prone to factory layout planning tools; section 3 describes, in
error (Ding et al, 2010). Relatively, small changes in the details, the architecture and the applications composing
position of a machine in a factory layout can affect the FLP; section 4 provides a real test case and
considerably the flow of materials. This, in turn, conclusions follow.
impacts on the costs and effectiveness of the overall
manufacturing operation. Therefore, any mistake can 2. STATE OF THE ART
lead to inefficiency, inflexibility, large volumes of The state of the art in 3D factory layout planning and
inventory and work in progress, high costs and unhappy simulation for discrete manufacturing is represented by
customers. Changing a layout can be expensive and some big software solutions, generally, classified as
PLM (Product Lifecycle Management) that provide a
support from the product to the process design and • To provide 3D and discrete event simulation
management. in a smart way.
The major references are: Dassault Systemes – • To guarantee a natural interaction.
Delmia and Siemens - Tecnomatix, which support both • To allow the collaboration between different
layout design and simulation and integrate modules for actors also remotely placed.
task programming and production process management. • To interface with other CAD systems.
These suites require technical capabilities, training • To provide some basic drawing functions.
courses, changes in the mindset of the involved people,
changes in the processes and, sometimes, in the The next paragraph will describe in details the
company organization that can discourage small or innovative aspects of the FLP.
medium enterprises. Another popular suite is Autodesk
– Factory design suite, that allows integrating 2D layout 3. FLP OVERVIEW
data with 3D models, but here the simulation feature is The FLP is not a single program but a suite of
still missing and it requires people with some CAD applications built on top of a set of common libraries.
skills. Finally, Visual Components supports 3D These applications are targeted at different users and
components programming and assembly for an easy contexts and can speak with each other, share
layout design, while simulation requires some specific documents and data thanks to the client/server
programming competences. architecture. The main common libraries are:
On the market, there are other small solutions more
oriented to discrete event simulation but with some 1. The collaborative engine, that allows multiple
features meant to support 3D animation. A first example users to act at the same time on the same
is Flexsim simulation, that allows to drag and drop 3D layout in a local or distributed environment.
objects, but requires consistent programming 2. The 3D visual engine, that provides the user
capabilities. Another example is Arena, where a “look- interface to edit the layout.
like 3D” layout creation is supported by an additional 3. The simulation engine, that enables to perform
module. Last we mention Simio, that allows to generate discrete event simulation (DES) on the layout
2D and again “look-like 3D” layouts. For those tools, that the user is composing.
simulation is focused only on the 2D objects. And again
all these tools require skill and know-how in simulation The FLP suite and its main technologies are
modelling and programming. described in the following subsections.
Several research works have been proposed over
the last decades addressing the benefits of using 3.1. FLP architecture
simulation during the design of new layouts for discrete The FLP is based on a two-level architecture with a fat
manufacturing (Avai et al., 2011, Kyle et al., 2008, client: the server is mainly a synchronization manager
Voorhorst et al., 2008). Some of them describe the and a repository. The documents are required data (e.g.
development of specific applications to facilitate the use catalogue of available components, results of
of such models or the results' interpretations (Fagent et simulations) and are stored on the server. The client
al., 2005). While Mert (Mert, 2005) investigated how applications can connect to the server to get all the
simulation helps in finding out the most performing needed data and to edit the layout. The used protocol
new layout when different techniques and principles are was optimized to minimize network traffic and to be
applied. tolerant of network delay, allowing a seamless remote
Additionally, the factory layout planning is editing experience. The FLP server is targeted at IT
considered in several European projects. “EuroShoe” staff and should run on server computers.
project studied “ad hoc” solution for mass customized Thanks to client/server architecture, the
production plants; “Difac” (Digital Factory for Human collaboration on the layout planning can be both remote
Oriented Production) was focused on the planning of and local. While the first allows users, distributed all
generic manufacturing factories and “Eupass” over the world, to cooperate in the layout creation, the
(Evolvable Ultra-Precision Assembly Systems) dealt latter allows users to act on the same device at the same
with the layout configuration of a work cell. time on a common model.
FLP should inspire the creativity of the team as
well, because, according to Harron (Harron et al., 2008) 3.2. FLP Desktop
the design of a new layout requires both art and This is the main application targeted at the users who
technology. It’s not only an application of technology, design, refine layouts or perform 3D and discrete event
but it’s also a creative process. simulation. It is mostly composed by a catalogue
The main features of the FLP can be described as browser and a 3D editing window. Clearly, the 3D
follows: components’ models can be imported from a CAD
system and saved in the catalogue. Each company can
• To allow planning all the components in a create its own catalogue. With very simple operations,
comfortable, intuitive and creative way. such as drag-and-drop or copy-and-paste, users can
place layout elements, features and equipment in the 3D
editing window on a user-defined grid, dragging them The layout editing in the traditional CAD systems
from the catalogue. They can also add columns, doors, is generally targeted towards the needs of technicians to
windows, fences, etc., in order to recreate the actual prepare the executive drawings. The FLP is meant to be
available space and to organize it in the best way. The used by a wider range of end users with different aims.
“snap to 3D grid” allows users to place equipments For instance, when a user places a component on the
easily. All the components in the catalogue are grid, it should connect itself with the nearest
parametric, enabling re-shaping at the time of components if needed, and it should communicate with
placement. The 3D editing window provides advanced the others. In this way, the material flow is generated in
capabilities, such as: direct manipulations, move, an automatic way: the components are animated in
alignment, mirroring, offset from object and snap in order to visualize their paths as well as their machining.
order to speed up the process of creating a first layout This gives a visual cue of how the layout will work,
and rapidly change the space organization when the both for technical analysis and commercial
factory layout evolves. presentations.
Moreover, users can define the material flows and These requirements were addressed combining
dependencies between the resources. several resources describing each component:

3.3. FLP Multi-touch • A geometrical 3D representation of the

The multi-touch application is a customized interface of component composed of coloured meshes and
the Desktop application tailored to work with touch a kinematic description.
devices. • A DXF drawing is used for the executive 2D
According to Wikipedia, “multi-touch refers to the layout, and it also provides the clutter of the
ability to simultaneously detect and fully resolve 3 or foundation.
more distinct positions of input touches”. In fact, this • A logical description of the component in
application can manage up to 32 simultaneously terms of ports (inputs/outputs) and parameters.
touches. This means that, in a very natural way, • A program (written in JavaScript or in custom
multiple users can interact on the same layout at the DSL under development) implementing the
same time to organize better the space, to move behaviour.
components, to plan a new factory layout. Furthermore,
the multi-touch application allows technicians, Each application can access only the required
managers, salesmen and stakeholders to interact with resources of a component. For example, the
the FLP with a very intuitive touch interface without visualization engine can display the 3D meshes; the
using any traditional input device such as keyboard or simulation engine can execute the behaviour program.
mouse. Nevertheless, changes to one aspect of a component are
This touch interface exploits new paradigms of reflected to the other aspects. For instance, if a
human-computer interaction: while single or double component is linked to another in the 3D window, this
touch devices are becoming common nowadays, multi- affects DES, creating a connection between the
user interaction managed by a multi-touch interaction is respective input and output ports.
genuinely innovative and can dramatically improve the
touch experience (Ramanahally et al., 2009). The main 3.5. FLP Simulation
challenges to build such a user interface are: The simulation is another core application of the FLP:
1. Multi-user aware widgets (i.e. buttons, input the basic idea is to combine 3D simulation with DES.
boxes, check boxes, menus), because These technologies are fundamental in planning a
traditional GUI has a single focused layout, because, at macro level, manufacturing can be
component, while in the FLP, many users can represented as “material in – process – material out”.
play with different widgets at the same time. Understanding the processes and the production
2. Adjustable widgets, all the people around a sequences helps to ensure efficient manufacturing and
table can interact from their position, so the control costs. DES allows to analyze the material flow
widgets have to be represented with the right and the resources' allocation at plant level (Voorhost et
orientation. In the traditional GUI, they have al., 2008), while 3D simulation allows to optimize the
only one orientation. layout and the relative process at workcell level (Schenk
et al., 2005).
3.4. FLP Layout editing From a technological point of view, each
The layout editing was designed to address the component has a set of input and output ports that are
following main needs: connected to each other to define the material flow and
resource dependencies. Along these ports, the
1. The generation of executive 2D layout components can send and receive signals that can be
drawings. primitive types such as integer or double values but also
2. The smart creation of simulation models. complex structures. Every time a new signal is
3. The preparation of commercial presentations. published to the output port, it is propagated to all the
connected input ports. In this way, the components can
react to changes in the status. Moreover, the Outfeed conveyors
components’ logic can schedule a task to be executed
after a predetermined time delay or when a certain
condition is met. Cartesian robot
The logic that defines the behaviour of a
component is handled by a program executed inside an Control station
interpreter. It gives virtual access to the complete layout
and its associated resources. It is possible, for example, CNC drilling and
to change the colour of the geometry of a downtime routing work
machine, to move a beam on the roller conveyor, etc.. centre of panel
The program controlling the behaviour of the side
component can be written in JavaScript, using an API to
access and define the required interfaces, or a DSL
(Domain Specific Language) that is currently under
development. The DSL will be similar to a state chart Reversing device
diagram and it will allow creating and editing the
program visually. A set of predefine behaviour will be Brushing machine
provided for common components such as sources,
sinks, buffers, conveyor transports and so on. CNC drilling and
routing work
centre
4. REAL TEST CASE
This paragraph describes a simple real test case. It is
meant to test some features of the FLP prototype and to Cartesian robot
demonstrate its industrial applicability.
This test case deals with an existing woodworking Infeed conveyors
plant making panel doors for the furniture industry. It is
composed by two identical and parallel processing lines Figure 1: The layout of the plant
as shown in Figure 1.
Each line is equipped with: All the 3D models of the layout components were
imported from a CAD system but their level of detail
• A CNC drilling and routing work centre (see was even too high for this scope. Thus there was the
Figure 2). need to simplify the 3D models trimming minor details
such as screws, bolts, electric wires, and, sometimes,
• A brushing machine.
reducing the number of triangles of holes, cylinders, etc.
• A reversing device.
Figure 2 shows the result of this simplification applied
• A CNC drilling and routing work centre of to the routing work centre. Unfortunately, this step
panel side. cannot be completely automatized (some automated
• A control station. procedures are in place, but human intervention is still
required) and it is very time consuming. However, it has
Looking at Figure 1, the material flows in the to be done once, and then the model can be used as
bottom-up direction. many times as needed in several different layouts.
At the beginning and at the end of these two lines Eventually, the kinematics has been added to the
there are two Cartesian robots in charge of loading and machines and work centres whose movements have to
unloading the wooden boards. Identical panel doors, be represented. These 3D models were saved in a
requiring the same processes, are stacked up on the proprietary XML format along with the other required
infeed roller conveyors. A single panel is picked by a information, and then imported in the catalogue of the
robot and put on the processing line. Each panel is FLP.
machined at the routing work centre and then it’s
brushed by the brushing machine. When needed, it is
turned upside down and comes back to the first centre,
otherwise, it goes on through the drilling and routing
work centre, where the panel sides are worked.
Eventually, each panel is checked at the control station
and then it is unloaded by the robot and put on the
outfeed roller conveyor.
 Table 1: Number of triangles for all the components of
the final layout
Total
Component Triangles #
triangles
Cartesian robot 174.624 2 349.248
Drilling and routing
616.481 2 1.232.962
work centre
Brushing machine 4.732 4 18.928
Reversing device 313.744 2 627.488
Drilling and routing
work centre of panel 23.624 2 47.248
side
Roller conveyor_1500 6.576 4 26.304
Figure 2: CNC drilling and routing work centre
Roller conveyor _4000 8.644 10 86.440
The FLP, with a filled catalogue, is now ready to Roller conveyor _4000 9.272 2 18.544
be tested by the plant designer along with the process Control station 9.552 2 19.104
manager working for the same company. Their goal is
Total 2.426.266
to re-create the existing woodworking plant, starting
from scratch using the FLP provided with the multi
touch feature. A very short training was made before As far as it concerns the multi-touch interface, it
starting the test case. The touch interface makes the was perceived as really immediate and comfortable in
layout creation very easy and intuitive and the team is creating the layout. Only the view orientation lacked
more concentrated on the component placement than on intuitiveness. Sometimes, it’s not instantaneous to
understanding how to use the new tool. understand how to move the fingers on the monitor
Figure 3 shows the result of the planning of the surface in order to get the desired 3D view. This
woodworking plant. functionality has to be further investigated in order to
improve its usability.
Other concerns, arisen during this testing phase,
regarded the accuracy in the component positioning and
sizing.
Even though the kinematic simulation application
is currently under development and thus not fully
accessible for inexperienced users (as it still requires a
great deal of programming), an IT expert worked it out
in order to reproduce the panels’ movement through the
plant as well as their machining at the work centres.
The simulation of material flow and machines
Figure 3: The final layout provides an added value, as expected, because it allows
checking for bottleneck, collisions, etc., providing also
The feedbacks gathered were positive in relation to some overall performances of the plant. The animation,
the interface and the simplicity in creating a new layout along with the simulation results, eases the discussion
and they appreciated the FLP speed during the walk- about the changes to apply to the layout in order to
through. This test ran on a standard desktop PC, even increase its performances. An alternative solution was
though the total number of triangles of this plant was analyzed, as shown in Figure 4, where a new line was
about 2,5 millions. Traditionally, CAD models are added just with a simple copy and paste operation.
challenging to be visualized at interactive frame rates The first impression about 3D animation was
(~30 fps) on a normal hardware. Mesh simplification is positive as well, and the company was surprised about
a common used technique to reduce the number of the realistic level of the animation.
triangles but to keep an acceptable level of constructive
details only topology-preserving simplification
algorithms can be applied (Luebke et al., 2002).
Research specific for CAD models have highlighted
that at least 2K triangles are needed to display a single
mechanical component (Tang et al., 2010). Table 1
shows the number of triangles needed to visualize each
component of the layout with an acceptable level of
detail.
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ACKNOWLEDGEMENT D. and Anagnost, C., 2009. Sparsh UI: A Multi-
This work has been partly funded by the European Touch Framework for Collaboration and Modular
Commission through NMP Project DOROTHY: Design Gesture Recognition. Proceedings of the World
Of customeR dRiven shOes and multi-siTe factorY Conference on Innovative VR 2009. Chalon sur
(No. FP7-NMP-2007-SMALL-1). The authors wish to Saone (France).
acknowledge the Commission for their support. We also Schenk, M., Strassburger, S., Kissner, H., 2005.
wish to acknowledge our gratitude and appreciation to Combining virtual reality and assembly simulation
all the DOROTHY project partners for their for production planning and worker qualification.
contribution during the development of various ideas Proceeding of CARV 2005, pp. 411-414. Munich
and concepts presented in this paper. (Germany)
Tang Y.; Gu H.; 2010. CAD Model's Simplification and
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AUTHORS BIOGRAPHY
Antonio Avai is a partner and technical director of
Technology Transfer System, an IT company located in
Milan. He has managed research programs with the
focus on methodologies and leading information
technologies to support all the life cycle of
manufacturing processes. He has more than 15 years of
experience in discrete event simulation and its
integration with other software tools and technologies,
and has authored several papers on these topics.

Giovanni Dal Maso is a partner and technology

consultant of Technology Transfer System. His interests
include simulation, computer graphics, multi-touch
devices, mobile and cross-platform development. He
has been responsible of software development in several
EU founded projects and managed the exploitation of
the results into commercial products.

Paolo Pedrazzoli works for SUPSI, as responsible for

the Bachelor of Science in Industrial Engineering and
for the Master of Science in Precision manufacturing.
There, he also acts as coordinator of two EU funded
project. Additionally he participates in several National
funded and EU funded projects. His field of interest lays
in Lean Manufacturing, Assembly Systems, 3D
simulation and CAx.

Diego Rovere works as a researcher for SUPSI. He is

responsible of the development group of applied
Simulation and professor in the Master of Science in
Precision manufacturing. He participated to several EU
founded projects managing software development. His
interests are concentrated on 3D simulation engines, CN
integration and real time physics simulation applied to
manufacturing environments.