Systems and methods for simulation-based resource and layout optimization

Abstract

A simulation-based framework for optimizing resource allocation and layout design is disclosed.

What is claimed is: 
     
         1 . A method for computerized layout-based resource allocation, comprising:
 utilizing at least one processor configured to perform operations associated with a simulation-based optimization framework operable to simultaneously find an optimal layout design for a facility and optimal resource allocation for the facility, including:
 accessing data including a plurality of parameters for generating an initial layout for a plurality of departments of a facility and a resource allocation defining a predetermined number of resources assigned to the plurality of departments of the facility; 
 defining a simulation model comprising a plurality of processes, wherein each of the plurality of processes is handled by a specific set of the predetermined number of resources; 
 applying a layout redesign algorithm to the data to generate a layout redesign, the layout redesign defining locations and sizes for each of the plurality of departments for the facility; and 
 applying a layout improvement algorithm to information associated with the layout redesign to identify possible exchanges to adjacent departments of the layout redesign that minimize material handling cost. 
   
     
     
         2 . The method of  claim 1 , further comprising:
 computing material handling time parameters based on a rectilinear distance between a centroid of each department of the layout redesign, and   applying the material handling time parameters to the simulation model to output a production value for comparison with a predetermined targeted production value to maximize production output for the facility.   
     
     
         3 . The method of  claim 1 , wherein the layout redesign algorithm further includes:
 estimating the sizes based on the predetermined number of resources assigned to each of the plurality of departments and a preassigned space within each department assigned to each resource,   iteratively ranking each of the plurality of departments based on commutation scores computed for the plurality of departments, and   identifying the locations based on the sizes and the commutation scores.   
     
     
         4 . The method of  claim 1 , wherein the data includes a first dataset defining information about dynamicity of worker performance, and a second dataset defining dynamicity of plant propagation such that the resource allocation and the layout redesign consider both dynamicity of human and plant behavior. 
     
     
         5 . The method of  claim 1 , wherein the layout redesign algorithm further includes mapping the locations of the plurality of departments of the layout redesign along the facility, by:
 selecting a first department of the facility; and   identifying a second department to be mapped adjacent to the first department based on a commutation score, the second department having a highest commutation exchange with the first department.   
     
     
         6 . The method of  claim 1 , wherein the layout improvement algorithm further includes:
 evaluating possible modifications to the layout redesign to minimize cost, by completing steps including:
 (i) defining centroids of each of the departments of the layout redesign, and 
 (ii) calculating an initial cost considering inter department rectilinear distances, commute scores, and a quantity of corners in each department; and 
   evaluating a possible exchange of a first department of the layout redesign with a second department adjacent to the first department;   repeating steps (i) through (ii) for departments affected by the exchange to compute an updated cost which improves upon the initial cost,   modifying the layout redesign to reflect the exchange between the first department of the layout redesign with the second department to minimize the cost.   
     
     
         7 . The method of  claim 1 , wherein the layout redesign minimizes material handling time and design impact, the material handling time being a summation over all commutation between different departments of the layout redesign considering a frequency and a distance of each origin-destination pair, the design impact based on a number of corners for each department of the layout redesign to define a realistic design. 
     
     
         8 . The method of  claim 7 , wherein effect of the material handling time and design impact is normalized using a plurality of predetermined weights. 
     
     
         9 . A computing device, the computing device configured to perform operations associated with a simulation-based optimization framework operable to find an optimal layout design for a facility and optimal resource allocation for the facility, the computing device comprising:
 a processor, configured with instructions for executing operations associated with:
 a simulation model defining a plurality of processes and further defining a resource allocation including a specific set of a predetermined number of resources for each of the plurality of processes of a facility, and 
 a plurality of optimization algorithms integrated with the simulation model, including:
 a layout redesign algorithm configured to generate a layout redesign from initial data associated with the facility, the layout redesign defining locations and sizes for each of the plurality of departments for the facility, and 
 a layout improvement algorithm configured to identify possible exchanges to adjacent departments of the layout redesign that minimize material handling cost. 
 
   
     
     
         10 . The computing device of  claim 9 , wherein the predetermined number of resources includes workers or equipment for completing a process or task. 
     
     
         11 . The computing device of  claim 9 , wherein the simulation model using predetermined production objectives and constraints. 
     
     
         12 . The computing device of  claim 9 , wherein the simulation model is formulated considering time and resources available in the facility. 
     
     
         13 . The computing device of  claim 9 , wherein the simulation model is configured to verify if resource allocation for the facility can satisfy a predetermined production threshold in view of the layout redesign. 
     
     
         14 . The computing device of  claim 9 , wherein the plurality of optimization algorithms considers a total number of the departments of the facility associated with plant propagation. 
     
     
         15 . The computing device of  claim 9 , wherein the simulation model controls tradeoff between different transported units passing through the departments of the facility. 
     
     
         16 . A method, comprising:
 configuring a processor to find an optimal layout design for a facility and optimal resource allocation for the facility by providing executable instructions to the processor to perform operations, including:
 accessing data including a plurality of parameters for generating an initial layout for a plurality of departments of a facility and a resource allocation defining a predetermined number of resources assigned to the plurality of departments of the facility; 
 defining a simulation model comprising a plurality of processes, wherein each of the plurality of processes is handled by a specific set of the predetermined number of resources; 
 applying a layout redesign algorithm to the data to generate a layout redesign, the layout redesign defining locations and sizes for each of the plurality of departments for the facility; and 
 applying a layout improvement algorithm to information associated with the layout redesign to identify possible exchanges to adjacent departments of the layout redesign that minimize material handling cost. 
   
     
     
         17 . The method of  claim 16 , wherein the layout redesign algorithm further includes mapping the locations of the plurality of departments of the layout redesign along the facility, by:
 selecting a first department of the facility; and   identifying a second department to be mapped adjacent to the first department based on a commutation score, the second department having a highest commutation exchange with the first department.   
     
     
         18 . The method of  claim 16 , wherein the layout redesign minimizes material handling time and design impact, the material handling time being a summation over all commutation between different departments of the layout redesign considering a frequency and a distance of each origin-destination pair, the design impact based on a number of corners for each department of the layout redesign to define a realistic design. 
     
     
         19 . The method of  claim 16 , wherein the data includes a first dataset defining information about dynamicity of worker performance, and a second dataset defining a dynamicity of plant propagation such that the resource allocation and the layout redesign consider both dynamicity of human and plant behavior. 
     
     
         20 . The method of  claim 16 , further comprising embedding the layout redesign algorithm and the layout improvement algorithm with the simulation model.