The Open Loop Layout Problem (OLLP) seeks to position rectangular cells of
varying dimensions on a plane without overlap, minimizing transportation costs
computed as the flow-weighted sum of pairwise distances between cells. A key
challenge in OLLP is to compute accurate inter-cell distances along feasible
paths that avoid rectangle intersections. Existing approaches approximate
inter-cell distances using centroids, a simplification that can ignore physical
constraints, resulting in infeasible layouts or underestimated distances. This
study proposes the first mathematical model that incorporates exact
door-to-door distances and feasible paths under the Euclidean metric, with cell
doors acting as pickup and delivery points. Feasible paths between doors must
either follow rectangle edges as corridors or take direct, unobstructed routes.
To address the NP-hardness of the problem, we present a metaheuristic framework
with a novel encoding scheme that embeds exact path calculations. Experiments
on standard benchmark instances confirm that our approach consistently
outperforms existing methods, delivering superior solution quality and
practical applicability.