Computer Aided Process

Computer Aided Process

Planning
Planning
Dr. Pulak M. Pandey
Dr. Pulak M. Pandey
http://paniit.iitd.ac.in/~pmpandey http://paniit.iitd.ac.in/~pmpandey
Computer Aided Process Planning (CAPP) Computer Aided Process Planning (CAPP)
..Process planning with the aid of computer ..Process planning with the aid of computer
Process planning is concerned with the preparation of route shee Process planning is concerned with the preparation of route sheets that ts that
list the sequence of operations and work centers require to prod list the sequence of operations and work centers require to produce the uce the
product and its components. product and its components.
Manufacturing firms try to automate the task of process planning Manufacturing firms try to automate the task of process planning using using
CAPP systems due to many limitations of manual process planning. CAPP systems due to many limitations of manual process planning.
These includes: These includes:
Tied to personal experience Tied to personal experience
and knowledge of planner of production facilities, equipment, th and knowledge of planner of production facilities, equipment, their eir
capabilities, process and tooling. This results in inconsistent capabilities, process and tooling. This results in inconsistent plans. plans.
Manual process planning is time consuming and slow. Manual process planning is time consuming and slow.
Slow in responding to changes in product design and production. Slow in responding to changes in product design and production.
The experience of manufacturing of different engineers, who are The experience of manufacturing of different engineers, who are likely likely
to retire, can be made available in future by CAPP. to retire, can be made available in future by CAPP.
CAPP is usually considered to be part of CAM, however this resul CAPP is usually considered to be part of CAM, however this results CAM ts CAM
as stand alone system. as stand alone system.
Synergy of CAM can be achieved by integrating it with CAD system Synergy of CAM can be achieved by integrating it with CAD systemand and
CAPP acts as a connection between the two. CAPP acts as a connection between the two.
Readymade CAPP systems are available today to prepare route she Readymade CAPP systems are available today to prepare route sheets. ets.
Computer Aided Design
(CAD)
Computer Aided Manufacturing
(CAM)
CAPP
Synergy results in when CAM is integrated with CAD
to form CAD/CAM systems than a stand alone CAD or
CAM systems. In such a system CAPP becomes a
direct connection between design and manufacturing
Benefits derived from CAPP
Benefits derived from CAPP

Process rationalization and standardization

Process rationalization and standardization

Increased productivity of process planners

Increased productivity of process planners

Reduced lead time for process planning

Reduced lead time for process planning

Improved legibility
Improved legibility

Incorporation of other application programs

Incorporation of other application programs
Preprocessor CAD system
CAPP
Knowledge
Input
Output
Planning rules
Postprocessor
Production planning and
Scheduling
CAPP Model
CAPP Model
CAPP Model
CAPP System Architecture
CAPP System Architecture
CAD System Preprocessor
Machining
Knowledge base
Machining selection
module
Constraint application
module
Process plan
generation module
Constraint
Creation module
Manufacturing
knowledge base
Design approaches of CAPP systems
Design approaches of CAPP systems
Retrieval CAPP systems/ Variant CAPP Retrieval CAPP systems/ Variant CAPP
This has evolved out of the traditional manual process planning This has evolved out of the traditional manual process planning
method. A process plan for a new part is created by identifying method. A process plan for a new part is created by identifying and and
retrieving an existing plan for a similar part, followed by the retrieving an existing plan for a similar part, followed by the
necessary modifications to adapt it to the new part. necessary modifications to adapt it to the new part.
It is based on GT principles, i.e., part classification and codi It is based on GT principles, i.e., part classification and coding. These ng. These
coding allow the CAPP system to select a baseline process plan f coding allow the CAPP system to select a baseline process plan for or
the part family and accomplish about 90% of the planning work. T the part family and accomplish about 90% of the planning work. The he
planner adds the remaining 10% of the planning by modifying the planner adds the remaining 10% of the planning by modifying the
baseline plan. baseline plan.
If the code of the part does not match with the codes stored in If the code of the part does not match with the codes stored in the the
database, a new process plan must be generated manually and then database, a new process plan must be generated manually and then
entered into database to create a new baseline process plan for entered into database to create a new baseline process plan for
future use. future use.
Advantages and limitations of Variant CAPP Advantages and limitations of Variant CAPP
Investment in hardware and software is not much. Investment in hardware and software is not much.
The system offers a shorter development time and lower manpower The system offers a shorter development time and lower manpower
consumption to develop process plan. consumption to develop process plan.
The system is very reliable and reasonable in real production The system is very reliable and reasonable in real production
environments for small and medium size companies. environments for small and medium size companies.
Quality of process plan depends on knowledge and background of Quality of process plan depends on knowledge and background of
process planner. process planner.
Generative CAPP
Generative CAPP

Process plans are generated by means of decision logics, Process plans are generated by means of decision logics,
formulas, algorithms, and geometry based data that are formulas, algorithms, and geometry based data that are
built or fed as input to the system. built or fed as input to the system.

Format of input Format of input

Text input (interactive) Text input (interactive)
Graphical input (from CAD models) Graphical input (from CAD models)

First key: to develop decision rules appropriate for the First key: to develop decision rules appropriate for the
part to be processed. These rules are specified using part to be processed. These rules are specified using
decision trees, logical statements, such as if decision trees, logical statements, such as if- -then then- -else, else,
or artificial intelligence approaches with object oriented or artificial intelligence approaches with object oriented
programming. programming.

Second key: Finding out the data related to part to drive Second key: Finding out the data related to part to drive
the planning. Simple forms of generative CAPP systems the planning. Simple forms of generative CAPP systems
may be driven by GT codes. may be driven by GT codes.

A pure generative system can produce a complete process plan A pure generative system can produce a complete process plan
from part classification and other design data which does not from part classification and other design data which does not
require any further modification or manual interaction. require any further modification or manual interaction.

In generating such plans, initial state of the part (stock) must In generating such plans, initial state of the part (stock) must
be defined in order to reach the final state i.e., finished part be defined in order to reach the final state i.e., finished part. .

Forward or backward planning can be done. Forward or backward planning can be done.

Forward and backward planning apparently appear to be similar Forward and backward planning apparently appear to be similar
but they effect programming significantly. The requirement and but they effect programming significantly. The requirement and
the results in of a setup in forward planning are the results an the results in of a setup in forward planning are the results and d
requirements , respectively, of the set up in backward planning. requirements , respectively, of the set up in backward planning.

Forward planning suffers from conditioning problems; the Forward planning suffers from conditioning problems; the
results of a setup affects the next set up. results of a setup affects the next set up.

In backward planning, conditioning problems are eliminated In backward planning, conditioning problems are eliminated
because setups are selected to satisfy the initial requirements because setups are selected to satisfy the initial requirements
only. only.

The generative CAPP has all the advantages of variant CAPP The generative CAPP has all the advantages of variant CAPP
however it has an additional advantage that it is fully automati however it has an additional advantage that it is fully automatic c
and a up and a up- -to to- -date process plan is generated at each time. date process plan is generated at each time.

It requires major revisions if a new equipment or processing It requires major revisions if a new equipment or processing
capabilities became available. capabilities became available.

The development of the systemin the beginning is a difficult The development of the systemin the beginning is a difficult