Computer Aided

UNIT 3 COMPUTER AIDED PROCESS Process Planning

PLANNING
Structure
3.1 Introduction
Objectives

3.2 Types of CAPP Systems

3.3 Benefits of CAPP
3.4 Differences between Process Planning (PP) and CAPP
3.5 Steps in Automatic Process Planning
3.6 Advantages and Disadvantages of CAPP
3.7 Process Planning
3.8 Summary
3.9 Key Words
3.10 Answers to SAQs

3.1 INTRODUCTION
Computer Aided Process Planning (CAPP) forms an imperative connection between
design and manufacturing operation in the computer-integrated manufacturing (CIM)
environment. A CAPP system aims to automate the generation of process plans so that
functions, such as process selection, tool selection, feature sequencing, and machine tool
selection can be performed without human intervention.
Process planning is a boundary function, (i.e. it lies on the boundary between design and
production) that requires input from both design (i.e. CAD files, etc.) and manufacturing
(i.e. process capabilities, etc.). Because of its position it can serve as a mechanism for
more completely integrating these functions. The rationalisation and standardisation
required to implement a CAPP system can provide useful information on problem
between design and manufacturing. It can also be used to more effectively integrate
information systems.
Objectives
After studying this unit, you should be able to
• understand the concept of computer aided process planning,
• know the different types of CAPP system,
• explain the benefits of CAPP system,
• differentiate between process planning and CAPP system,
• explain the steps in automatic process planning, and
• describe the advantages and disadvantages of CAPP.

3.2 TYPES OF CAPP SYSTEMS

There are two types of computer aided process planning system. These are as follows :
(a) Variant CAPP, and
(b) Generative CAPP.
Variant of Retrieval CAPP 25
Introduction to Process A process planning system that creates new plans by retrieving and modifying a
Planning standard process plan for a given part family. Typically requires input form a
human planner.
Generative CAPP
A process planning system, including a database and decision logic, that will
automatically generate a process plan from graphical and textual information on
the part.

3.3 BENEFITS OF CAPP

Let us try to understand what are the benefits of CAPP. We may list out the following
benefits of CAPP :
(a) Improved rationalisation and standardisation of plans.
(b) Increased productivity.
(c) Reduced time to production.
(d) Increased integration of design and manufacturing.
Implementation of either a variant or generative CAPP system forces a firm/organisation
to standardise their process planning procedures. This standardisation should reduce, if
not eliminate, process planning errors and improve overall plan consistency relative to
manual systems. A variant system attempts to augment the process planners skills, not
replace them. A generative system, on the other hand, could theoretically take over
process planning of simple parts, leaving the planner to denote time to more complex
planning tasks. The increased productive of CAPP systems should also reduce the time
required to move a product into production.
“Fully Automated Factory” or in other words “unmanned factory” has been a major and
long-term goal of the people both from industry and academia for a long time, although
some authorities claim that it is impossible to achieve. CAD and CAM are two of the
most important activities to be amalgamated in a typical automated environment. Due to
developments in computer technology, numerically controlled equipment, robots and
computer controlled automation in CAD and CAM systems, many manual functions have
been automated, thus resulting in reduction of lead times, improvements in production
and improvement in manufacturing quality. However, the full integration of CAD and
CAM systems in industry has not yet been achieved. One of the most important obstacles
to be overcome is the automation of process planning activities that bridges CAD to
CAM. The CAPP was first proposed by Niebel. Schenck supported the CAPP idea of
Niebel by his Ph.D dissertation at Purdue University in 1996. Due to the limitation of
computer hardware and software, the CAPP had not been feasible until the early 1980s.
CAPP is very inclusive and basically consists of the determination of processes and
parameters required to convert a blank into a finished product. The key elements of
process planning include; material selection, operation selection, machine tool selection,
operation sequencing, cutting tool selection, set-up selection and design, etc.
Computer aided process planning accomplishes these tasks of process planners by
viewing the total operation as an integrated system, so that the individual operations and
steps involved in making each part are coordinated with each other and are performed
efficiently and reliably. This process is done with the help of computers.
Today, it has been recognised that Computer Aided Process Planning is the key for
promoting the integration of CAD and CAM systems. It has been seen as the only tool
for removing the slash between CAD/CAM.
Process planning forming the link between CAD and CAM, actually translates the design
language into the manufacturing language. There have been a great number of efforts and
studies to achieve the major goal via CAPP; to effectively integrate the design and
manufacturing, providing the automation and standardisation of the process planning
function. However, it is worth noticing that the industrial use and applications of the
26 developed CAPP systems are quite limited. One of the main reasons behind this lack of
 industrial use is that the process planning is a complicated and divergent task including Computer Aided
many sub-activities from the interpretation of the product data to the tool path planning Process Planning
and CNC part program generation, and between these sub-activities there are many
highly complex and ill-defined relationships. Another reason may be the differences
between the assumed conditions and actual conditions on the shop floor, or unexpected
disturbances, or continuously changing demand, or improved technology. The
performance and applicability of the CAPP systems can be improved by including a
higher number of the actual manufacturing variables and by providing an adaptive
structure to the system.
An ideal computer aided process planning system is shown in Figure 3.1. The system
consists of several modules ranging from feature extraction module to intermediate
surface generation module. Each module may require execution several times in order to
generate optimum process plan. The factors that are taken into considerations in
computer aided process planning are shown in Figure 3.2.

Display Cad Data

1. Surface Identification Base
Module
11. Classification
Module 2.
Material Selection Module Process
Capability
Data Base
3.
Process Selection Module
12. Parameter
Selection Machine
Module 4. Machine Selection Module Data Base

5. Tool Selection Module Tool Data

Base 13. System
Machinability Maintenance
Data Base Module
6. Fixture Selection Module
Material
Data Base
7. End Effector Selection

Standard Time Fixture Data

Data Base 8. Process Sequencing Base
Module

9. Cutter Path Generation End Effctor

Data Base

10. Intermediate Surface

Standard Cost
Data Base Generation Process
Plan File

Figure 3.1 : The Structure of a Computer Aided Process Planning System

The other data required for the generation of process plan are :
(a) Part list and specifications
(b) Annual demand
(c) Accuracy and surface requirement
(d) Shopfloor details – process capabilities
(e) Jigs, fixtures, gauges, etc.
(f) Machining and cost/time data.
plant in form of metallurgic

Accessible machines and

Accessible technological
Resources of production

materials and semi-

their characteristics
finished products

fixtures and their

27
characteristic

Formalised Description
of Machining Part
Introduction to Process
Planning

Figure 3.2 : Activities in Computer Process Planning

3.4 DIFFERENCES BETWEEN PROCESS PLANNING AND

COMPUTER AIDED PROCESS PLANNING
The following benefits of CAPP over manual PP illustrate the differences between
them :
(a) CAPP can systematically produce accurate and consistent process plans
when compared with PP which produces inconsistent results.
(b) CAPP reduces the lead time of process planning whereas PP is more time
consuming.
(c) The skill requirements of process planners are less for CAPP when
compared with manual PP.
(d) It results in increased productivity of process planners.
(e) The application programs such as cost and manufacturing lead time
estimation and work standards can easily be interfaced.

3.5 STEPS IN AUTOMATIC PROCESS PLANNING

The various steps in automated process planning are :
(a) Surface identification
(b) Material selection
(c) Process selection
(d) Machine selection, tool selection and fixture selection
(e) End effector’s selection
(f) Process sequencing
(g) Cutter path generation
(h) Intermediate surface generation
(i) Unit production time cost computation.

3.6 ADVANATGES AND DISADVANTAGES OF CAPP

Advantages
Automated process planning brings about following advantages :
28
 • reduction in process planning time Computer Aided
Process Planning
• reduction in the required skill of the process planner
• reduction in costs due to efficient use of resources
• increased productivity and process rationalisation
• production of accurate and consistent process plans
• maximisation of Just-In-Time performance
Disadvantages
When compared with manual process planning the CAPP systems have few
disadvantages :
• The initial cost of establishing a CAPP system is high when compared
with manual process planning.
• The inability to represent special manufacturing techniques.
SAQ 1
(a) Briefly explain about computer aided process planning systems.
(b) Differentiate between manual process planning and computer aided process
planning.
(c) Mention the advantages and disadvantages of CAPP systems.

3.7 PROCESS PLANNING

Process planning translates design information into the process steps and instructions to
efficiently and effectively manufacturer products. As the design process is supported by
many computer-aided tools, computer-aided process planning (CAPP) has evolved to
simplify and improve process planning and achieve more effective use of manufacturing
resources.
Process planning encompasses the activities and functions to prepare a detailed set of
plans and instructions to produce a part. The planning begins with engineering drawings,
specifications, parts or material lists and a forecast of demand. The results of the planning
are :
(a) Routings with specify operations, operation sequences, work centers,
standards, tooling and fixtures. This routing becomes a major input to the
manufacturing resources planning system to define operations for
production activity control purposes and define required resources for
capacity requirements planning purposes.
(b) Process plans which typically provide more detailed, step-by-step work
instructions including dimensions related to individual operations,
machining parameters, set-up instructions, and quality assurance
checkpoints.
(c) Fabrication and assembly drawings to support manufacture (as opposed to
engineering drawings to define the part).
Manual process planning is based on a manufacturing engineer’s experience and
knowledge of production facilities, equipment, their capabilities, processes and tooling.
Process planning is very time-consuming and the results vary based on the person doing
the planning.
Computer-Aided Process Planning
29
Introduction to Process Manufacturers have been pursuing an evolutionary path to improve and
Planning computerise process planning in the following five stages :
(a) Stage 1 : Manual classification, standardised process plans
(b) Stage II : Computer maintained process plans
(c) Stage III : Variant CAPP
(d) Stage IV : Generative CAPP
(e) Stage V : Dynamic, generative CAPP
Prior to CAPP, manufacturers attempted to overcome the problems of manual
process planning by basic classification of parts into families and developing
somewhat standardised process plans for parts families (Stage I). When a new part
was introduced, the process plan for the family would be manually retrieved,
marked-up and retyped. While this improved productivity, it did not improve the
quality of the planning of processes and it did not easily take into account the
differences between parts in a family nor improvements in production processes.
Computer-aided process planning initially evolved as a means to electronically
store a process plan once it was created, retrieve it, modify it for a new part and
print the plan (Stage II). Other capabilities of this stage are table-driven cost and
standard estimating systems.
This initial computer-aided approach evolved into what is now known as “variant”
CAPP. However, variant CAPP is based on a Group Technology (GT) coding and
classification approach to identify a large number of part attributes or parameters.
These attributes allow the system to select a baseline process plan for the part
family and accomplish about ninety percent of the planning work. The planner will
add the remaining ten percent of the effort modifying or fine-tuning the process
plan. The baseline process plans stored in the computer are manually entered using
a super planner concept, that is, developing standardised plans based on the
accumulated experience and knowledge of multiple planners and manufacturing
engineers (Stage III).
The next stage of evolution is toward generative CAPP (Stage IV). At this stage,
process planning decision rules are built into the system. These decision rules will
operate based on a part’s group technology or features technology coding to
produce a process plan that will require minimal manual interaction and
modification (e.g. entry of dimensions).
While CAPP systems are moving more and more towards being generative, a pure
generative system that can produce a complete process plan from part
classification and other design data is a goal of the future. This type of purely
generative system (in Stage V) will involve the use of artificial intelligence type
capabilities to produce process plans as well as be fully integrated in a CIM
environment. A further step in this stage is dynamic, generative CAPP which
would consider plant and machine capacities, tooling availability, work centre and
equipment loads, and equipment status (e.g. maintenance downtime) in developing
process plans.
The process plan developed with a CAPP system at Stage V would vary over time
depending on the resources and workload in the factory. For example, if a primary
work centre for an operation(s) was overloaded, the generative planning process
would evaluate work to be released involving that work centre, alternate processes
and the related routings. The primary work centre by using an alternate routing that
would have the leas cost impact. Since finite scheduling is still a long way off.
Dynamic, generative CAPP also implies the need for online display of the process
plan on a work order oriented basis to insure that the appropriate process plan was
provided to the floor. Tight integration with a manufacturing resource planning
system is needed to track shop floor status and load data and assess alternate
routing vis-à-vis the schedule. Finally, this stage of CAPP would directly feed
30
 shop floor equipment controllers or, in the less automated environment, display Computer Aided
assembly drawings online in conjunction with process plans. Process Planning

CAPP Planning Process

The system logic involved in establishing a variant process planning system is
relatively straight forward – it is one of matching a code with a pre-established
process plan maintained in the system. The initial challenge is in developing the
GT classification and coding structure for the part families and in manually
developing a standard baseline process plan for each part family.
The first key to implementing a generative system is the development of decision
rules appropriate for the items to be processed. These decision rules are specified
using decision trees, computer languages involving logical “if-then” type
statements, or artificial intelligence approaches with object-oriented programming.
The nature or the parts will affect the complexity of the decision rules for
generative planning and ultimately the degree of success in implementing the
generative CAPP system. The majority of generative CAPP systems implemented
to date have focused on process planning for fabrication of sheet metal parts and
less complex machined parts. In addition, there has been significant recent effort
with generative process planning for assembly operations, including PCB
assembly.
A second key to generative process planning is the available data related to the part
to drive the planning. Simple forms of generative planning systems may be driven
by GT codes. Group technology or features technology (FT) type classification
with a numeric code may be used to drive CAPP. This approach would involve a
user responding to a series of questions about a part that in essence capture in same
information as in a GT of FT code. Eventually, when features-oriented data is
captured in CAD system during the design process, this data can directly drive
CAPP.
CAD/CAM Integration and CAPP Features
A frequently overlooked step in the integration of CAD/CAM is the process
planning that must occur. CAD systems generate graphically oriented data and
may go so far as graphically identifying metal, etc. to be removed during
processing. In order to produce such things as NC instructions for CAM
equipment, basic decisions regarding equipment to be used, tooling and operation
sequence need to be made. This is the function of CAPP. Without some element of
CAPP, there would not be such a thing as CAD/CAM integration. Thus,
CAD/CAM systems that generate tool paths and NC programs include limited
CAPP capabilities or imply a certain approach to processing.
CAD systems also provide graphically-oriented data to CAPP systems to use to
produce assembly drawings, etc. Further, this graphically-oriented data can then be
provided to manufacturing in the form of hardcopy drawings or work instruction
displays. This type of system uses work instruction displays at factory
workstations to display process plans graphically and guide employees through
assembly step-by-step. The assembly is shown on the screen and as a employee
steps through the assembly process with a footswitch, the components to be
inserted or assembled are shown on the CRT graphically along with text
instructions and warnings for each step.
If NC machining processes are involved, CAPP software exists which will select
tools, feeds and speeds, and prepare a NC programs.
CAPP Benefits
Significant benefits can result from the implementation of CAPP. In a detailed
survey of twenty-two large and small companies using generative-type CAPP
systems, the following estimated cost savings were achieved :
(a) 58% reduction in process planning effort. 31
Introduction to Process (b) 10% saving in direct labour.
Planning
(c) 4% saving in material.
(d) 10% saving in scrap.
(e) 12% saving in tooling.
(f) 6% reduction in work-in-process.
In addition, there are intangible benefits as follows :
(a) Reduced process planning and production lead-time; faster response
to engineering changes.
(b) Greater process plan consistency; access to up-to-date information in
a central database.
(c) Improved cost estimating procedures and fewer calculation errors.
(d) More complete and detailed process plans.
(e) Improved production scheduling and capacity utilisation.
(f) Improved ability to introduce new manufacturing technology and
rapidly update process plans to utilise the improved technology.
SAQ 2
(a) What are the three key elements upon which computer-aided process
planning is built?
(b) What are the major objectives of computer-aided process planning?

3.8 SUMMARY
Computer-aided process planning (CAPP) is a relatively new technology that has been
developed to increase the accuracy and productivity of the total manufacturing planning
effort. In this unit we introduced you the CAPP system.
CAPP is a highly effective technology for discrete manufacturing with a significant
number of products and process steps. Rapid strides are being made to develop
generative planning capabilities and incorporate CAPP into a computer-integrated
manufacturing architecture. The first step is the implementation of GT of FT
classification and coding. Commercially available software tools currently exist to
support with minimal cost and risk. Effective use of these tools can improve a
manufacturer’s competitive advantage.
One of the most important steps in converting a design concept into a manufactured
product is process planning. The essence of that task is the creation of a complete
package of information on how to perform the manufacturing process, which may
include work instructions for the shop floor, a bill of material, a quality control plan, tool
planning, and so on. Also, there may be links to other manufacturing systems such as
material requirements planning (MRP), product data management (PDM), time
standards, engineering and manufacturing change control, shop floor control and data
collection systems. In most cases, this initial package of information ultimately
determines the final cost and quality of the product.
Traditionally, manufacturing engineers produced the necessary process planning
documents from scratch using manual techniques. That required the retrieval and
manipulation of a great deal of information from many sources including established
standards, machinability data, machine capabilities, tooling inventories, stock availability
and hopefully, existing practice. The resulting process plan was then manifest in the form
of printed text, lists and drawings.
32
The introduction of computers into manufacturing has certainly made the planning Computer Aided
function more efficient, but there are additional advantages. For one, computers can Process Planning
readily perform vast numbers of comparisons and, therefore, many more alternative plans
can be explored than would be practical in a manual setup. Also, the application of
computers can bring greater uniformity to process planning. Ask ten engineers to develop
a process plan for the same part, and you will probably end up with ten different plans.
Not only does this mean some plans will be better than others, but also that essentially
similar jobs planned at different times will be done differently. However, with the
comparative capabilities brought about by computer-aided process planning (CAPP), it
becomes easier to answer the questions : Which plan best utilises the facility’s
capabilities? Which can be used for estimating future work? Which is best for scheduling
and shop loading? And most important, which plan reflects the best practice based on
past experience?
While CAPP can indeed answer these questions, to be of optimum value, particularly in
larger manufacturing facilities, companies must carefully consider its implementation and
integration with other systems. Here are some factors to think about if CAPP is to
achieve its potential.
CAPP got its start with Group Technology (GT), which was touted as a solution to
manufacturing in an environment of smaller lots and shorter product life cycles. The
underlying principle of GT is relatively simple : Use a well-structured coding and
classification system to identify similar components and processes. Then once “families
of parts” are identified, they can be manufactured with standardised process plans.
Early CAPP systems were based on this general principle, and still are, though there are
now basically two approaches to how systems work – variant and generative. In the
variant approach, a set of standard process plans is established for all the parts families
identified thought GT. Then when a new plans is required, an applicable standard plan is
retrieved and edited to suit the specific requirements of the new part.
In the generative approach, an attempt is made to synthesise each individual part using
appropriate algorithms that define the various technological decisions that must be made
in the course of manufacturing. In a truly generative system, the sequence of operations
as well as all the process parameters would be established automatically, without
reference to prior plans. The costs of setting up such a system are so high, however, that
so-called generative process planning systems have been developed only for specific
operations – selection of feeds and speeds, for example, or for uniform families of similar
parts.
Although some early CAPP systems contained elaborate classification and retrieval
capabilities, coding all parts in a typical manufacturing environment proved to be
unrealistic. It was simply too tedious, time-consuming and expensive. And in time, many
of these systems were used primarily as work processors with some retrieval of standard
texts. Nevertheless, this was a great improvement over the old ways of paper-driven
process planning. It simply lacked the sophisticated retrieval and modification
capabilities of a modern CAPP system.
CAPP is the link between CAD and CAM system. The CAPP system consists of several
modules ranging from feature extraction module to intermediate surface generation
module. Computer aided process planning systems reduce process planning times,
improve consistency, increases productivity, etc. when compared with the manual
process planning systems.

3.9 KEY WORDS

Computer Aided Process : The use of computers to automate the process of
Planning (CAPP) preparing the set of detailed work instructions
required to manufacture a product.

33
Introduction to Process
Planning
3.10 ANSWERS TO SAQs
Refer the preceding text for all the Answers to SAQs.

REFERENCES
Herman W. Pollcak, (1978), Tool Design, Prentice Hall, USA.
Atul Thakur and S. S. Pande, (2006), Web Based Feature Modeling and Process
Planning System for Sheet Metal Components, Proc. 22nd All India Mfg. Technology
Research Dev. Conf. (AIMTDR), IIT Roorke, 20-22 Dec., pp. 297-302.
34
L. J. Devin, J. DeVries, T. Strepple, (2000), Process Planning for Small Batch Computer Aided
Manufacturing of Sheet Metal Parts, Int. Journal of Prod. Research, Taylor and Fransis, Process Planning
UK, V38, n 17, pp. 4273-4283.
Y. K. D. V Prasad and S. Somasundaram, (1992), CADDS – An Automated Die Design
System for Sheet Metal Blanking, Computers and Control Engineering Journal,
pp. 185-191.
K. S. H. Toh, H. T. Loh et. al., (1995), A Feature Based Flat Pattern Development
System for Sheet Metal Parts, Jl. of Materials Processing Technology, Elsevier,
Volume 48, pp. 89-95.
J. C. Choli, B. M. Kim and C. Kim, (1999), An Automated Progressive Process
Planning, Die Design and Working System for Blanking Piercing and Bending of a Sheet
Metal Product, Int. Journal of advanced Mfg. Technology, Volume 15, pp. 485-497.
W. M Sing and K. P. Rao, (1997), Knowledge Based Process Layout System for
Axisymmetrical Deep Drawing using Decision Tables, Computers Ind. Engg, Pergaman,
Volume 32, pp. 299-319.

INTRODUCTION TO PROCESS PLANNING

CAPP is relatively new technology that has been developed to increase the accuracy and
productivity of the total manufacturing planning effort.
35
Introduction to Process First block on Introduction to Process Planning has three units.
Planning
Unit 1 deals with introduction to production planning, process planning and operations
planning.
Unit 2 describes process planning. Process planning involves determining the most
appropriate manufacturing and assembly process and the sequence in which they should
be accomplished to produce a given part or product according to specification set forth in
the product design documentation.
Unit 3 deals with the basics of Computer Aided Process Planning. Types of CAPP
systems, benefits of CAPP and steps in automatic process planning have been also
described in this unit.

COMPUTER AIDED PROCESS PLANNING

Computer Aided Process Planning (CAPP) is an effective technology for discrete
manufacturers with a significant number of products and process steps. Prior to CAPP,
manufacturers used to do basic classification of parts into families and developed
36 standardised process plans for part families. Initially CAPP evolved as a means to
electronically store a process plan once it was created, retrieve it, modify it for a new part Computer Aided
and print the plan. Now CAPP is based on a Group Technology (GT) coding and Process Planning
classification approach to identify a large number of part attributes or parameters. The
course on CAPP consists of four blocks having fifteen units.
First block is an introduction to process planning. In this block, you will study
production planning, process planning and operations planning.
Elements of CAPP have been explained in second block. This block discusses the
importance of CAPP in achieving a fully automated factory. The importance of part print
analysis and the problems associated in understanding the part drawing have been
explained in this block. The important properties influencing the selection of cutting tools
are also described. This block also covers description about various types of materials
used for industry purpose.
Block 3 of this course deals with some of the basics of CAPP analysis. This block
provides descriptions about concepts of tolerances along with various methods of
tolerance analysis. The concepts of capability studies have been explained in this block.
Time calculation method of various machining processes like turning, milling and
drilling have been also discussed with the help of some numericals.
Block 4 deals with implementation of CAPP. The scope of process planning in
machining and other manufacturing process has been discussed. The preparatory stage
and the production stage of the variant process planning have been described. Step wise
procedure for implementation of a variant process planning system has been explained in
this block. Here CAPP for casting and CAPP for welding have been described. In this
block you will also study CAPP for forming, for stamping dies and for drawing dies.

37