Master Data:

 Master data have to be set up only once when the flexible manufacturing cell is put into
operation and this comprise of System-specific data (related to the architecture of the
system) and Resource master data which includes tool master data and work piece carrier
master data (data relating to the work piece carriers and clamping fixtures)
CLASSIFICATION OF CAPP - VARIANT TYPE AND GENERATIVE TYPE
 A computer aided process planning (CAPP) system aims to integrate design and production
data into a system that generates process plans which are rational, consistent and optimal.
 The two approaches used to generate computer aided process planning (CAPP) are
(i) Variant or retrieval type CAPP system
(ii) Generative CAPP system
 VARIANT PROCESS PLANNING:
 A variant or retrieval type process planning system uses the similarity among components
to retrieve the existing process plans.
 A process plan that can be used by a family of components is called a standard plan.
 A standard plan is stored permanently with a family number as its key.
 Some form of parts classification and coding system is required to organize the computer
files and to permit efficient retrieval of the appropriate process plan for a new work part.
 The user would initiate the procedure by entering the part code number at a computer
terminal.
 The CAPP program then searches the part family matrix file to determine if a match exists.
If the file contains an identical code number, the standard machine routing and operation
sequence are retrieved from the respective computer files for display to the user.
 The standard process plan is examined by the user to permit any necessary editing of the
plan to make it compatible with the new part design.
 After editing, the process plan for matter prepares the paper document in the proper form.
 Flow-Chart of a Retrieval - Type Computer - Aided Process Planning System
 If an exact match cannot be found between the code numbers in the computer file and the
code number for the new part, the user may search the machine routing file and the
operation sequence file for similar parts that could be used to develop the plan for the new
part.
 Once the process plan for a new part code number has been entered, it becomes the standard
process for future parts of the same classification.
 It is easier to find a match in the machine routing file than in the operation sequence file.
 The process plan for matter may use other application programs like programs to compute
machining conditions, work standards and standard costs.
 Standard cost programs can be used to determine total product costs for pricing purposes.

(ii) GENERATIVE PROCESS PLANNING

 Generative process planning is a system that synthesizes process information in order to
create a process plan for a new component automatically.
 In a generative planning system, process plans are created from information available in
manufacturing database without human intervention.
 Upon receiving the design model, the system can generate the required operations and
operations sequences for the component.
 Knowledge of manufacturing must be captured and encoded into efficient software. Other
planning functions such as machine selection, tool selection. process optimization etc., can
also be automated using generative planning techniques.
 Structure of a Generative CAPP System
ADVANTAGES OF CAPP
The advantages of generative process planning are
 It can generate consistent process plans rapidly
 New components can be planned as easily as the existing components
 It can be interfaced with an automated manufacturing facility to provide detailed
and up to date control information
 To generate a more universal process planning system, variables such as process
limitations, and capabilities, process costs etc., must be defined at the production stage.
 Some of the methods implemented for generative process planning are
 Forward and Backward planning
  The input format
 CAD models
 Decision logic
 decision trees
 decision tables
 Artificial intelligence.
AGGREGATE PRODUCTION PLANNING – MASTER PRODUCTION SCHEDULE
(MPS) - CAPACITY PLANNING
 Production planning also called as aggregate production planning, its objective is to
establish general production levels for product groups over next year or so.
 It is based on the sales forecast and is used to raise or lower inventories, stabilize production
over the planning horizon, and allow for the launching of new products into the company's
product line.
 Aggregate production planning precedes the detailed master production schedule.
MASTER PRODUCTION SCHEDULE (MPS)
 The production plan is in turn translated into the master production schedule (MPS).
 The master schedule is a macro level document which sets top-level priorities for what will
be manufactured and when, looking at the material that will be required over the production
cycle.
 The MPS planning period, or horizon, can be of any length, but should be at least as long
as a company's longest cumulative lead time (the time it takes to complete a product from
raw material to finished goods.).