CH 2 Process Planning

MS3132 Perencanaan Proes dan Ongkos Produksi
Process Planning
MS3132 Process Planning & production cost estimation
Arif Sugiharto, M.T
Prof. Dr. Yatna Yuwana Matawirya
Content
Approaches
03
Activities
02
Definiton
01
Process Planning
Definition
• Process planning has been defined as

• the sub-system responsible for the conversion of design data to work
instruction.
• Process planning can also be defined as
• the systematic determination of the methods by which a product is to be
manufactured economically and competitively.
• It consists of devising, selecting and specifying processes, machine tools
and other equipment to convert raw material into finished and assembled
products.
Process Planning
Design Machine
Tool
Process
Planning
Scheduling and Production Control

Concept of
Process Planning
CAM
CAD Process Planner
• drawing i nterpretation
2-D
• variant type plan generation NC control
Drafting
• i nteractive part programming
2-D • automatic drawing interpretation Automatic part

Drafting • gen. type plan generation programmi ng
• i nteractive drawing interpret ation

3-D CAD canned cut ter
• gen./variant type plan
Model path cycles
generation
• geometric reasoning
3-D automatic part
• expert planner
Solid Model programmi ng
• no human decis ion
• feature refinement
Feature based • l imited geometric reasoning canned/aut o. cutter
solid model • generative pl anning path cycle
• s eq may dictated by design
How do we process engineer?
• How can we make it?

• How much does it cost?
• How long will it take us to complete it?
• How reliable will it be?
• How can we recycle it
How can we make it?
• Is this like something else that we’ve done?

• Yes; What methods were used?
• No; Design a new process

What methods were used?
• Machining methods
• Pressworking
• Welding/fabrication
• Casting
• Powder materials
• Layered deposition
• Others
Welding/fabrication:
Additive techniques
Final Product
Weld Weld
Initial
Add-on Add-on
Stock
Machining Methods:
Subtractive techniques
Final Product
Initial Slotting Drilling
Stock
Casting:
Form Methods
2. Process planning activities
Preparing the process Drawing interpretation

planning documentation 1
8 2 Material evaluation and
Costing process selection
7 PP
Activities
3 Selection of machines and
Selecting quality tooling
assurance methods
6 4 Setting process
Work-holding devices parameters
5
2.1 Drawing Interpretation
• The interpretation of the drawing

will include assessing the part
geometry, dimensions and
associated tolerances, geometric
tolerances, surface finish
specifications, the material
specification and the number of
parts required.
• give some indication of candidate
manufacturing processes
2.2 Material evaluation and process selection
• the materials specified, based on the

availability of manufacturing processes.
• a thorough knowledge of the materials
used in manufacturing is essential for
effective process planning.
For example:
• brittle materials are more suited to casting or
material removal processes.
• not well suited for use with forming
processes
2.3 Selection of machines and tooling
• Typical factors to be considered include the

component size and weight, the physical size and
construction of the machine, and the power and
torque of the machine.
• Another factor to be considered is the number
and type of tools available for the machine under
consideration.
• There are various factors that will be considered
in selecting an appropriate tool including
workpiece material, type of cut, tool material,
machining data and quality/capability
requirements.
For example, all processes and production equipment have an
inherent capability in terms of surface finish. Thus, any
process or production equipment that can't meet the surface
finish specification would be discounted at an early stage of
the selection process.
2.4 Setting process parameters
• These include calculating appropriate

feeds, speeds and depth of cut for each
tool for each operation.
• It is also normal to calculate the time
taken for each operation based on the
part geometry and the speeds and feeds
employed.
• Times taken for non-value added tasks,
such as setting and handling, are also calculate the maximum surface speeds for facing,
established. turning all surfaces and parting off.
• This enables the total time taken for the The maximum spindle speed of the lathe being used is
job to be compiled. 600rpm.
• A major part of this task will be the use of
reference materials such as machine
manufacturer's data and tool
manufacturer's data.
2.5 Workholding devices
• General-purpose
workholders: which include
the likes of chucks and
collets, and
• Specialist workholders:
which are taken to mean
jigs and fixtures.
2.6 Selecting quality assurance methods
• To specify the inspection criteria

for all these critical processing
factors as all manufacturing
processes have some degree of
inherent variability.
• In some cases, the process

planner might be responsible for
specifying the tools and
techniques to be employed to
ensure adherence to specification.
2.7 Cost
• Used to formulate the process

plan itself.
• Establishing relationships
between cost and volume,
decisions can be made about what
material to use, the
manufacturing processes to be
used, the batch size to be
employed and whether to make or
buy a product or component.
• Relative cost data for materials
and processes is used to help
make process planning decisions
2.8 Preparing the process planning documentation
2.8 Preparing the process planning documentation
Flow process
Process Planning Method
Traditional
Manual approach
Process
Planning Workbook
approach
Process
Planning
Variant
Computer approach
Aided Process
Planning Generative
approach
Part Features Identification and Processes Selection
• A wide variety of manufacturing processes are used to

produce a workpiece
• These processes can be classified as:
• Casting processes
• Forming and shaping processes
• Machining processes
• Joining processes
• Finishing processes
25
• Machining processes
• Drilling
• drilling, countering, countersinking, deep-hole drilling, etc.
• Boring
• Tapping
• Milling
• face milling, end milling
• Turning
• facing, straight turning, taper turning, parting, etc.
• Threading
26
• Features that must be considered in selecting

machining processes include:
• part features
• required dimensional and geometric accuracy and
tolerance
• required surface finish
• available resources, including NC machines and cutting
tools
• cost
27
• Part features:
• distinctive geometric form or shape to be produced from raw
material
• it determines process type, tool types (shapes and size),
machine requirements (3-, 4-, or 5-axis), and tool path
• Two types of part features
• Basic features
• simple forms/shapes that require only one machining operation
• include holes, slots, pockets, shoulders, profiles, and angles
• Compound features
• consist of two or more basic part features
• e.g. the combined result of two holes with different diameters
28
Fact!
Several studies have been conducted to investigate the efficiency of

manual process planning methods.
One, conducted by Cincinnati Milacron, reports the results of a study
into the process planning for the production of a family of spur
gears.
For a sample of 425 relatively simple spur gears, there were 377
different process plans (operation sequence and machine groups),
54 different types of machines required, and 15 different materials
utilized.
The plans gave 252 unique combinations of machine tools for
successive operations. The inefficiency arising from this situation
must be obvious to anybody with manufacturing experience
Example: Machining Processes Selection

• Select the machining processes for the part shown in the
figure given in the below
• Assume required dimensional accuracy and surface
roughness are within process capability of drilling and
milling operations.
• The four sides of the raw material have been pre-machined
to required dimensions.
31
Example: Machining Processes Selection (cont.)

Solution:
• Top flat surface
• Outer profile
• Three holes
• Recommended machining processes for features are
• Face-milling: the top surface
• Rough-milling: the outer profile
• Finish-milling: the outer profile
• Center-drilling: the three holes
• Drilling: the three holes
32
Processes Sequencing
Sequence of operations determined by three considerations:

1. Datum surfaces should be machined first if multiple work-
holding setups required
• If possible, datum surfaces should be pre-machined in manually
operated machine to facilitate workpiece locating and clamping
• In cases where  2 holding setups are required:
• rough datum surfaces are preprocessed in a manually operated
machine
• then used as setup references to produce finished datum surfaces for
the final work-holding
• this ensures the accuracy of the finished part
33
Processes Sequencing
Sequence of operations determined by 3 considerations

(cont.)
2. Surfaces with larger area have precedence
• Larger surfaces tend to be more adaptable to disturbances
resulting from machining operations
3. Feature interference should be avoided.
• Feature interference occurs when machining of one feature
destroys a requirement for the production of other features
• This happens when there is interaction or dependency between
machining operations
34
Processes Sequencing:
Example
• The figure shown in the below is a workpiece in which
some features are interrelated.
• The workpiece has five basic features
• a through slot in side C
• two angle strips (strip 1, strip 2)
• two through holes on strip 1 that are perpendicular to side A
• compound features are two tapped holes perpendicular to strip
1
• Develop the process sequence for producing the part.
35
Example (cont.)
Solution:
•The raw material is cut from a block stock with dimensions: 6.25 x 4.25 x
2.25 in
•Studying the part features reveals:
• 2 through holes on strip 1 interact with the formation of angle 
• slot in side C interacts with the cutting of angle β
•Machining angle strip 1 first  difficulty in drilling 2 holes
•  2 holes must be produced before angle strip 1
•Likewise, making angle strip 2 first  difficulty in setting up workpiece to
produce the through slot
•  the slot has to be machined before angle strip 2 is made
36
Example (cont.)
Recommended processes sequence is:
• Setup A for machining side B
• Setup B for:
• machining sides A and E
• also drilling two holes on Side A
• Setup C for:
• machining sides C and F
• also cutting the slot in side C
• Setup D for:
• cutting angle strip 1
• drilling two tap holes and tapping the two holes.
• Setup E for cutting angle strip 2
37
38
Computer Aided Process Planning
CAPP is an interactive system which permits a planner to sit at a

terminal and locate process plans, modify existing plans, or
carry out any other normal process planning operations
without any need to know computer programming
CAPP System
Operations Overview
Process plan in CAPP

ICAPPS
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MS3132 Perencanaan Proes dan Ongkos Produksi

• Process planning has been defined as

Scheduling and Production Control

2-D • automatic drawing interpretation Automatic part

• i nteractive drawing interpret ation

• How can we make it?

• Is this like something else that we’ve done?

• No; Design a new process

Preparing the process Drawing interpretation

• The interpretation of the drawing

• the materials specified, based on the

• Typical factors to be considered include the

• These include calculating appropriate

• To specify the inspection criteria

• In some cases, the process

• Used to formulate the process

• A wide variety of manufacturing processes are used to

• Features that must be considered in selecting

Several studies have been conducted to investigate the efficiency of

Example: Machining Processes Selection

Example: Machining Processes Selection (cont.)

Sequence of operations determined by three considerations:

Sequence of operations determined by 3 considerations

CAPP is an interactive system which permits a planner to sit at a

Process plan in CAPP

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