ComputerIntegrated

ufacturing Systems
Manfacturing,

2.14
PLANNING (CAPP)
2.5. CoMPUTER AIDED PROCESS planning,
the compute
computer.
process
manual
the of
In order to overcome drawbacks

aided process planning (CAPP) is used. reduce he

the routine
can
one
planning,
With the use of computers in the process
clerical work of manufacturing engineers.
consistent and
opimal plans,
to generate
rational,
AISO it provides the opportunity
CAN
CAM.
CAD and
In addition, CAPP provides the interface between

2.5.1. Benefits of CAPP

The benefits ofimplementing CAPP include the followin8
leads to more 1ogical and
standardization: CAPP
.Process rationalization and
consistent process plans than manual process planning
result of standard process plan, the|
2. Productivity improvement: As a

productivity is improved (due to more

efficient utilization ofresources such as
nmachines, tooling, stock material and labour).
3. Product cost reduction: Standard plans tend to result in lower manufacturing

costs and higher product quality

4. Elimination of human error

5. Reduction in time: As a result of computerising the work, a job that used to

take several days, is now done in a few minutes.

6. Reduced clerical effort and paper work

7. Improved legibility: Computer-prepared route sheets are neater and easier to

read than manually prepared route sheets.

8. Faster response to engineering changes: Since the logic is stored in the

memory of the computer, CAPP becomes more responsive to any changes in

the production parametersthan the manual method of process planning.

9 Incorporation of other application programs: The CAPP progra can be
interfaced with other application programs, such as cost estimating and wor
standards.
 Process Planning 2.15
Computerised
and Control &
Planning
Production

2.5.2.
Approaches ofCAPP CAPP system
are:

approaches or types of
The two basic
and
CAPP system,
1. Retrieval (or variant)
CAPP system.
2. Generative

RETRIEVAL (OR VARIANT) CAPPSYSTEM

2.6.
variant CAPP system, has been widely
CAPP system, also called
a
A retrieval
used in machining applications.
have similar
the retrieval CAPP is
that similar parts will
The basic idea behind
process plans.
plan for a new part is
created by recalling, identifying
I n this system, a process
and making the necessary
and retrieving an existing plan for a similar part,
modifications for the new part.

. 6 . 1 . Procedure for Using Retrieval CAPP System

A retrieval CAPP system is based on the principles of group technology (GT) and
parts classification and coding. In this system, for each part family a standard process

plan (i.e., route sheet) is prepared and stored in computer files. Through classification
and coding, a code number is generated. These codes are often used to identify the
part family and the associated standard plan. The standard plan is retrieved and edited
for the new part.
Fig.2.6 illustrates the general procedure for using one of the retrieval CAPP
systems.
2.6.2. Advantages of Retrieval CAPP System
The retrieval CAPP has the
following advantages:
Once a standard plan has been written, a variety of parts can be planned.
witn
Comparatively sinple programming and installation (compared w
Benerative CAPP systems) is reqüired to
implement a planning sys
T h e system is understandable, and the planner has control Or unc plan.
iv) It is easy to learn
and easy to use.
 C o m p u t e r I n t e g r a t e a M u n y l

2.16
New part design

Preparatory
Derive GT code
number for part stage

Select coding
system and form

H
Search part p a r t families
Part family file
family file for
GT code number
Prepare standard

process plans for

Retrieve standard H Standard process part families
plan file
process plan

Edit existing
plan or write
new plan

Other application
Process plan programs such as

L formatter cost estimating and

work standards

Process plan
(route sheet)

Fix. 2.6. General procedure for using one of the retrieval CAPP systems
2.6.3. Drawbacks ofRetrieval CAPP System
The retrieval CAPP system has the following drawbacks:
i The components to be planned are limited to
similar components
planned.
previously
ii) Experienced process planners are still required to modify the
for the specific component. standard plan
Note 1. The retrieval CAPP system has the
capacity to alter an
it is also known as variant CAPP system, existing process plan.
an. That' why
That' w
The commercially availabie rerieval CAPP Systems are
MultiCapp and MIPLAN.
Production Planning
and Control & Computerised Process Planning 2.17

2.6.4. Some Commercial

Variant CAPP Systems
variant CAP systems are available. Table 2.2
There are many commerc1al
CAPP systems that are available commercially
some of the variant
Summarizes
David D.Bedworth et al.].
Source: commercial variant CAPP systems
Table 2.2. Some =

Part data Planning functions

Decision logic
System n a m e Company inputfrom
Standard plans Process sequence
Metcut Code
CUTPLAN and decision Materials
tree Machines
Tools
Fixtures
Feeds and speeds
Standard plans Process sequence
CAM-I Code
CAPP Standard plans Process sequence
COMCAPP V MDSI Code Process sequence
CAM Lab | Interactive part Decision tree
DCLASS Materials
BYU description Machines
Tools
Interactive part Decision tree Process sequence
INTELLICAP Cim Materials
Telligence description
Machines
Tools
Decision tree Process sequence
Maynard Interactive part
MAYCAPP Materials.
description
Machines
Tools
Standard times

Speeds and feeds

selected. The major function of the
Decision logic detérmines how a process or processes are
decision logic is to match the process capabilities with the design specification.
and display complex decision logic in
TDecision tree is a system/logic tool to bring together, analyse,
be readily grasped.
such a way that its meaning can
2.7. GENERATIVE CAPP SYSTEMS
I n the generative approach, an automatic computerised system is used to
synthesize or generate each individual process plan automatically and witho
reference to any prior plan.
The automatic computerised system normally consists of decision logic, formulas,
technology algorithms, and geometry based data to uniquely determine the many
processing decisions required for generating process plans.
 Computer Integrated Manyfacturing .
2.18
plans are nre,
Inlike the
retrieval CAPP, no standard manutacturing

automatically generates
a unique
predefined,ed o
unique operatior
Instead,
stored.
the computer

whenever the part is ordered.

nWroute
sheet
the process plan based on de
Thus generative
a
CAPP system generates
of manufae
stores the rules of manufacturir decision
algorithms. The computer
logics and pre-coded plans).
capabilities (not any group of process
and the equipment
for specific part can be gene..
using a system, a specific process plan a
eratet
When
involvement of a process planner.
without any

running the system includes: (i) inputting

the GT code th.
ofthe
The human role in
the function.
given part design, and (i) monitoring
CAPP System
2.7.1. Components of a Generative
The various components of a generative system are:
of componentseries characteristics,
(a) A part description, which identifies a
and surface condition,.
including geometric features, dimensions, tolerances
(b) A subsystem to define the nachining parameters, for example using look-
up tables and analytical results for cutting parameters.
(c) A subsystem to select and sequence individual operations. Decision logic
is used to associate appropriate operations with features of a component,
and heuristics and algorithms are used to calculate operation steps, times
and sequences.
(d) A database of available machines and tooling.
(e) A report generator which prepares the process plan report.
2.7.2. Structure of a Generative CAPP System
Fig.2.7 illustrates a typical modular structure of a
generative CAPP system.
2.7.3. Advantages of
The
Generative CAPP
generative CAPP has the
following advantages:
) It can generate
consistent process plans rapidly.
Gi) New
components can be planned as easily as
in) It has
potential for integrating with an existing components.
provide detailed control automated manufacturing facility
information.
 and Control & Computerised Process Planning
Production Planning 2.19
Start

New Old
New/
old

Component representation Copy existing part-

module geometry file to
geometry file
Geometry - Code generation
Part geometry creation
No Yes
Edit
YIN
Editing
module

Operation extraction
sequencing module

Operation selection
Intermediate process dimensions
computations
Operations sequencing
Machine
Material
Machine tool selection module
Tool
- Machine selection Machinability
Process selection
Tool selection

Standard time and cost

Standard
Computation module
time
Idle time/machine time calculation library
Cost calculation

Report generation module

Editing
Modification
Printing

Process chart

Fig. 2.7. Structure of a generative CAPP

system
2.7.4. Drawbacks of
Thene generative approachGenerative CAPP System
is complex
and very difficult to develp.
2.20
Computer Integrated Manufacturing Sy
systemy
2.7.5. Some Commercial Generative CAPP
Systems
Several commercial and experimental generative CAPP
systems have ha
developed. Table 2.3 summarises some of the commercial generative CAPPP syster
systen
Source: David D. Bedworth et al.].

Table 2.3. Some commercial generative CAPP systems

System name Decision
Author Part data input Planning functions
logic
AUTAP Evershiem, Part description Decision Sequence of operations
Fuchs, and approach table Process plan output
Zons
CMPP Sack Part description Decision Sequence of operations
approach model Tolerance control
operations
Reference surface
selection
Process plan output
GENPLAN Tulkoff Group Decision
technology model
|LOCAM Logan Part description
approach
OPTA-PLAN
99

MGS