College of Engineering

Department of Mechanical Engineering

Process planning & product costing (MEng 5322)

L3- Process Planning Methods

Prepared by Gebre F.
Dec. 2022
Learning objectives
Students are able to know

 To differentiate and select the appropriate

process planning method for a part/parts.

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 Process planning methods

❖There are two basic methods employed in process

planning :
➢ Manual process planning
✓ the traditional approach
✓ the workbook approach

Figure- Basic classification of processing planning

Computer-aided process planning (CAPP)
✓ Variant CAPP
✓ Generative CAPP
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Process planning methods contd.
1. Manual process planning method
1.1. Traditional Approach
➢ Approach is carried out in the traditional way
➢ Three broad stages in which the process planner is
involved in the activities:
1. Uses his experience of manufacturing methods,
combined with knowledge of the types of resource
available to decide how the component be made.
2. Refers to manuals to ascertain the company’s
recommended tools, feeds and speeds.
3. Documents- list of all operations (step1) on routing sheets
and methods.
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Process planning methods Contd.
1.2- Workbook approach
➢ It is considered a more efficient and derivative of the
traditional approach.

➢ Pre-determined sequence of operations can be selected

from the workbook and incorporated into the process plan.

➢ Manual process planning is:

✓ largely subjective and

✓ dependent on the skill & experience of the planner

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 Process planning methods Contd.
General Guidelines For Manual Process Planning
➢ General guidelines which can be followed when
preparing the routing sheet include:

✓ Establishing one datum as soon as processing

commences and using this as a reference for all
subsequent operations.
✓ Creating as many surfaces as possible at the same
setting (i.e. without clamping and unclamping) to
maximize dimensional accuracy.
✓ Avoiding the use of secondary surface data as much as
possible.
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 Process planning methods Contd.
✓Precision operations, for example, those producing high-
quality surface finishes, should be carried out last to
reduce the possibility of damage.

✓Inspection operations should be included at appropriate

intervals to minimize scrap (reject) and rework.

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 Process planning methods Contd.
Advantages and Disadvantages of Manual Process
Planning
➢ The advantages of manual process planning:
✓ it is a low-cost task
✓ it is flexible, in terms that the system can be changed
easily
➢ The disadvantages of manual process planning:
✓ Excessive clerical content– excessive paperwork
✓ Lack of consistency in planning- similar parts can be
made differently if carried out by different process
planner.
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Process planning methods Contd.

➢ Late design modifications– manual process planning is

not very responsive to design changes.

➢ Changing technology– manual process planning is not

very responsive to new processes, tooling and materials
that are being introduced more frequently in the rapidly
changing manufacturing environment.

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 Process planning methods Contd.
2. Computer Aided Process Planning (CAPP)
✓ A huge amount of research has been carried out in the
area of CAPP to avoid the limitations of manual process
planning.

✓A huge number of CAPP systems have been developed.

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Process planning methods Contd.
Computer Aided Process Planning (CAPP)
➢ Computer Aided Process Planning (CAPP) is a means of
involving the preparation and documentation of the
process plans for manufacturing of the products using
computers.
➢ The advantages of CAPP systems are:
✓ less time spent on process planning
✓ less reliance on the process planner
✓ more efficient use of manufacturing resources
✓ improved productivity
✓ accurate and consistent process plans
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Process planning methods Contd.

Limitations of CAPP
✓Non-availability
oA fully satisfactory CAPP system is unfortunately non-
existent today!!

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 Process planning methods Contd.
❖ There are two basic approaches to CAPP:
✓ Variant (Retrieval) CAPP Systems and
✓ Generative CAPP Systems
2.1. Variant (Retrieval) CAPP Systems
✓ This approach to CAPP is similar to the manual
approach as it retrieves a standard plan and modifies
it to suit for a given part.
✓ Approach is based on the principles of Group
Technology and parts classification and coding.
 Prerequisites- a large computer database of
standard completed process plans.
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Process planning method Contd.
➢Variant process planning procedures

Figure- Variant process planning procedures

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Process planning methods Contd.

❖Group Technology (GT)

✓Group Technology (GT)- is the realization that many
problems are similar and that by grouping similar
problems, a single solution can be found to a set of
problems thus;

 Saving time and effort.

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Process planning methods Contd.

✓Similar design but different manufacturing attributes

Figure- GT based on design

✓They belong to the same group for the purposes of
design but to different groups for the purpose of process
planning.
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 Process planning method contd.
✓GT- Different design but similar manufacturing attributes

Figure- GT based on manufacturing

✓ Geometrically different parts but similar in processing

steps.
✓ Therefore, they belong to the same group for the purposes
of process planning but to different groups for the purpose
of design.
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Process planning method contd.
✓GT- Different design but similar manufacturing attributes

Figure- GT based on manufacturing

✓They belong to the same group for the purposes of

process planning but to different groups for the purpose
of design.
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Process planning method Contd.
Benefits of GT
✓Reuse of existing design and process plans.

✓Standardization of tools, fixtures and setups.

✓Reduction in material handling and WIP due to the cellular

layout.

✓Higher quality due to job specialization in each group.

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Process planning method contd.
Advantages of Variant CAPP
✓Once a standard plan has been written, a variety of
components can be planned.

✓Comparatively simple programming and installation

(compared with generative systems) is required to
implement a planning system.

✓ The system is understandable, and the planner has control

of the final plan.

✓It is easy to learn, and easy to use.

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Process planning method Contd.
Limitations of Variant CAPP
✓Variant planning is semi-automatic.
✓Experienced process planners are still required to
modify the standard plan for the specific component.

✓It does not exploit recent developments in technologies.

✓It cannot be used in an entirely automated manufacturing

system.

✓The components to be planned are limited to similar

components previously planned.
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Process planning methods Contd.
2.2 Generative CAPP Systems
✓This approach to CAPP is based on developing a
completely new plan for every part.

✓ The plans are produced by the computer using:

▪ Decision logic
▪ Formulae
▪ Algorithms and
▪ Geometric analysis
✓ In theory, there need be no human intervention.
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 Process planning methods Contd.
➢ The main components of a generative system are
✓ A part description that defines the geometry including
geometric and dimensional tolerances and surface finish
specifications.
✓ A subsystem to define the process parameters.
✓ A subsystem which identifies and sequences the individual
operations.
✓ A database of information on the production equipment
available.
✓ A report generator to produce the process plan.

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 Basic process planning terminologies
❖ Process planning comprises the selection and sequencing
of processes and operations to transform a chosen raw
material into a finished component.

❖ The three basic terms employed in process planning for

machining processes are;
1. Process
2. Operation and
3. cut

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Basic process planning terminologies contd.
1. Process
➢ A process is the basic unit for compiling a process plan.
➢It can be defined as a procedure in which one or more
operators machine one or more workpieces on one
machine or workstation.
➢ Examples of this are:
✓ rough turning on a lathe
✓ finish turning on a lathe or
✓ Drilling a hole on a drilling machine

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Basic process planning terminologies contd.
2. Operation
✓An operation is the sub-unit of a process and a process
consists of a number of operations.

✓Each operation is usually accomplished without changing the

cutting conditions or machining parameters.

✓The operations are carried out in a desired order known as

operations sequencing.

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Basic process planning terminologies contd.

3. Cut
✓A cut is the sub-unit of an operation and is a basic part of
an operation.

✓It is defined as a procedure during which the cutting tool

passes the workpiece surface only once.

✓Some operations may require several cuts, under the same

cutting conditions, or in some cases only one cut.

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