PROCESS PLANNING

SYLLABUS
OBJECTIVES:
To introduce the process planning concepts to make cost
estimation for various products after process planning
UNIT I INTRODUCTION TO PROCESS PLANNING
(10)
Introduction- methods of process planning-Drawing
interpretation-Material evaluation steps in process
selection-.Production equipment and tooling selection
UNIT II PROCESS PLANNING ACTIVITIES (10)
Process parameters calculation for various production
processes-Selection jigs and fixtures election of quality
assurance methods Set of documents for process planning-
Economics of process planning- case studies
 UNIT III INTRODUCTION TO COST ESTIMATION (8)
Importance of costing and estimation methods of costing-
elements of cost estimation Types of estimates Estimating
procedure- Estimation labor cost, material cost- allocation of over
head charges- Calculation of depreciation cost
UNIT IV PRODUCTION COST ESTIMATION (8)
Estimation of Different Types of Jobs Estimation of Forging Shop,
Estimation of Welding Shop, Estimation of Foundry Shop
UNIT V MACHINING TIME CALCULATION (9)
Estimation of Machining Time Importance of Machine Time
Calculation- Calculation of Machining Time for Different Lathe
Operations ,Drilling and Boring Machining Time Calculation for
Milling, Shaping and Planning -Machining Time Calculation for
Grinding
UNIT-1 OBJECTIVES
After studying this unit, the student should be able to :
Explain how a product is designed.

Explain the steps involved in process design.

Enumerate the factors affecting process design.

List the types of production and their characteristics.

Distinguish between specialization, simplification and

standardization.
Define process planning and list the steps involved in

process planning.
State what is BOM (Bill of Materials) and its uses.

State the data that will be present in a process sheet, and

the uses of process sheet.

INSTRUCTIONAL OBJECTIVES
Explain Routing and Route Sheet in the context of process
planning.
Calculate man-hrs. and machine-hrs. for a manufacturing situation.
Explain the use of computers in process planning and cost
estimation.
State the two approaches adopted in CAPP (Computer Aided
Process Planning).
Explain what is Retrieval CAPP system and Generative CAPP
system.
Distinguish between Retrieval CAPP system and Generative CAPP
system.
State the advantages of CAPP.
State the factors involving in selecting a particular process.
INSTRUCTIONAL OBJECTIVES
List the factors involved in machine selection.
List the process selection parameters.
State the parameters involved in material selection.
List the documents required for process planning.
Develop manufacturing logic involved in process
planning by studying certain examples.
Select cost optimal process using break-even chart.
Draw a break-even chart given various cost elements.
Work out certain problems involving break-even quantity.
Determine break-even quantity from various cost data
given.
INTRODUCTION
A process is defined as any group of
actions instrumental to the
achievement of the output of an
operations system in accordance with
a specified measure of effectiveness.
PROCESS PLANNINGDEFINITION
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.
DEFINITION
Process planning has been defined as
the sub-system responsible for the
conversion of design data to work
instruction.
PURPOSE OF PROCESS PLANNING
The purpose of process planning is to determine and
describe the best process for each job so that,
Specific requirements are established for which

machines, tools and others equipment can be

designed or selected.
The efforts of all engaged in manufacturing the

product are coordinated.

A guide is furnished to show the best way to use the

existing or the providing facilities.

Process planning is an intermediate stage between
designing the product and manufacturing it
SCOPE OF PROCESS PLANNING
This process leads to the same output
despite organizational differences.
The following are business objectives for
operations planning:
New product manufacture
Sales
Quantity
Effective use of facilities
Cost reduction
INFORMATIONS REQUIRED TO DO PROCESS PLANNING

1. Quantity of work to be done along with product

specifications.
2. Quality of work to be completed.
3. Availability of equipments, tools and personnels.
4. Sequence in which operations will be performed
on the raw material.
5. Names of equipment on which the operations
will be performed.
6. Standard time for each operation.
7. When the operations will be performed?
STEPS INVOLVED (PROCEDURE) IN PROCESS PLANNING
The following are the steps involved in carrying out the process
planning manually. Past experience of process planners are used in
arriving at the economical manufacturing of the product.

The steps involved in process planning are :

(i) The finished product is analyzed so that its sub-assemblies and

individual components are identified from manufacturing point of

view.

(ii) Prepare a Bill Of Materials [BOM] for all components of the product
which forms a basis for purchase of raw materials.

(iii) Decide which parts are to be manufactured in the plant and which
parts are to be purchased from the market depending upon the
facilities available in the plant, i.e., decision with regard to make or
buy to be taken.
STEPS INVOLVED (PROCEDURE) IN PROCESS PLANNING

(iv) Choose the appropriate blank size i.e., raw material size and
select the most economical process to be followed to manufacture
components of the product. This is done by comparing the various
possible methods of obtaining the final product. The basic factors
of volume to be produced, i.e., production quantity, required
quality of the product and the capabilities of the equipment
available are carefully considered in this step.

(v) Decide the sequence of operations to be performed on each

component in the process selected.

(vi) Each operation is assigned to the type and size of machine or

work station that will perform the job most economically.
STEPS INVOLVED (PROCEDURE) IN PROCESS PLANNING

(vii) Depending upon the accuracies called for by the

drawings, determine the machine tools to do the operations
(viii) Determine the need for any special equipment like jigs,

fixtures, cutting tools etc.,

(ix) Determine the inspection stages and instruments

required and the need for designing any inspection devices

(say gauges, etc.).
(x) Estimate the standard time for performing the job.

(xi) Determine the type of labour (skilled, semi-skilled or

unskilled) required to do the job.

Process planning has been traditionally carried out by methods
engineers, manufacturing engineers, industrial engineers or
by process planners
PROCESS PLANNING ACTIVITIES
Concept of Process Planning
The concept of process planning is to determine
1. The operations involved in the manufacture of
each product.
2. The machines on which operations are to be done.
3. The tools, jigs and fixtures required.
4. The material requirements including scrap.
5. The speeds and feeds that are to be used.
6. The type of labour required.
7. The time required for each operation.
 The main objective of process planning is to find the
most economic method of performing an activity
The following information are necessary to carry out
this function effectively:
1. Product data.
2. Volume of production.
3. Quality requirements.
4. Equipment and personnel available.
5. Time available to perform the work or delivery
date.
PREPARING OPERATION PLANNING SHEET
The following informations are required to do the process planning
effectively:
1. Quantity of work to be done along with product specifications.
2. Quality of work to be completed.
3. Availability of equipment, tools and personnel.
4. Sequence in which operations will be performed on the raw
material.
5. Names of equipments on which the operations will be
performed.
6. Standard time for each operation.
7. When the operations will be performed?
8. Cutting speed
9. Feed
10. Material specification.
11. Job rating of labours.
PROCESS PLANNING PROCEDURE
1. Preparation of working drawings.
2. Deciding to make or buy.
3. Selecting manufacturing process.
4. Machine capacity and machine selection.
5. Selection of material and bill of materials.
6. Selection of jigs, fixtures and other
attachments.
7. Operation planning and tooling requirement.
8. Preparation of documents such as operation
sheet and route sheet etc.
MAKE OR BUY DECISION
Make
It requires appropriate production equipment,
suitable personnel, material, adequate space,
supervisions, design standards and overheads
maintenance, taxes, insurances, management
attention and other indirect and hidden costs.
BUY

It permits lower investments, small labour force, less

handling, lower plant cost for building and up keep, less
overhead or taxes, insurance and supervision and less
problems of man-management relations.
A company has a choice of three alternatives before
starting for a new product.
1. Purchase the product from a contracted manufacturer.
2. Purchase some components and materials and
manufacture and assemble the balance in
its own plant.
3. Manufacture the product completely, starting with the
extraction of basic raw materials.
DETERMINATION OF MATERIAL REQUIREMENTS

1. Existing requirements for works on

hand.
2. The new or extra material required.
It is to be calculated from bill of
materials.
3. Total material required.
4. Existing stock of materials.
5. Additional materials to be produced.
SELECTION OF MATERIAL, JIGS, FIXTURES ETC.

The material should be of right quality

and chemical composition as per the
product specifications.
The shape and size of material should
restrict the scrap.
(I) BILL OF MATERIAL
Selection of jigs, fixture and other
special attachments
These supporting devices are
necessary
1. To give higher production rate, and

2. To reduce the cost of production per

piece.
(D) SELECTION OF MACHINERY
The size and shape of the workpiece.
The work material.
The accuracy and surface quality
required.
The quantity of parts.
The sizes of lots required and,
Personal preferences.
(E) OPERATION PLANNING SHEET

A process plan is a complete concept of a process.

It is recorded and transmitted in a number of ways
to suit various conditions.
In a small plant or where skilled workers may be
relied upon to perform without detailed
instructions, process plans may be recorded quite
incompletely.
In a large organization with a complex product
and highly refined procedures, process plans may
be recorded in minute details.
OPERATION PLANNING SHEET