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manufacturing planning.
 The information and documentation that
constitute the design of the product are
considered in the manufacturing planning.

 The Departments in the organization that

perform manufacturing planning include
manufacturing engineering, industrial
engineering, production planning and process
planning.

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Process planning with Design
Manufacturing Interface

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Process planning

Process planning can be defined as an

act of preparing a detailed processing
documentation for the manufacture
of a piece, part or assembly

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Process planning activities

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Process planning activities

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APPROACHES TO PROCESS PLANNING

 1. Manual Process planning

 2. Computer Aided Process planning (CAPP)

a. Retrieval CAPP system
b. Generative CAPP system

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MANUAL PROCESS PLANNING

 Manually prepared
Task involves
◦ examining and interrupting engineering
drawings
◦ making decisions on machining
process selection
◦ equipment selection
◦ operation sequence and
◦ shop practices Dependent on judgment
and experience of process planner

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 Advantages
Very much suitable for small scale companies
Highly flexible
Low investment costs

 Disadvantages
Very complex
Time consuming
Requires large amount of data
Requires skilled process planner
More possibilities for human error
Increases paper work
Inconsistent process plans results in reduced
productivity
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 Types of production

 Batch Production
 Mass Production

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 Batch Production
 In this type, the products are made in small batches
and in large variety. The orders may be repeated
with intervals of time.
 The characteristics of this type of production are:
(i) Products are manufactured in batches.
(ii) General purpose machines are used.
(iii) Flow of material is intermittent.
(iv) Plant layout is process type.
(v) In process inventory is high.
(vi) Process and product planning is done for each
batch.
(vii) Work loads on various machines or sections are
unbalanced.
(viii) Machine operators are highly skilled.
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 Batch Production
 Batch production is also a form of
intermittent production.

 This is a very common type of production.

Drugs, chemicals, paints, sheet metal
components, forgings and parts manufactured
on turret/capstan lathes come under this type

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Mass Production

 Mass production means the production of

items in large quantity using very
specialized machines and processes.
 Items like metal screws, nuts and bolts
and plastic products are made in mass
production.
 In this type of production there is a
continuous and steady flow of materials.

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 Mass Production
The various characteristics of mass production
are:
(i) Small varieties and large volumes are
manufactured.
(ii) Product type plant layout is used.
(iii) The flow of work is balanced i.e., machine
capacities are balanced.
(iv) Specialized machines and processes are used,
hence high initial investment in equipment.
(v) Materials move by conveyors.
(vi) It results in lowest cost of production.
(vii) Easier production planning and control

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 Computer Aided Process Planning (CAPP)
 CAPP systems are available today to prepare these route sheets.
Process planning involves the preparation and documentation of the plans
for manufacturing the products.

 Computer-Aided Process Planning (CAPP) is a means of implementing this

planning function by the use of computers

 Computer Aided Process Planning represents the link between design and
manufacturing in a CAD/CAM system.

 Process planning is concerned with determining the sequence of processing

and assembly steps that must be accomplished to make the product.

 The processing sequence is documented on a sheet called a route sheet.

 The route sheet typically lists the production operations, machine tools,
work centers or work stations where each operation is performed, jigs,
fixtures and tooling required and standard time for each task. 16
Computer Aided Process
Planning (CAPP)
Benefits
Process rationalization and standardization
Productivity improvement
Product cost reduction
Elimination of human error
Reduction in time
Reduced clerical effort and paper work
Improved legibility

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RETRIEVAL CAPP SYSTEM
It is also called as variant CAPP, widely used in
machining applications
Basic idea behind is, similar parts will have
similar process plans
Process plan for new part is created by
recalling, identifying and retrieving an existing
plan for a similar part, and making necessary
modification for new part

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General layout for RETRIEVAL CAPP SYSTEM
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 PROCEDURE FOR
RETRIEVAL CAPP SYSTEM
Retrieval CAPP system is based on principles of group
technology (GT) and part classification and coding
For each part family, standard process plan is prepared and
stored in computer files Through classification and coding, code
number is generated

Advantages
Once a standard plan has been written, variety of parts can be
planned
Requires simple programming and installation
Understandable, and planner has control of final plan
Easy to learn and easy to use
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 Generative Method of Process Planning
(Generative CAPP System)
The second method of computerized process
planning is the generative method.
In this method the computer uses the stored
manufacturing and design data to generate a
complete list of all possible process plans that
could be used to manufacture the current part.
It then exhaustively searches this list for the one
which optimizes the cost function. This method
always yields the optimum process plan
for manufacturing a particular part.
However, it has a very high cost in terms of time
and computer processing expenses.
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 Generative Method of Process Planning
(Generative CAPP System)
The computations required to provide even a single
process plan for an arbitrary part design can be
enormously complex.
To repeat this for every feasible process plan or a part
can become very costly.
This approach of process planning is also known as
Generative CAPP System.

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Components of Generative CAPP system
Part descriptor
Subsystem to identify machine parameters
Subsystem to select and sequence individual
operations Database
Report generator

Advantages
Generate consistent process plan rapidly
New components can be planned as easily as existing
components
It has potential for integrating with automated manufacturing
facility to provide detailed control information

Disadvantage
Complex and very difficult to develop
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Drawing interpretation

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Collective Single Part Drawing

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Process selection

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Classification of manufacturing processes

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Factors in process selection

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Materials and process selection factors

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PROCESS PLANNING ACTIVITIES
Specific activities involved in Process planning
are
Analysis of the finished part requirements as
specified in the engineering design
Determining the sequence of operation
required Selecting the proper equipment to
accomplish the required operations
Calculating the specific operation setup times
and cycle times on each machine
Documenting the established process plans
Communicating the manufacturing knowledge
to the shop floor

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Analyze finished part requirements

Component drawing should be analyzed to

identify its features, dimensions, and
tolerance specifications

Part’s requirement defined by its features,

dimensions, and tolerance specifications
will determine corresponding processing
requirements

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2. Determine operating sequence
Basic aim is to determine the type of processing
operation that has the capability to generate various
types of features, given the tolerance requirements

There are two ways of viewing decision process

First view is to consider processing evaluation of part
from rough state to finished final state.
In this view material is removed or modified on rough
part in stages in order to transform it into finished
part

Second view is to consider part evaluation from

finished state back to rough/ initial state. In
this view material is added back onto the part
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 Risk management strategy

1. Identify risk factors

2. Determine risk exposure (probability * effect)

3. Develop strategies to mitigate risks

◦ Avoid, transfer, or accept

4. Handle risks
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 Categories of risks
Level of control

low high

customers and users scope and requirements

Importance

low
(C1) (C2)

environment execution
high
(C4) (C3)

Order of handling: first C3, then C2, then C4 and C1

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Techniques for project planning and
control
 Work breakdown structure (WBS)
 PERT chart
 Gantt chart

 Agile planning and control

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Work Breakdown Structure

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PERT chart

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Gantt chart

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Why task-oriented planning is
problematic
 Activities never finish early
◦ Parkinson’s law: work fills the time available

 Lateness is passed down the schedule

◦ If either design or coding is late, subsequent
testing will be late

 Tasks are not independent

◦ If design takes more time, so will
implementation
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Agile planning factors
 Estimate value of features
◦ e.g. the MoSCoW way
 Cost of implementing features
◦ Cost of doing it now versus cost of doing it later
 New knowledge acquired
◦ First do features that bring a lot of new knowledge
 Risk removed by implementing feature
◦ First high-value-low risk features, then low risk-low
value features
◦ Avoid high value-high risk features

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