Process Planning

What is meant by Process Planning?

To convert the product design into a
product, a manufacturing plan is required.
The activity of developing such a plan is
called process planning.
Process planning consists of preparing set
of instructions that describe how to
manufacture the product and its parts.
 What is meant by Process Planning?

• The task of process planning consists of

determining the manufacturing operations
required to transform a part from a rough
(raw material) to the finished state
specified on the engineering drawing.
•Process planning, also known as
operations planning, is the systematic
determination of the engineering processes
and systems to manufacture a product
competitively and economically.
Process planning is a detailed specification
which lists the operations, tools, and
facilities.
Process planning is usually accomplished in
manufacturing department.
 Process Planning Defined
• Process planning can be defined as "an
act of preparing a detailed processing
documentation for the manufacture of a
piece part or assembly."
• According to the American Society of Tool
and Manufacturing Engineers, "process
planning is the systematic determination
of the methods by which a product is to
be manufactured, economically and
competitively."
importance of Process Planning
• Process planning establishes the link
between engineering design and shop
floor manufacturing. Since process
planning determines how a part/product
will be manufactured, it becomes the
important determinant of production costs
and profitability.
importance of Process Planning
• Also, production process plans should be
based on in-depth knowledge of process
and equipment capabilities, tooling
availability, material processing
characteristics, related costs, and shop
practices.
importance of Process Planning
• The economic future of the industry
demands that process plans that are
developed should be feasible, low cost,
and consistent with plans for similar parts.
In addition, process planning facilitates the
feedback from the shop floor to design
engineering regarding the
manufacturability of alternative.
TECHNOLOGICAL VIEW OF
PROCESS PLANNING
 DETAILS OF A PROCESS PLAN

• A detailed process plan usually contains

the route, processes, process parameters,
and machine and tool selections.
 DETAILS OF A PROCESS PLAN
• Informations required for process
planning: In order to prepare a process
plan (also called as route sheet), one
require the following informations:
 1. Assembly and component drawings and bill
of materials (part list): This detail give the
information regarding the general description of
the part to be manufactured,raw material
specification, dimensions and tolerances required,
the surface finish and treatment required.
Informations required for process planning

2.Machine and equipment details:

 The various possible operations that
can be performed.
 The maximum and minimum
dimensions that can machined on the
machines.
• The accuracy of the dimensions that can
be obtained.
• Available feeds and speeds on the
machine.
 Informations required for
process planning
3.Standard time for each operation and
details of setup time for each job.
4. Availability of machines, equipment and
tools
 Responsibilities of Process
Planning Engineer
The specialists managing the process planning task are called
process engineers or process planners.
The various responsibilities of a process engineer are given below:
 Interpreting part print analysis, and symbols.
 Gathering the fundamental details of product design, such as
(1) type of rough stock,
(2) dimensional tolerances,
(3) type of finish,
(4) production rate,
(5) production volume,
(6) scrap losses,
(7) downtime,
(8) design changes, etc.
 Responsibilities of Process
Planning Engineer
 Selecting the machining processes.
 Selecting proper machining with allied tooling based on:
(1) required machine capability,
(2) set-uptime,
(3) practical lot size,
(4) quality of parts,
(5) cost of tooling, and
(6) type of tooling.
 Sequencing the operations.
 Deciding on the inspection equipment in order to meet the desired
quality.
 Determining appropriate production tolerances
 Determining proper cutting tools and cutting conditions.
 Calculating over all times using work measurement techniques.
 Factors Affecting process
planning
 Volume of production
The skill and expertise of manpower
 Delivery dates for parts or products
 Material specifications
 Accuracy and process capability of machines
 Accuracy requirements of parts or products
 PROCESS PLANNING
ACTIVITIES
The different steps or specific activities
involved in process planning are:
Analysis of the finished part requirements
as specified in the engineering design.
Determining the sequence of operations
required.
Selecting the proper equipment to
accomplish the required operations.
 PROCESS PLANNING
ACTIVITIES
• Calculating the specific operation setup
times and cycle ti on each machine.
• Documenting the established process
plans.
• Communicating the manufacturing
knowledge to the shop floor.
• The above process planning activities are
diagrammatically presented in chart
 Analyze Finished Part
Requirements
The first step in the process planning is to
analyse the finished pan requirements as
specified in the engineering design.
The engineering design may be shown
either on an engineering drawing or in a
CAD model format.
The component drawings should be
analysed in detail to identify its features,
dimensions, and tolerance specifications.
 Analyze Finished Part
Requirements
The part's requirement defined by its
feature, dimensions, and tolerance
specifications will determine the
corresponding processing requirements
(such as operations encompassing part
shape generation, inspections, testing,
heat treatment, surface coating,
packaging, etc.)
 Determine Operating
Sequence
 The second step in the process planning
is to determine the sequence of operations
required to transform the features,
dimensions, and tolerances on the part
from a rough (initial) to a finished state
The basic aim of this step is to determine
the type of processing operation that has
the capability to generate the various
types of features, given the tolerance
requirements.
 Determine Operating
Sequence
There are two alternative ways of viewing
the decision process in determining the
sequence of operation.
 The first view is to consider the
processing evolution of the part from the
rough (i.e., initial) state to the finished final
state. In this view ,like in conventional
production shop ,material is removed or
modified on the rough part in stages in
order to transform it to the finished part.
 Determine Operating
Sequence
 The second view is to consider part
evolution from a finished state back to
a rough/initial state .In this view ,in
contrast to the first view , the operation
processing is planned by adding material
back onto the part.
It should be noted that the tolerance
specifications are primary factors in
determining the sequence of operations.
 Select "Machines"
• Once the appropriate type of
manufacturing process has been
determined, the next step in process
planning is to select appropriate machines,
equipment, and tools to accomplish the
required operations.
• There are many factors which influence
the selection of machines. The following
considerations are to be made while
selecting a machine:
 Select "Machines"
• There are many factors which influence
the selection of machines.
The following considerations are to be
made while selecting a machine:
• (i) Economic considerations: Due analysis
should be made with respect to the initial
cost, maintenance and running cost. An
alternative which results in lower total cost
should be selected.
 Select "Machines"
(ii) Production rate and unit cost of
production.
(iii) Durability and dependability.
(iv) Lower process rejection.
(v) Minimum set up and put away times.
(vi) Longer productive life of machines or
equipment.
(vii)Functional versatility ie, ability to
perform more than one functions.
 Select "Machines"
• Machine selection generally requires
determining how the part would be
processed on each of the alternative
machines so that the best machine can be
selected.
• also at the machine selection phase, the
firm has to decide whether to make
(manufacture) or buy (purchase) the
component part.
 Select "Machines"
• In this regard, break-even analysis is the
most convenient method for selecting the
optimum method of manufacture or
machine amongst the competing ones.
 Material Selection
Parameters
• The selection of a sound, economic
material is an another important aspect of
process planning. The primary parameters
affecting the choice of a material are given
below:
 Material Selection
Parameters
• Function: Many of the parameters
developed for material selection are
related to the functions the product must
perfomi in terms of mechanical, physical,
electrical, and thermal properties of
materials.
• 2. Appearance: The aesthetic value of
the material must be considered while
selecting the material.
 Material Selection
Parameters
• 3. Reliability: Reliability is another
important criterion for material
selection because of increasing consumer
demands for trouble free products.
• 4. Service life: The length of service life
over which the material maintains its
desirable characteristics is a very
important consideration in material
selection.
 Material Selection
Parameters
• Environment: The environment to which
the material is exposed during the product
life is a very important consideration,
depending on whether the environment is
beneficial or harmful.
 Material Selection
Parameters
• Compatibility: This is an important factor
• influencing material selection, especially
whenever more than one type of material
is used in a product or assembly.
• Producibility: parameter in the selection of
material.
8. Cost: The cost of the material is
contributing the overall cost.
 Calculate Processing Times
• After an appropriate set of machines
required is selected, the next step in
process planning is to calculate the
specific operation setup times and cycle
times on each machine.
• The determination of setup times requires
knowledge of available tooling and the
sequence of steps necessary to prepare
the machine for processing the given
workpiece.
 Calculate Processing Times
• For establishing accurate setup times,
detailed knowledge of equipment
capability, tooling, and shop practice is
required.
• The calculation of part processing time
requires the determination of the
sequence of processing steps on each
machine. This activity is often called
outplanning.
 Calculate Processing Times
• After the given machining or processing
time is calculated, the appropriate times
for part loading, part unloading, machine
indexing, and other factors involved in one
complete cycle for processing a part must
be included to compute the expected
machine cycle time.
 Calculate Processing Times
• With the calculated machine cycle time,
allowances (for operator personal time,
fatigue time, and supplemental time) are
added to calculate the standard cycle time
for processing one piece.
• With the calculated cycle time, appropriate
machine rates {i.e., the cost of machine
ownership/use in Rupees per unit of time)
are applied to calculate the expected
standard cost for the given operation.
 Document Process Planning

• Having selected the best processing

alternatives and associated machines, the
next step in process planning is to
document clearly all the information in
detail.
Document Process Planning
 Document Process Planning

• The route sheet usually provides the

following information
• (i)part identification (numbers and names)
• (ii) Description of the processing steps in
each operation.
• (iii) Operation sequence and machines,
• (iv) Standard setup and cycle times,
 Document Process Planning

• (v) Tooling requirements for each

operation
• (vi) Production control information showing
the planning lead time at each operation.
 Document Process Planning

• Reasons for process documentation:

Process planning is essentially
documented for the following three
reasons:
• (i) To have a record on how a part is
processed in order to plan future parts with
similar design requirements in a consistent
manner.
 Document Process Planning

• Reasons for process documentation:

(ii) To provide a record for future job
quoting, cost estimating,and standard
costing systems.
• (iii) To act as a vehicle for
communication.
 Communicate Process
Knowledge
• The final step in process planning is to
communicate the manufacturing
knowledge to the shop floor (through the
operations sheet and process drawing).
• This communication is essential to ensure
that the part will be processed according
to the most economically possible way
determined through process planning.
 Communicate Process
Knowledge
• Also, the process documentation and
corresponding communication provide a
basis for improved part consistency and
quality in manufacturing.
APPROACHES TO PROCESS
PLANNING
• The two general approaches to process
planning are :
1. Manual process planning, and
2. Computer Aided Process Planning
(CAPP).
(i) Retrieval CAPP system, and
(ii)Generative CAPP system.
 MANUAL PROCESS
PLANNING
• In traditional process planning systems the
process plan is prepay manually.
• The task involves examining and
interpreting engineering drawings, making
decisions on machining processes
selection, equipment selection, operations
sequence, and shop practices.
 MANUAL PROCESS
PLANNING
• Therefore the manual process plan is very
much dependent on the skill, judgement
and experience of the process planner.
• That's why, jf different planners were
asked to develop a process plan for the
same part, they would probably come up
with different plans.
Advantages of Manual Process
Planning
• Manual process planning is very much
suitable for small scale companies with
few process plans to generate.
• This method is highly flexible.
• This requires low investment costs.
 Disadvantages of Manual
Process Planning
• Manual process planning is a very
complex and time consuming job requiring
a large amount of data.
• This method requires the skilled process
planner.
 Disadvantages of Manual
Process Planning
• More possibilities for human error because
this method depends on the planner's skill,
judgement and experience.
• It increases paper work.
• Inconsistent process plans result in
reduced productivity.
COMPUTER AIDED PROCESS
PLANNING (CAPP)
• In order to overcome the drawbacks of
manual process planning ,the computer-
aided process planning (CAPP) is used.
• With the use of computers in the process
planning, one can reduce the routine
clerical work of manufacturing engineers.
COMPUTER AIDED PROCESS
PLANNING (CAPP)
• Also it provides the opportunity to
generate rational, consistent and optimal
plans.
• In addition, CAPP provides the interface
between CAD and CAM.
 Benefits of CAPP
• The benefits of implementing CAPP
include the following :
• Process rationalization and
standardization:
CAPP leads to more logical and
consistent process plans than manual
process planning.
 Benefits of CAPP
• Productivity improvement: As a result of
standard process plan, the productivity is
improved (due to more efficient utilization
of resources such as machines, tooling,
stock material and labour).
• Product cost reduction : Standard plans
tend to result in lower manufacturing costs
and higher product quality.
 Benefits of CAPP
• Elimination of human error
• 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.
 Benefits of CAPP
• Reduced clerical effort and
paper work
• Improved legibility : Computer
prepared route sheets are neater
and easier to read than manually
prepared route sheets.
 Benefits of CAPP
• 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 parameters
than the manual method of process
planning.
 Benefits of CAPP
• Incorporation of other application
programs:

The CAPP program can be

interfaced with other application
programs, such as cost estimating
and work standards.
 APPROACHES OF CAPP

The two basic approaches or types of CAPP

system are :
Retrieval (or variant) CAPP system, and
Generative CAPP system.
 Retrieval (or variant) CAPP
system
• A retrieval CAPP system, also called a
variant CAPP system, has been widely
used in machining applications.
• The basic idea behind the retrieval CAPP
is that similar parts will have similar
process plans.
 Retrieval (or variant) CAPP
system
• In this system, a process plan for a new
part is created by recalling identifying and
retrieving an existing plan for a similar
part, and making the necessary
modifications for the new part.
Procedure for Using Retrieval
CAPP System
• A retrieval CAPP system is based on the
principles of group technology(GT) and
parts classification and coding.
general procedure for using one of the
retrieval CAPP systems.
Procedure for Using Retrieval
CAPP System
• In this part system ,for each part family a
standard process plan (ie route sheet) is
prepared and stored in computer files.
Procedure for Using Retrieval
CAPP System
• 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.
 Advantages of Retrieval CAPP
System
• Once a standard plan has been written, a
variety of parts can be planned.
• Comparatively simple programming and
installation (compared with generative
CAPP systems) is required to implement a
planning system.
 Advantages of Retrieval CAPP
System
• The system is understandable, and the
planner has control of the final plan.
• It is easy to learn and easy to use.
 Drawbacks of Retrieval CAPP
System
• The components to be planned are limited
to similar components previously planned.
• Experienced process planners are still
required to modify the standard plan for
the specific component.
 Drawbacks of Retrieval CAPP
System
Note
1. The retrieval CAPP system has the
capacity to alter an existing process plan.
That's why it is also known as variant
CAPP system.
• 2. The commercially available retrieval
CAPP systems are MultiCapp and
MIPLAN.
 GENERATIVE CAPP
SYSTEMS
• In the generative approach, the computer
is used to synthesize or generate each
individual process plan automatically and
without reference to any prior plan.
 GENERATIVE CAPP
SYSTEMS
• A GENERATIVE CAPP system generates
the process plan based on decision logics
and pre-coded algorithms.
• The computer stores the rules of
manufacturing and the equipment
capabilities (not any group of process
plans).
 GENERATIVE CAPP
SYSTEMS
• When using a system, a specific process
plan for a specific part can be generated
without any involvement of a process
planner.
• The human role in running the system
includes :
(i) inputting the GT code of the given
part design, and
(ii) monitoring the function.
 Components of a Generative
CAPP System
• The various components of a generative
system are :
A part description, which identifies a
series of component characteristics,
including geometric features, dimensions,
tolerances and surface condition.
 Components of a Generative
CAPP System
• A subsystem to define the machining
parameters, for example using look-up
tables and analytical results for cutting
parameters.
 Components of a Generative
CAPP System
• 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.
 Components of a Generative
CAPP System
• A database of available machines and
tooling.
• A report generator which prepares the
process plan report.
Advantages of Generative CAPP

The generative CAPP has the following

advantages :
• It can generate consistent process plans
rapidly.
• New components can be planned as
easily as existing components.
• It has potential for integrating with an
automated manufacturing facility to
provide detailed control information.
Drawbacks of Generative CAPP
System
• The generative approach is complex and
very difficult to develop.
Note: The commercially available
generative CAPP systems are APPAS,
CMPP, EXCAP and XPLAN.
DEVELOPING MANUFACTURING LOGIC
AND KNOWLEDGE
• To support a process planning system, the
acquisition and documentation of
manufacturing knowledge is very
essential.
• it is generally agreed that knowledge
structure should be determined prior to
any type of program coding or data
presentation.
DEVELOPING MANUFACTURING LOGIC
AND KNOWLEDGE
• A sound knowledge structure will help to
ensure error reduction, debugging case,
clarity, and future modification.
DEVELOPING MANUFACTURING LOGIC
AND KNOWLEDGE
• Thus production engineers need a tool to
develop a knowledge structure format that
can be used in an interactive process and
will emphasize what questions to ask and
what data to collect to support a
standardized format.
DEVELOPING MANUFACTURING LOGIC
AND KNOWLEDGE
• Also there is a need for system tools that
can acquire and document knowledge in
such a manner as to bring together,
analyse, and display the resulting
manufacturing knowledge in a consistent
and well-structured format.
DEVELOPING MANUFACTURING LOGIC
AND KNOWLEDGE
• Three commonly used tools for acquiring
and documenting knowledge are:
Flowcharts,
Decision tables, and
Expert system shells.
 FLOW CHARTS

• Flow chart is one of the most commonly

used tools for the collection and display of
manufacturing knowledge.
• Flow charts are widely used because they
are commonly taught in computer
programming subjects.
• The format of flow chart is shown in .
Flow chart format
 Disadvantages
• Though flow charts are commonly used,
they are defective for organising and
presenting logic for the following three
reasons:
1.Flow charts focus on process rather
than on the structure of decision logic.
 Disadvantages
2.Flow charts provide no check
against incompleteness,contradiction, and
redundancy.
3. Flow charts often employ
abbreviations and hence they are
defective for effective communication of
knowledge.
 Decision Tables
• Decision tables are a system/logic tool to
bring together,analyse and display
complex decision logic in such a way that
its meaning can be readily grasped.
• The format of decision table is shown
below
• In Fig. the top IF portion of the table shows
the various conditions that may apply,
• while the lower THEN portion of the table
indicates the appropriate actions available.
• The left portion of the table contains the
stub in which each of the possible
conditions or actions is stated, while the
right portion lists the various entries (yes
or no) that are possible for each of the
stub conditions and actions.
 Benefits of decision tables
• Decision tables assist the production
engineers in thinking through a problem
thoroughly and presenting its resolution in
a systematic and rationally structured
format.
• Decision tables ensure accuracy, eliminate
redundancy, and avoid contradiction.
 Benefits of decision tables

• Decision tables assist in stating the

problem, agreeing on criteria, stating
alternatives, and accepting actions
between criteria and alternatives.
• Decision tables provide knowledge
structure and readable documentation as
a by-product.
 Expert System Shells

• Expert system is one of the latest

system tools for the development and
display of manufacturing knowledge.
 Expert System Shells

• Using an expert system shell, the

knowledge engineers can collect the
information to develop a knowledge
base within the pre defined decision
structure of the shell.
 Expert System Shells
• The basic expert system structure is
shown in Fig.
• It can be seen from Fig that the basic
format of a rule-based expert system shell
is quite similar to the decision tables
format.
• Like decision tables format, in rule-based
expert system, the knowledge base is
formatted in structures of "if this condition
then this action", or "if this condition then
this action, or else this action".
 SELECTION OF PROCESS
PLANNING SYSTEM
• The evaluation and selection of the best
process planning system for a particular
firm involves numerous engineering
management decisions.
• The process involves identifying, weighing,
and comparing various interrelated factors.
• The major factors to be considered while
selecting the best process planning
system are:
1.the general environment in which process
planning is conducted,
2. the organisational structure of the
company
• The major factors to be considered while
selecting the best process planning
system are:
3.the technical expertise available to the
company, and
4.the needs and objectives of the company
regarding the generation of
manufacturing information and process
plans.