Unit - 1

Velammal College of Engineering and Technology
Department of Mechanical Engineering
ME8793
PROCESS PLANNING AND COST ESTIMATION
PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 1

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
INTRODUCTION
 The Product design for each product has been developed in the
design department. 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 is a detailed specification which lists the
operation, tools, and facilities.
 Usually accomplished in manufacturing department.
 Also known as operations planning.

DEFINITION
 Process planning can be defined as an act of preparing a detailed
processing documentation for the manufacture of a piece part or
assembly.
(or)
 According to the American Society of Tool and Manufacturing
Engineers,
 “Process planning is a systematic determination of the methods
by which a product is to be manufactured economically and
competitively”
PROCESS PLANNING:
LINK B/W DESIGN AND MANUFACTURING

RESPONSIBILITIES OF PROCESS
PLANNING ENGINEER
1.Interpreting part print analysis and symbols.
2.Gathering the fundamental details of product design, such as

(i) Type of rough stock,
(ii) Dimensional tolerances,
(iii) Type of finish,
(iv) Production rate,
(v) Production volume,
(vi) Scrap losses,
(vii) Downtime,
(viii) Design changes, etc.

PLANNING ENGINEER… Cont..
3. Selecting the machining processes.
4. Selecting proper machining with allied tooling based on
(i) Required machine capability,
(ii) Practical lot size,
(iii) Set-up time,
(iv) Quality of parts,
5. Sequencing the operations.

6. Deciding on the inspection equipment in order to
meet the desired quality.

PLANNING ENGINEER… Cont..
7. Determining appropriate production tolerances.
8. Determining proper cutting tools and cutting

conditions.
9. Calculating the overall times using work

measurement techniques.

PROCESS PLANNING ACTIVITIES
Step 1 Drawing Interpretation-Analysis of the finished part
Step 2 Material Evaluation and Process selection
Step 3 Selection of Machines, Tooling and Work holding
Step 4 Setting Process parameters
Step 5 Selection of Quality Assurance methods
Step 6 Cost Estimating
Step 7 Preparing the Process planning Documentation
Step 8 Communicating the manufacturing knowledge to the shop floor

PROCESS PLANNING ACTIVITIES

DRAWING INTERPRETATION
 Technical drawing prepared by Design dept
 The following information are needed

 Material of component
 Number of parts to be produced
 Weight of component
 Dimensions of parts
 Size and accuracy

TYPES OF DRAWINGS
There are three types of drawings used in the industry are
I. Detail drawings
a. Single part drawings and
b. Collective drawings
II. Assembly drawings and
a. Single part assembly drawing and
b. Collective assembly drawings
III.Combined drawings

TYPES OF DRAWINGS
I. Detail drawings
It provide all the information required for manufacture of the required

component / product
a. Single part drawings
It contain the complete detailed information to enable a single

component to be manufactured without reference to other sources
b. Collective drawings
The collective single part drawings are used where one or two
dimensions of a component are variable, all other being standard
COLLECTIVE SINGLE PART DRAWING OF A RIVET

TYPES OF DRAWINGS
II. Assembly drawings
Machine and mechanisms consists of numerous parts and a drawing
which shows the complete product with all its components.
a. Single part assembly drawings
It contains the information to build a single sub assembly
b. Collective assembly drawings
The collective assembly drawings are used where a range of products
which are similar in appearance but differing in size is manufactured
and assembled
TYPICAL COLLECTIVE ASSEMBLY DRAWING OF
A NUT WITH BOLTS OF VARIOUS LENGTHS

TYPES OF DRAWINGS
III. Combined drawings

A combined detail and assembly drawing shows as
assembly with part list and the details of these parts
on one drawing

COMBINED DETAIL AND ASSEMBLY DRAWING
OF HUB-PULLER

CRITICAL PROCESS PLANNING
FACTORS
Information of the drawing sheet required for process planning
(Critical Processing factors)
 Geometric and dimensions

 Material specifications
 Notes on special material treatments
 Dimensional tolerances specifications
 Geometrical tolerances specifications
 Surface finish specifications
 Tool references
 Gauge references
 Quantity to be produced
 Part lists
 Notes on equivalent parts
 Notes on screw thread forms
LIMITS AND FITS FOR SHAFTS AND
HOLES
The basic size or nominal size is the size of shaft or hole
that the design specifies before applying the limits to it.
There are two systems
I. Basic hole system: Starts with the basic hole size and
adjusts shaft size to fit.
II. Basic shaft system: Starts with the basic shaft size
and adjusts hole size to fit
FIT
 The fit represents the tightness or looseness resulting

from the application of tolerances to mating parts
 Clearance fit-Creates running and sliding assemblies
(Assemble and dissemble by hand)
 Transition fit-Assembly usually requires press tooling
 Inference fit- Parts need to be forced (Permanent

assemblies)

z
MATERIAL SELECTION
PROCESS AND METHODS
z
PPCE UNIT I
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T.KAMATCHI, K. MEENAKSHI SUNDAR
MATERIAL SELECTION PROCESS
There are four step material selection process , they are
I. Translation- Interpreting the design requirements in terms of
functions, constraints, objectives and free variables.
II.Screening – deriving attribute limits from the constraints
III.
Ranking – ordering the variable candidates by the value of
material index
IV.Seeking supporting information- exploring their past history and
behavior in relevant environment

MATERIAL SELECTION PROCESS

z
MATERIAL SELECTION
AND EVALUATION
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PPCE UNIT I
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T.KAMATCHI, K. MEENAKSHI SUNDAR
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PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR
MATERIAL SELECTION METHODS
The commonly used methods for material selection are
I. Selection with computer aided databases
II. Performance indices
III. Decision matrices
IV. Selection with expert systems
V. Value analysis
VI. Failure analysis
VII. Cost-benefit analysis

MATERIAL EVALUATION METHODS
The material considered for selection are evaluated based on the following
three considerations;
I. Shape or geometry consideration
(Size, Shape, Dimensional, Surface finish, Allowances and Design)
II. Material property requirements
(Mechanical, Physical and Service environment)
III. Manufacturing considerations
(Quality and rate of components)

PROCESS SELECTION
 A process is a method of shaping, joining or

finishing a material.
 To select right manufacturing process

CLASSIFICATION OF MANUFACTURING
PROCESSESS

FACTORS IN PROCESSESS SELECTION
 Material form
 Component size
 Economic considerations
 Dimensional and geometric accuracy
 Surface finish specification
 Batch size
 Production rate

MATERIAL & PROCESSESS SELECTION
FACTORS

STEPS/STAGES IN PROCESS SELECTION
(PROCESS SELECTION METHOD)
1. Drawing Interpretation
2. Identification of critical processing factors

3. Comparison of potential manufacturing
processes
4. Identification of suitable processes

PROCESS SELECTION METHOD

PRODUCTION EQUIPMENT
The following factors are considered during the selection of production

equipment
Component size
Component weight
Physical size of the machine
Construction of the machine
Power and torque of the machining
Number of tools available for the machine
Types of tools available for the machine

EQUIPMENT SELECTION
The following factors are considered during the equipment selection
I. Technical factor
Physical size of the workpiece
Machine accuracy
Surface finish
Cutting forces
Power of the machine
II. Operational factors

Batch size
Capacity
Availability

MACHINE SELECTION METHOD(STEPS IN
MACHINE SELECTION
The machine selection involves the following

fours stages
Stage 1-First cut selection
Stage 2-Power/force analysis
Stage 3-Capability analysis

Stage 4-Operational analysis
MACHINE SELECTION METHOD

FACTORS IN TOOLING SELECTION
1. Constraints on tool selection
a. Manufacturing practice
b. Manufacturing process
c. Machine tool characteristics
d. Capability
e. Processing time
f. Cutting tool availability
2. Operating requirements for tool selection
a. Workpiece material
b. Operation
c. Part geometry
d. Tooling data
3. Factors affecting tooling performance
a. Cutting tool materials
b. Cutting tool geometry
c. Cutting fluids
TOOL PERFORMANCE FACTORS

TOOLING SELECTION METHOD
Stage 1-Evaluation of process and machine

selection
Stage 2-Analysis of machining operation
Stage 3-Analysis of work piece characteristics
Stage 4-Tooling analysis
Stage 5- Selection of tooling
PROCESS CHART
The following charts and diagrams are used in method study.
1. Operation process chart (or) Outline process chart.
2. Flow process chart.

(a) Material type
(b) Operator type
(c) Equipment type
3. Two-handed process chart. (or) Left hand-Right hand chart
4. Multiple activity chart.
5. Flow diagram.
6. String diagram.
PROCESS CHART SYMBOLS

OPERATION PROCESS CHART

PROCESS FLOW CHART – MATERIAL TYPE

PROCESS FLOW CHART –
OPERATOR & MATERIAL TYPE

TWO-HANDED PROCESS CHART (OR)
LEFT HAND-RIGHT HAND CHART

MULTIPLE ACTIVITY CHART

FLOW DIAGRAM

STRING DIAGRAM

METHODS OF PROCESS PLANNING
1. Manual Process planning

2. Computer Aided Process planning (CAPP)
a. Retrieval CAPP system
b. Generative CAPP system

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.

MANUAL PROCESS PLANNING
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
COMPUTER AIDED PROCESS PLANNING
(CAPP)
 To overcome drawbacks of manual process

planning Computer Aided Process planning
(CAPP) is used
 Provides interface between CAD and CAM

BENEFITS OF COMPUTER AIDED
PROCESS PLANNING (CAPP)
 Process rationalization and standardization
 Productivity improvement
 Product cost reduction
 Elimination of human error
 Reduction in time
 Reduced clerical effort and paper work
 Improved legibility
 Faster response to engineering changes
 Incorporation of other application programs

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

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
• Standard PPCE
plan is retrieved
UNIT I
andT.KAMATCHI,
editedK. for new part
MEENAKSHI SUNDAR 58
PROCEDURE FOR RETRIEVAL CAPP
SYSTEM
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
Disadvantages
 Components to be planned are limited to similar components
previously planned
 Requires experienced process planners to modify the standard
plan for specific component

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PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR
GENERATIVE CAPP SYSTEM
 In this approach computer is used to synthesize or generate each
individual process plan automatically without reference to any
prior plan
 Generates the process plan based on decision logics and pre-
coded algorithms. Computer stores the rules of manufacturing
and equipment capabilities
 Specific process plan for specific part can be generated without
any involvement of process planner

COMPONENTS OF GENERATIVE CAPP
SYSTEM
 Part descriptor
 Subsystem to identify machine parameters
 Subsystem to select and sequence individual
operations
 Database
 Report generator
COMPONENTS OF GENERATIVE CAPP
SYSTEM
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
Drawbacks
 Complex and very difficult to develop


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Velammal College of Engineering and Technology

Department of Mechanical Engineering

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 1

Introduction - Methods of process planning-

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 3

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 5

2.Gathering the fundamental details of product design, such as

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 6

5. Sequencing the operations.

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 7

8. Determining proper cutting tools and cutting

9. Calculating the overall times using work

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 8

Step 1 Drawing Interpretation-Analysis of the finished part

Step 2 Material Evaluation and Process selection

Step 3 Selection of Machines, Tooling and Work holding

Step 4 Setting Process parameters

Step 5 Selection of Quality Assurance methods

Step 6 Cost Estimating

Step 7 Preparing the Process planning Documentation

Step 8 Communicating the manufacturing knowledge to the shop floor

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 9

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 10

 Technical drawing prepared by Design dept

 The following information are needed

 Number of parts to be produced

 Size and accuracy

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 11

There are three types of drawings used in the industry are

a. Single part drawings and

II. Assembly drawings and

a. Single part assembly drawing and

b. Collective assembly drawings

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 12

It provide all the information required for manufacture of the required

a. Single part drawings

It contain the complete detailed information to enable a single

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 14

Machine and mechanisms consists of numerous parts and a drawing

which shows the complete product with all its components.

a. Single part assembly drawings

It contains the information to build a single sub assembly

b. Collective assembly drawings

The collective assembly drawings are used where a range of products

which are similar in appearance but differing in size is manufactured

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 16

III. Combined drawings

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 17

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 18

 Geometric and dimensions

There are two systems

 The fit represents the tightness or looseness resulting

 Inference fit- Parts need to be forced (Permanent

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 21

I. Translation- Interpreting the design requirements in terms of

functions, constraints, objectives and free variables.

II.Screening – deriving attribute limits from the constraints

IV.Seeking supporting information- exploring their past history and

behavior in relevant environment

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 23

PPCE UNIT I T.KAMATCHI, K. MEENAKSHI SUNDAR 24

I. Selection with computer aided databases

II. Performance indices