PROCESS PLANNING

Product design Process plan Physical entity (product) Process planning consists of preparing a set of instructions that describe how to fabricate a part or build an assembly, which will satisfy engineering design specifications Decisions and details usually included within the scope of process planning are: Interpretation of design drawings Process and sequence Equipment selection Tools, dies, moulds, fixtures and gauges Method analysis Work standards Cutting tools and cutting conditions

Process planning for parts

The process sequence is documented on a form called a route sheet (operation sheet) A typical route sheet includes the following information All operations to be performed on the workpart, listed in which they should be performed A brief description of each operation with reference to dimensions and tolerances on the part drawing The specific machines on which the work is to be done Any special tooling, such as dies, moulds, cutting tools, jigs or fixtures and gauges Cycle time standards, setup times and other data Typical Guidelines in Preparing a Route Sheet Operation numbers for consecutive processing steps should be listed as 10, 20, 30, etc A new operation and number should be specified when a workpart leaves one workstation and is transferred to another station A new operation and number should be specified if a part is transferred to another workholder (eg:- jig or fixture), even if it is on the same machine tool A new operation and number should be specified if the workpart is transferred from one worker to another as on a production line

Decision on processes to be used to fabricate a given part based largely on the starting material The product designer selects this starting material A typical processing sequence to fabricate an individual part consists of: (1) a basic process, (2) secondary processes, (3) operations to enhance physical properties, and (4) finishing operations Property-enhancing process not always required

Starting raw material

Basic process

Secondary processes

Property-enhancing processes

Finishing operations

Finished part

Additional secondary processes sometimes required following property enhancement Fig. Typical sequence of processes required in part fabrication Near net shape processes Operations that require some but not much secondary processing Operations that require no subsequent secondary processing Net shape processes

Process planning for assemblies

The type of assembly method used for a given product depends on factors v The anticipated production quantities v Complexity of the assembled product v Assembly processes used Process planning for assembly involves Development of assembly instructions (List of work elements with precedence relationship and time) For high production on an assembly, process planning consists of allocating work elements to the individual stations of the line, a procedure called line balancing

Manual Process Planning A former machinist uses his knowledge, skill and experience A planner with a very good memory retrieves and modifies a process plan for similar part Process plans developed for the same part by different planners will usually differ unless the part is simple to make subjective judgment, preferences and experience The same planner may develop a different process plan for the same part if there is a long time lag between analyses for the part Certain process plan (part in the aerospace industry) task involves documentation labour intensive, time-consuming and tedious Manual approach is preferred for small firms that have a few process plans to prepare Computerised system is preferred when volume of plans to be prepared is high

Computer-Aided Process Planning (CAPP)

Benefits Process rationalisation and standardisation Increased productivity of process planners Reduced lead time for process planning Improved legibility Incorporation of other application programs Variant (Retrieval) approach Generative approach

Different CAPP approaches

Variant Process Planning Group technology - parts classification and coding A library of standard process planning Part families are formed and standard process plan is prepared for each family Standard process plan for a family consists of all instructions that would be included in a process plan for any part in that family Interactive editing Storage, retrieval and documentation capabilities The plan for a new part is created by retrieving and modifying the standard process plan for a given part family

If the part being planned cannot be classified into an existing family of parts, the planner can develop a new standard process plan using the interactive computer programs E.g.:- CAM-I CAPP (Computer-Aided Manufacturing International completed in 1976), MultiCapp ( OIR Organisation for Industrial Research) New part design

Derive GT code number for part

Preparatory stage

Search part family file for GT code number

Part family file

Select coding system and form part families

Retrieve standard process plan

Standard process plan file

Prepare standard process plans for part families

Edit existing plan or write new plan

Process plan formatter

Other application programs

Process plan (Route sheet)

Fig. General procedure for using retrieval CAPP system

Generative Process Planning A process planning system which includes a data base and decision logic, that will automatically generate a process plan from engineering specification (graphical and textual) of the finished part The generative CAPP belongs to the field of expert system a computer program that is capable of solving complex problems that normally require a human with years of education and experience Knowledge base contain the knowledge and logic of human process planner Computer-compatible description of the part to be produced the geometric model of the part that is developed on a CAD system during product design a GT code number of the part that defines the part features Capability to apply the process knowledge and planning logic contained in the knowledge base to given part description inference engine

The ingredients of generative CAPP