Process Planning

Sections: 1. Process Planning 2. Computer-Aided Process Planning 1. Retrieval (variant) approach 2. Generative approach 3. Advanced Manufacturing Planning

Process Planning
Determining the most appropriate manufacturing processes and the sequence in which they should be performed to produce a given part or product specified by design engineering Limitations imposed by available processing equipment and productive capacity of the factory must be considered Parts or subassemblies that cannot be made internally must be purchased from external suppliers

Process planning

Design Machine tool

Process planning

Scheduling and production control

Who does Process Planning?

Traditionally, process planning is accomplished by manufacturing engineers (process planners) who are familiar with the particular processes in the factory and are able to read engineering drawings Based on their knowledge, skill, and experience, they develop the processing steps in the most logical sequence required to make each part Some details are often delegated to specialists, such as tool designers But manufacturing engineering has overall responsibility

The functions included in process planning

Raw material preparation Processes selection Process sequencing Machining parameter selection Tool path planning Machine selection Fixture selection

Details in Process Planning

Interpretation of design drawings The part or product design must be analyzed to begin the process planning procedure Starting materials Dimensions Tolerances Processes and sequence The process plan should briefly describe all processing steps used to produce the work unit and the order in which they will be performed

More Details in Process Planning

Equipment selection The process planner attempts to develop process plans that utilize existing plant equipment Otherwise, the part must be purchased, or new equipment must be installed in the plant Tools, dies, molds, fixtures, and gages Design of special tooling is usually delegated to the tool design group, and fabrication is accomplished by the tool room

More Details in Process Planning

Methods analysis Hand and body motions, workplace layout, small tools, hoists for lifting heavy parts Methods must be specified for manual operations (e.g., assembly) and manual portions of machine cycles (e.g., loading and unloading a production machine) Work standards Time standards set by work measurement techniques Cutting tools and cutting conditions for machining operations

Process Planning for Parts

Processes needed to manufacture a given part are determined largely by: the material out of which the part is made the part design itself The material is selected by the product designer based on functional requirements Once the material has been selected, the choice of possible processes is narrowed considerably

Processes Selection
A wide variety of manufacturing processes are used to produce a workpiece. These processes can be classified as: Casting processes ( ) Forming and shaping processes ( Machining processes ( ) Joining processes () Finishing processes ( )

Machining processes
The machining processes include: Drilling ( ) Countering, countersinking, deep-hole drilling Boring Tapping Milling Face milling, end milling Turning facing, straight turning, taper turning, parting Threading.

Typical Processing Sequence

A typical processing sequence to fabricate a discrete part consists of 1. A basic process 2. One or more secondary processes 3. Operations to enhance physical properties 4. Finishing operations

Typical Processing Sequence

Typical sequence of processes required in part fabrication

Basic and Secondary Operations

Basic process Establishes initial geometry of workpart Examples: metal casting, forging, sheet metal rolling

Secondary processes In most cases, the starting geometry must be modified or refined by a series of secondary processes, which transform the basic shape into the final geometry Examples: machining, stamping

Property Enhancement and Finishing Operations

Operations to enhance properties Heat treatment operations Treatments to strengthen metal components In many cases, parts do not require these property enhancing steps Finishing operations The final operations in the sequence Usually provide a coating on the work surface Examples: electroplating, painting

Examples of Typical Process Sequences

Basic process Sand casting Rolling sheet Forging Extrusion (Al) Casting of glass Secondary Process(es) Machining Blanking, bending Machining Cut to length Press, blowing Property enhancing Heat treating (none) (none) (none) Annealing Finishing operations Painting Plating Painting Anodizing Chem. etch

The Route Sheet

The document that specifies the details of the process plan The route sheet is to the process planner what the engineering drawing is to the product designer Route sheet should include all manufacturing operations to be performed on the workpart, listed in the order in which they are to be performed The detailed plan contains:
Route Processes Process parameters Machine and tool selections Fixtures

Route Sheet for Process Planning

Process Planning for Assemblies

For single stations, the documentation contains a list of the assembly steps in the order in which they must be accomplished For assembly line production, process planning consists of line balancing - allocating work elements to particular stations along the line As with process planning for individual parts: tools and fixtures needed to accomplish a given assembly task must be decided the workplace layout must be designed

Computer-Aided Process Planning

During the last several decades, there has been considerable interest in automating the process planning function by computer systems Shop people knowledgeable in manufacturing processes are gradually retiring An alternative approach to process planning is needed, and computer-aided process planning (CAPP) provides this alternative

Benefits of CAPP
Process rationalization and standardization CAPP leads to more logical and consistent process plans than traditional process planning Increased productivity of process planners Reduced lead time to prepare process plans Improved legibility over manually written route sheets Incorporation of other application programs CAPP programs can be interfaced with other application programs, such as cost estimating, work standards, and NC part programming

CAPP Systems
Computer-aided process planning systems are designed around either of two approaches: 1. Retrieval (or variant) systems 2. Generative systems

Retrieval CAPP Systems

Based on group technology and parts classification and coding A standard process plan is stored in computer files for each part code number The standard plans are based on current part routings in use in the factory, or on an ideal plan prepared for each family For each new part, the standard plan is edited if modifications are needed Also known as variant CAPP systems

Retrieval CAPP System

Operation of a retrieval type computer-aided process planning system

Retrieval CAPP Systems - continued

If the file does not contain a standard process plan for the given code number, the user may search the file for a similar code number By editing an existing process plan, or starting from scratch, the user develops a new process plan that becomes the standard plan for the new part code Final step is the process plan formatter Formatter may call other application programs: determining cutting conditions, calculating standard times, or computing cost estimates

Generative CAPP Systems

Rather than retrieving and editing an existing plan from a data base, the process plan is created using systematic procedures that might be applied by a human planner In a fully generative CAPP system, the process sequence is planned without human assistance and without predefined standard plans Designing a generative CAPP system is a problem in expert systems Computer programs capable of solving complex problems that normally require a human with years of education and experience

Components of an Expert System

Knowledge base The technical knowledge of manufacturing and logic used by process planners must be captured and coded in a computer program Computer-compatible part description The description must contain all the pertinent data needed to plan the process sequence Inference engine The algorithm that applies the planning logic and process knowledge contained in the knowledge base to a given part description

Advanced Manufacturing Planning

Emphasizes planning for the future Distinct from process planning because it is concerned with products being contemplated in the company's long-term plans rather than products currently being designed and released Advanced manufacturing planning attempts to forecast the new products that will be introduced in the two to 10 year future And to determine what production resources will be needed to make those future products

Activities in Advanced Manufacturing Planning

1. New technology evaluation Decisions required whether to develop new processes for future products in-house or purchase from vendors 2. Investment project management Investments required for new process technologies must be planned and managed 3. Facilities planning New plants may be needed to produce new products 4. Manufacturing research and development To develop the new process technologies

Advanced Manufacturing Planning