ROHINI COLLEGE OF ENGINEERING & TECHNOLOGY

ME8793 PROCESS PLANNING AND COST ESTIMATION

UNIT 1 INTRODUCTION TO PROCESS PLANNING

2. METHODS OF PROCESS PLANNING:

The two general methods / approaches to process planning are

1. Manual process Planning and

(i) Traditional approach

(ii) Workbench approach

2. Computer Aided Process Planning

(i) Retrieval CAPP system

(ii) Generative CAPP system

Manual process Planning

(i) Traditional approach

In traditional process planning systems, the process plan is prepared

manually. The task involves examining and interpreting engineering
drawing.

Making decisions on machining process selection, equipment selection,

operations sequence, and shop practices.

The manual process plan is very much dependent on the skill, judgment and
experience of the process planner. That‟s Why, if different planners were asked to
develop a process plan for the same part, they would probably come up with different
plans.

The traditional process planning usually involves the following three stages, are;

ME8793 PROCESS PLANNING AND COST ESTIMATION

 ROHINI COLLEGE OF ENGINEERING & TECHNOLOGY

Stage 1: The process planner interprets the component/product drawing using his own
experience and intuition. Taking into account the type of resources available, he decides
on how the component / product should be made. He lists the sequence of operations to
be carried out in order to manufacture the product.

Stage 2: The process planner refers the manual to decide on tools, feeds, speeds. etc.,
for each element of each operation, Also the specific operation setup times and
operation times for each operation are calculated using the manual.

Stage 3: Finally, the resulting process plan is documented as a routing sheet.

Workbook Approach

 The workbook approach is a modified version of traditional approach of process

planning that uses the developed workbook for preparing route sheet.
 In this approach, the workbooks of predetermined sequence of operations for
possible elements of operations of components / products arc developed. Once
the drawing interpretation is carried out, the suitable predetermined sequence of
operations are selected from the developed workbook and the details are
documented in the route sheet.

Advantages of Manual Process Planning

The advantages of employing manual process planning are as follows:

(i) Manual process planning is very much suitable for small scale companies
with few process plans to generate.

(ii) This method is highly flexible.

(iii) This requires low investment costs.

Disadvantages of Manual Process Planning

The disadvantages of manual process planning include the following:

(i) Manual process planning is a very complex and time consuming job
requiring a large amount of data.

ME8793 PROCESS PLANNING AND COST ESTIMATION

 ROHINI COLLEGE OF ENGINEERING & TECHNOLOGY

(ii) This method requires the skilled process planner.

(iii) More possibilities for human error because this method depends on the
planner’s skill, judgement and experience.

(iv) It increases paper work.

(v) Inconsistent process plans result in reduced productivity.

(vi) It is not very responsive to changing manufacturing environment, new

processes, new tooling, new materials, etc.

COMPUTER AIDED PROCESS PLANNNG (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.
 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.
 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.

 Elimination of human error

ME8793 PROCESS PLANNING AND COST ESTIMATION

 ROHINI COLLEGE OF ENGINEERING & TECHNOLOGY

 Reduction in time: As a result of computerizing the work, a job that used to lake
several days, is now done in a few minutes.
 Reduced clerical effort and paper work
 Improved legibility: Computer-prepared route sheets are neater and easier to
read than manually prepared route sheets.
 Faster response to engineering changes: Since the logic is stored in the memory
of the computer.
 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

1. Retrieval CAPP system

2. Generative CAPP system

1. Retrieval 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.
 In this system, a process plan flit a new part is created by recalling, Identifying
aid 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 past classification and coding. In this system, for each part family a standard
process plan (i.e., route sheet) is prepared and stored in computer files. Through
classification and coding, a code number is generated. These codes are often used to
identify the part (amity and the associated standard plan. The standard plan is retrieved
edited for the new part.

ME8793 PROCESS PLANNING AND COST ESTIMATION

 ROHINI COLLEGE OF ENGINEERING & TECHNOLOGY

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.
 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.

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.
 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).
 When using a system, a specific process plan for a specific part can be generated
without army 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. A part description, which identifies a series of component characteristics,

including geometric features, dimensions, tolerances and surface condition.

b. A subsystem to define the machining parameters, for example using look-

up tables and analytical results for parameters.

ME8793 PROCESS PLANNING AND COST ESTIMATION

 ROHINI COLLEGE OF ENGINEERING & TECHNOLOGY

c. 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.

d. A database of available machines and tooling.

e. A report generator which prepares the process pIan report

Advantages of Generative CAPP

The generative CAPP has the following advantages:

i. It can generate consistent process plans rapidly.

ii. New components can be planned as easily as existing components.

iii. 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.

ME8793 PROCESS PLANNING AND COST ESTIMATION