6ME4-02: Computer Integrated Manufacturing Systems

Tarun Kumar Aseri

Asst. Prof.
Mechanical Engineering
Engineering College, Ajmer
Barliya Circle, NH-8,
Ajmer-305025, India
Email: tarunaseri[at]ecajmer.ac.in

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Learning Outcomes

About Computer Aided

process Planning (CAPP)

Types of CAPP, merits and

demerits

Process Planning information

flow

Computer generated time

standards
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 CAPP
A link between design and manufacturing
Also named as a Route sheet

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 Computerized Manufacturing Planning System

Computerized
Manufacturing
Planning System

Computer Aided Computer Integrated Material

Process Planning Production Planning Requirements
(CAPP) Systems (CIPP) Planning (MRP)

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 Manufacturing Engineer and Process Planning
Based on the planner’s knowledge, skill and experience, the processing
steps are developed in the most logical sequence.
▪ Interpretation of design drawing: material, dimensions, tolerance,
surface finish.
▪ Processed sequence: Brief description of all processing steps.
▪ Equipment selection: To utilized existing equipments or procure
new equipments. Like tools, dies, molds, fixtures, Jigs.
▪ Work standards: time and motion study for each operation.

Likely to be change frequently/continuously

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 Computer Aided Process Planning: Why?
• Systematically produce product accurate and consistent process
plan,
• Reduce the cost (manufacturing) and lead time,
• Reduce non-productive residence time,
• Increased productivity by utilizing idle machine tools
• Identify short material flow route
• Interfacing between cost, manufacturing lead time and work
standards.
• Efficient utilization of man, machine and material/money (3Ms)

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 Computer Aided Process Planning
• Translation of design information into the process steps and
instructions to efficient and effective manufacturing
• Helps in simplifying and efficiently carrying out the conventional
process planning and optimizing used of resources.
• Detailed set of instructions, engineering drawings, specifications,
parts and material list, etc.

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 Computer Aided Process Planning: Framework
Production Design and
Organizational Development Request
Planning System

Part list Connected Data

CAD

Geometry Data
MRP Material Parts master files
Resource Planning CAPP
Capacity Planning
Process Data

Machine, tool,
Production Actual
order data fixture, Data NC Connected
bank Program Data

CAM Production Control

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 Computer Aided Process Planning: Types or Approaches

1. Variant or Retrieval CAPP

2. Generative CAPP
3. Hybrid

• Old CAPP – New CAPP

• Design changes – Changes cost estimates
• Machine breakdown – alternate solution/effective solution

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 Computer Aided Process Planning: Types or Approaches

Variant or Retrieval CAPP

- Process plan for a new part is generated by recalling, identifying
and retrieving an existing plan for a similar part and making
necessary modification for new part

- Coding and classification schemes of group technology (GT)

used, number of algorithms, mathematical models are developed
for family part formation and plan retrieval

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 Variant or Retrieval CAPP: Advantages
- Processing and evaluation of complicated activities and
managerial issues done in an efficient manner, thus reduction of
time and labor requirement
- Reduced development and hardware cost and shorter
development time

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 Variant or Retrieval CAPP: Disadvantages
- Difficult to maintain consistency during editing,
- Proper accommodation of various combinations of attributes
such as material, geometry, size, precision, quality, alternate
processing sequence and machine loading among many other
factors are difficult,
- The quality of the final process plan largely depends on the
knowledge and experience of process planner.

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 Computer Aided Process Planning: Types or Approaches

Generative CAPP
- Process plans are generated by means of decision logic,
formulas, technology algorithms, etc.
- Main aim is to convert a part from raw material to
finished state,
- Input to the system includes the description of the part
in the form of part code number.

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 Generative CAPP

Consist of two major components:

i. Geometry based coding scheme

ii. Knowledge based coding scheme

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 Generative CAPP: Types
Geometry based coding scheme
• All the geometric features for all process such as related
surfaces, feature dimensions are defined by geometry
based coding scheme,
• The level of detail is much greater in generative system
than a variant system.
Knowledge based coding scheme
• Process knowledge in the form of decision logic and data
are used for matching of part geometry requirement
with the manufacturing capabilities
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 Generative CAPP: Advantages
▪ They rely less on group technology code numbers.
Usually uses decision tree to categorize parts into
families,
▪ Maintenance and updating of stored process plans are
largely unnecessary,
▪ New components can be planned as easy as existing
components.

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 Engineering design Manufacturing Data
Process Planning - New product design - Machining data
information flow - Engineering changes - Standard procedures
- Existing equipment, tooling, layout, etc.
- Inspection requirements
New methods - Material types
Manufacturing Engineering
New processes - Producibility limitations
- Process plans
New equipment - Documentation requirements
- Tool designs
New layout - Standard time data

Manufacturing
- Sequence of operations
- Work-centers Accounting Purchasing Production control
- Standard times - Work-centers - Material - Sequence of operations
- Tooling and fixturing - Standard times - Time estimates - Work-centers
- Material - Material - Drawings - Standard times
- Drawings - Drawings
- Manufacturing instructions - Material
- NC programs
- Inspection instructions
- Methods
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 Computer Generated Time Standard
➢Work measurement can be defined as:
“a development of a time standard to indicate the value of a work task”
➢Various purposes for work measurement are:
▪ To evaluate wage incentives
▪ Estimating cost of a job
▪ To schedule production and plan capacity to manufactured
▪ To measure and estimate performance of worker
➢Work measurement is related to process planning because:
▪ In well-organized process planning system, a time standard must be determined
for each of the operation listed on the route sheet so as to meet out the estimated
order delivery schedule

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 Computer Generated Time Standard

• Techniques usually used to estimate TIME STANDARDS

▪ Direct time study

▪ The use of standard data

▪ Predetermined time standard systems

▪ Estimates based on previous experience

▪ Work sampling

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 Computer Generated Time Standard
• The advantages of using a computerized system for generating time
standards are:
• Reduction in time required for the time study analyst to set the standards
• Greater accuracy and uniformity in the time standards
• Ease of maintaining the method file and standard file when engineering and
method change occurs
• Eliminating of controversial performance rating step
• The time standards can often be set before the job gets into the production
• Improved manufacturing data base for production planning, scheduling,
forecasting labor requirements, tool control etc.

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 Computer Aided Process Planning

General steps involved

Design input, Material selection,
Process selection,
Process sequencing, Machine & Tool
selection,
Fixture selection, Machining parameter
selection,
Cost/time estimation, Plan preparation,
etc.

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 CAPP: Overall Advantages
▪ It can systematically produce accurate and consistent
process plans,
▪ It leads to the reduction of cost and lead times of process
plan,
▪ Skill requirement of process planer are reduced to
develop feasible process plan,
▪ Interfacing of software cost, manufacturing lead time
estimation and work standards can easily be done,
▪ Leads to the increased productivity of process planar

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 Summary
❖CAPP: Translation of design information into the various
process steps and instructions to get efficient and effective
manufacturing
❖Based on product process plan can be retrieved from earlier
plan or generate a fresh new plan or hybrid of both
❖Computer Generated Time Standard, its techniques and
advantages

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Thank you for
your kind
attention

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