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Manufacturing Support Systems Unit-6

Manufacturing support systems are essential for managing production, addressing technical and logistics issues, and ensuring product quality through a cycle of information processing activities, including business functions, product design, manufacturing planning, and manufacturing control. Computer Aided Process Planning (CAPP) plays a crucial role in translating design specifications into manufacturing instructions, with approaches categorized into variant and generative planning. These systems enhance efficiency by automating process planning and optimizing manufacturing operations.

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61 views4 pages

Manufacturing Support Systems Unit-6

Manufacturing support systems are essential for managing production, addressing technical and logistics issues, and ensuring product quality through a cycle of information processing activities, including business functions, product design, manufacturing planning, and manufacturing control. Computer Aided Process Planning (CAPP) plays a crucial role in translating design specifications into manufacturing instructions, with approaches categorized into variant and generative planning. These systems enhance efficiency by automating process planning and optimizing manufacturing operations.

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gaurav kulkarni
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Unit-06

Manufacturing Support Systems


Introduction
This is the set of procedures used by the company to manage production and to solve the
Technical & logistics problems encountered. Thin system mainly involves design of process and
equipment, plan & Control the production orders and satisfying product quality requirement.
These functions are accomplished by manufacturing support systems. These supply systems do
not directly Contact the product, but they plan & Control its pogrom through we factory.

Thin involves a cycle of information processing activities. They include;

1. Business Functions
2. Manufacturing planning
3. Product Design
4. Manufacturing Control.

Most of these support systems do not directly contact the product, but they plan and control its
progress through the factory.

Manufacturing support involves a cycle of information-processing activities, as illus-traded in


Figure 1.3. The production system facilities described in Section 1.1.1 are pictured in the center
of the figure. The information-processing cycle can be described as consisting of four functions:
(1) business functions, (2) product design, (3) manufacturing planning, and (4) manufacturing
control.

Business functions. The business functions are the principal means of communicating with the
customer. They are, therefore, the beginning and the end of the information-processing cycle.
Included in this category are sales and marketing, sales forecasting, order entry, cost
accounting, and customer billing,

The order to produce a product typically originates from the customer and proceeds into the
company through the sales and marketing department of the firm. The production order will be
in one of the following forms: (1) an order to manufacture an item to the customer's
specifications, (2) a customer order to buy one or more of the manufacturer's pro-prietary
products, or (3) an internal company order based on a forecast of future demand for a
proprietary product.

Product design- If the product is to be manufactured to customer design, the design will have
been provided by the customer. The manufacturer's product design department will not be
involved. If the product is to be produced to customer specifications, the manufacturer's
product design department may be contracted to do the design work for the product as well as
to manufacture it.

If the product is proprietary, the manufacturing firm is responsible for its development and
design. The cycle of events that initiates a new product design often originates in the sales and
marketing department; the information flow is indicated in Figure 1.3. The departments of the
firm that are organized to accomplish product design might include research and development,
design engineering, and perhaps a prototype shop.

Manufacturing Planning- The information and documentation that constitute the product
design flows into the manufacturing planning function. The information-processing activities in
manufacturing planning include process planning, master scheduling, requirements planning,
and capacity planning.

Process planning consists of determining the sequence of individual processing and assembly
operations needed to produce the part. The manufacturing engineering and industrial
engineering departments are responsible for planning the processes and related technical
details. Manufacturing planning includes logistics issues, commonly known as production
planning. The authorization to produce the product must be translated into the master
production schedule. The master production schedule is a listing of the products to be made,
the dates on which they are to be delivered, and the quantities of each. Months are
traditionally used to specify deliveries in the master schedule. Based on this schedule, the
individual components and subassemblies that make up each product must be planned. Raw
materials must be purchased or requisitioned from storage, purchased parts must be ordered
from suppliers, and all of these items must be planned so that they are available when needed.
This entire task is called material requirements planning. In addition, the master schedule must
not list more quantities of products than the factory is capable of producing each month with
its given number of machines and manpower. A. function called capacity planning is concerned
with planning the manpower and machine resources of the firm.

Manufacturing Control- Manufacturing control is concerned with managing and controlling the
physical operations in the factory to implement the manufacturing plans. The flow of
information is from planning to control as indicated in Figure 1.3. Information also flows back
and forth between manufacturing control and the factory operations. Included in the
manufacturing control function are shop floor control, inventory control, and quality control.

Computer Aided Process planning (CAPP)


This is the planning strategy for manufacturing the part. It is defined as the activity that translates part
design specifications from an engineering drawing into the manufacturing operation instructions
required to convert a part from a rough to a finished state. It represents the link between engineering
design and shop-floor manufacturing. It is a major determinant of manufacturing cost and profitability.
The gap between CAD and CAM can be shortened considerably by developing better systems for process
planning. There are two levels of process planning High-level planning'
The planner identifies the machine able features (surfaces) of the part, groups them into set-ups, and
orders these set-ups. The features to be cut in each of the set-ups, and the tools for cutting each
feature. Low-level planning- Specifying the details of performing each step that results from the first
level such as choosing machines, cutting conditions (speed and feed), type of fixture, cost and time
estimates, etc.

Thr current approaches for computer aided process planning can be classified into two groups:
i. Variant
ii. Generative

Structure of a Process Planning Software


The modules are not necessarily arranged in the proper sequence but can be based on importance
or decision sequence. Each module may require execution several times in order to obtain the
optimum process plan. The input to the system will most probably be a solid model from a CAD data
base or a 2-D model. The process plan after generation and validation can then be routed directly to
the production planning system and production control system.

Information required for Process Planning


The geometric model of the part is the input for the process planning system. The system outputs
the process plan (Fig.). The input to the process planning system may be engineering drawing or
CAD model.

I) Variant Process Planning


A variant process planning system uses the similarity among components to retrieve the existing
process plans. A process plan that can be used by a family of components is called a standard plan. A
standard plan is stored permanently with a family number as its key. A family is represented by a
family matrix which includes all possible members. The variant process planning system has two
operational stages:
• A preparatory stage and
• A production stage. During the preparatory stage, existing components are coded, classified, and
subsequently grouped into families. The process begins by summarizing process plans already
prepared for components in the family.
The operation stage occurs when the system is ready for production. An incoming part is first coded.
The code is then input to a part family search routine to find the family to which the component
belongs. The family number is then used to retrieve a standard plan. Some other functions, such as
parameter selection and standard time calculations, can also be added to make the system more
complete.
II) Generative Process Planning
Generative process planning is a system that synthesizes process information in order to create a
process plan for a new component automatically In a generative planning system, process plans are
created from information available in manufacturing data base without human intervention. Upon
receiving the design model, the system can generate the required operations and operation
sequences for the component. Knowledge of manufacturing must be captured and encoded into
efficient software. By applying decision logic, a process planner’s decision making can be imitated.
Other planning functions, such as machine selection, tool selection, process optimization, and so on,
can also be automated using generative planning techniques. The generative planning has the
following advantages:
i. It can generate consistent process plans rapidly.
ii. New process plans can be created as easily as retrieving the plans of existing components.
iii. It can be interfaced with an automated manufacturing facility to provide detailed and up-to-
date control information.

he generative part consists of:


• Component representation module
• Feature extraction module
• Feature process correlation module
• Operation selection and sequencing module
• Machine tool selection module

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