Practical No: 6

CO: 6: Adapt recent practices like CAPP, CIM, AI, RP and FOF for effective production .
Title of Practical: Recent Trends in Manufacturing

Computer Aided Process Planning (CAPP):

It is linkage between the CAD module and CAM module, which confers it a special space in the CIM system.
Main idea to develop CAPP is to structure the data concerning part design, manufacturing facilities and capabilities
into categories. CAPP should have following characteristics:
• CAPP must be capable of understanding and analyzing the part characteristics.
• It must possess knowledge about machine tools, cutting tools etc.
• It must possess the capabilities of analyzing the interdependencies between part, machining processes, quality
and cost.
• It must possess multiple calculating capabilities.
CAPP is a method of automatically generating the sequence of manufacturing operations. CAPP provides the
opportunity to produce manufacturing routing which is rational, consistent and even optimal. Two alternative
approaches to CAPP have been developed: Retrieve type and generative type.
Retrieve (Variant) type CAPP: This system works on basis of group technology and part classification and coding
system. Parts are grouped into the part families on the basis of design and manufacturing attributes.These parts
are called master parts. Process plan for a part is created by recalling, identification and retrieving an existing
plan for identical part and making needful modification for new part. A standard process plan is stored in computer
file for each code number. The database of these files are prepared and maintained. Then appropriate standard plan
is retrieved as per part or component. The procedure of variant process plan consistsof following steps:
Classify the parts and label
the parts as per the
appropriate code.
1) Prepare the part families
on the basis of design and
manufacturingattributes.
2) Prepare the operation
sheet or rout sheet of
each part familiesdefined
in above step-2.
3) Enter new part with part
code to get the process
plan.
4) The CAPP program will
search the part family. If
file contains an identical code then standard process plan is retrieved.
Steps 1 to 3 are the preparatory steps which are required to make up the database of standard process plan. This
is called preparatory stage. Next steps are production stage where standard process plan are retrieve from database.
Standard process plan is examined by the use to make any necessary modification to accommodate unique features
of the new parts. The success of process planning system depends upon the coding scheme, standard process plan
and then underlying modification process. Number of variant process planning systems has been developed like
MIPLAN, COMCAPP etc.

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 Advantages of Retrieve (Variant) type CAPP: There are following advantages of variant process planning
approach:
• Once a standard process plan is prepared, a variety of components can be prepared.
• It reduces time and labour requirements because of efficient processing and evaluation of complicated
activities.
• Simple programming and installation is required to implement a planning system as compared to generative
process planning system.
• It is understandable and easy to learn and use.
• Lower development and hardware costs.
• It provides standard procedure.
Disadvantaged of Retrieve (Variant) type CAPP: There are few limitation of variant process planning
system:
• It is difficult to maintain consistency in editing.
• Detail of plan can’t be generated.
• It requires experience person to get quality of final process plan because it is required to modify the standard
plan for specific component.
• It can’t be used in an entirely automated manufacturing system without additional process planning.
Generative type CAPP: Generative process planning is a system which creates the plan by means of decision
logic, formulas and other logical procedures. In this method process plans are prepared from scratch without the
assistance of human and predefined standard plans. Input to the system includes the description of the part in the
form of part code number. After receiving this information, the system can generate the required processes and
process sequences for work parts. Then it synchronizes this process information in order to create a process plan
for this new component by using decision logic.
Major elements required in
generative process planning system
are as follows:
• The technical knowledge of
manufacturing and the logicmust
be confined and coded into the
computer program.
• Computer compatible description
of the part to be produced. It is
required to plan the process
sequence.
• The capability to apply the
process knowledge and logic
contained in the knowledge base
to a given part description.
Hence it is comprised of mainly two
components:
• Geometry description and coding component: It involves all the geometric features for all process related
surface together with feature dimensions, locations, tolerances and surface finish.
• Process knowledge database and decision making logic: The knowledge will be in the form of decision logic.
It is required to match the part geometry requirement with manufacturing capability using decision logic and
data. It includes selection of processes, manufacturing equipments, work holding devices, jigs and fixtures,
inspection instruments etc. The decision tables will make easier to document process knowledge.

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 Advantages of Generative type system: The generative process planning system offers the following
advantages:
• It can generate consistent process plans rapidly.
• It provides process plan in much greater detail than variant process plan.
• It can plan the new parts as easy as existing parts.
• It can be interfaced with automated manufacturing facility to provide detailed control information.
Benefits of CAPP: The following are the benefits of CAPP.
• It will generate the accurate and consistent process plan than manual process planning.
• It will generate the process plans more quickly hence lead will be laser.
• It will reduce the routine clerical works.
• It will increase the ability to introduce new technology.
• It will improve the productivity.
• Process planning cost will be lesser than manual process planning.
• It will increase the utilization of man machine.

Computer Integrated Manufacturing (CIM):

CIM is the integration of the total manufacturing enterprise through the use of integrated system and data
communications coupled with new managerial philosophies that improve organisation and personal efficiency.
CIM is an effective utilisation of computer technology in management, control and operation of the entire
manufacturing process by utilising all resources, including information, to best serve the customer; typically
incorporating together the following technologies: CAM, CAD, CAPP, CAQC. CIM an approach to the organisation
and management of a firm, in which the function of design, manufacturing and production management are mutually
rationalised and completely coordinated, through the use of appropriate levels of computer and information/
communication technologies.
Elements of CIM: The five main elements of the CIM
system are: Product Design, Production Planning,
Production Control, Production Equipments and
Production Process. These elements must be an integral
part of the manufacturing system to be automated,
optimised and integrated by applying the computer.
• Product Design: this establishes the initial database
for production of a proposed product. Ina CIM
system, this is accomplished through
activities such as geometric modelling and CAD while considering the product requirements and concepts
created by the creativity of design engineering. The cost constraint and the capabilities of existing production
equipment and process must also be kept in mind during the design process.
• Production Planning: It takes the database established by product design and enriches it with production
data and information to produce a plan for production of product. The cost incurred and production equipments
capability should be key consideration for generating an optimised plan.
• Production Control: This requirement further enrichment of the data base with performance data and
information about the production equipment and process. In a CIM system, this requires activities such as
modelling, simulation and computer aided scheduling of product activities. Continuous optimization of the
production activity is must.
• Production Equipments: Production equipment further enrich the data base with equipment and process
data and information, resident either in the operators or equipments, to carry out production process. In a

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 CIM system, this equipment consists of computer controlled process machineries such as CNC machine
tools, FMS, Computer controlled robots, AS/RS, inspection equipments, etc.
• Production Process: Production processes that create the finished products are carried out by the production
equipment. This is done under the guidance of the data, information and knowledge resident inthe operator
or for CIM system in the equipment and the total integrated data base supporting it. These processes consist of
material removal, material forming or material consolidation as well as automated quality assurance.
Advantages of CIM: The integration of the technologies brings the following advantages:
• Creation of truly interactive system that enables manufacturing functions to communicate easily with other
relevant functional units.
• Accurate data transferability among the manufacturing plant or subcontracting facilities at in plant or diverse
locations.
• Faster response to data changes for manufacturing flexibility.
• Increased flexibility towards introduction of new products.
• Improve accuracy and quality in the manufacturing process.
• Improve quality of the products.
• Control of data flow among various units and maintenance of user library for system wide data
• Reduction of lead times which generates a competitive advantages.
• Streamlined manufacturing flow from a order to delivery.
• Easier training and retraining facilities.

Computer Aided Inspection (CAI):

Computer Aided Inspection (CAI) is the use of computer based software tools that assists quality engineers,
machinist and inspectors in manufacturing of products and components. The CAI methods may be classified as
below:
1) Contact Inspection methods
a) Coordinate Measuring Machine (CMM)
b) Flexible Inspection System (FIS)
c) Mechanical Probe
2) Non contact inspection methods
a) Optical Technique
I. Machine Vision
II. Scanning Laser Beam Devices
III. Photogrammetric
b) Non Optical Techniques
I. Electrical Field Techniques
II. Reluctance
III. Capacitance
IV. Inductance
V. Radiation Techniques
VI. Ultrasonic
Advantages of CAI: CAI has following advantages as below:
• Speed of measurement.
• Accuracy of measurement from 0.001 to 0.005mm.
• Capability of in-process measurement.

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 • CAI is capable to measure the curvature and cavity of the products.
• CAI compares the CAD model with actual model by techniques such as coordinate measuring and 3D.
• CAI introduces a faster and easier process for directly comparison between 3D CAD model and machined or
prepared parts.
• Computerized data records of measured parts.

Rapid Prototyping (RP):

The term RP refer to a class of technology that can automatically construct physical model from computer aided
design data. In addition to prototypes, RP techniques can also be used to make tooling and even production
quality parts.
Need of RP: Rapid prototype came into
existence due to the following limitations in
traditional prototyping methods. They are as
below:
• Time require to make the prototype.
• Overall complexity of the model.
• Extremely labour intensive.
• Metal removal techniques by manual and
machining involve time and cost.
Basic Process: although several rapid prototyping techniques exist, all employ the same basic five steps
process.
• Create CAD Model of design: First, the object to build is 3D solid modelled using CAD software package like
CREO, Solid Works, Solid Edge, Inventor etc. The designer can use a pre-existing CAD file or may wish to
create one expressly for prototype purposes. This process is identical for all of the RP build techniques.
• Convert CAD model to STL format: The various CAD packages use a number of different algorithm to
represent solid object. To establish consistency, the STL format has been adopted as standard of the RP industries.
The second step is to convert the CAD file in to STL format.
• Slice STL file into thin cross-sectional layer: In the third step, a pre-processing program prepare the STL file
to be built. Several programs are available, and most allow adjusting the size, location and orientation of the
model. The pre-processing software slices the STL model into number of layer form 0.01mm to 0.7mm thick,
depending on building technique. The program may also generate an auxiliary structure to support the model
during build. Supports are useful for delicate feature such as overhang, internal cavities, thin walled section etc.
Each RP machine manufacturers supplies their own proprietary pre-processing software.
• Construct layer by layer model: The fourth step is actual construction of the part using one of several
techniques RP machine build one layer at a time from polymer, paper or powdered metal. Most machines are
fairly autonomous, needing little human intervention.
• Clean and finish model: The final step is post-processing. This involves removing the prototype form the
machine and detaching any supports. Some photosensitive materials need to be fully cured before use.
Prototyping may also require minor cleaning and surface treatment. Sanding, sealing and painting the model will
improve its appearance and durability.
Techniques of RP:
• Stereolithography
• Inkjet Deposition
• Multi Jet Modeling
• Laminated Object Manufacturing

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 • Fused Deposition Modeling
• Solid Ground Curing
• Three Dimensional (3D) Printing
• Selective Laser Sintering
Application of RP: RP is widely used in automotive, aerospace, medical and consumer product industries.
Although the possible applications are virtually limitless, nearly all fall into one of the following categories:
• Prototyping: As its name suggest, the primary use of RP is to quickly make prototypes for communication
and testing purpose. Prototypes dramatically improve communication because most people, include engineers,
find 3D (Three Dimensional) objects easier to understand than 2D (Two Dimensional) drawing. Such improved
understanding leads to substantial cost and time saving. Prototypes are also useful for testing a design, to see
if it performs as desired or needs improvement. Engineers have always tested prototypes, but RP expands their
capabilities. It is now easy to perform iterative testing: build a prototype, test it, redesign, build etc. Such an
approach would be far too time consuming using traditional prototyping techniques, but it is easy using RP.
• Rapid Tooling: A much anticipated application of RP is rapid tooling, the automatic fabrication of production
quality machine tools. Tooling is one of the slowest and most expensive steps in the manufacturing process,
because of the extremely high quality required. Tools often have complex geometries, yet must be
dimensionally accurate to within a hundred of a millimetre. In addition, tools must be hard, wear resistance
and have very low surface roughness. To meet this requirements, mould and dies are traditionally made by
CNC machining, electro discharge machining or by hand. All are expensive and time consuming, so
manufacturing would like to incorporate RP techniques to speed the process. Toolingcost and development
time can be reduces by 75% or more by using rapid tooling and related technologies. Rapid tooling can be divided
in to two categories, indirect and direct tooling.
Most rapid tooling today is indirect: RP parts are used as pattern for making moulds and dies. RP models
can be indirectly used in a number of manufacturing processes: Vacuum casting, sand casting, investment
casting, injection moulding.
To directly make hard tooling from CAD data is the holy grail of rapid tooling. Realization of this objective
is still several years away, but some strong strides are being made: Rapid tool, Laser engineering net shaping,
Direct ACES injection moulds, LOM composite, sand moulding, etc.
• Rapid Manufacturing: A natural extension of RP is rapid manufacturing, the automated production of saleable
products directly from CAD data. Currently only a few final products are produced by RP machines, but the
number will increase as metals and other materials become more widely available. Rapid manufacturing will
never completely replace other manufacturing techniques, especially in large production runs where mass
production is more economical. The other major use of Rapid Manufacturing is for products that simply
cannot be made by subtractive or compressive processes. This includes objects with complex feature, internal
voids and layered structures.
Advantages of RP: Some of the advantages of RP are below:
• Improve production development includes customer satisfaction.
• Improve sales and marketing.
• Reduction in overall time of development and production.
• Many modifications can be done before it is sent for production.
• Internal cavities and complex geometry’s can be produced.
• It is valuable key for efficient and concurrent engineering.
Limitation of RP: Some of limitations of rapid prototyping are as below:
• The use of RP materials are different from those specified for the part being design.
• Poor mechanical properties.

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 • It is cost effective when it is produced in small numbers.

Artificial Intelligence:
Artificial Intelligence (AI) is the science of making machines do things that would require intelligence if done by
men. AI encompasses a diverse number of computer applications or components within applications that use sets of
rules and knowledge to make inference.
In business application, AI capabilities are often integrated with system that serves the day to day needs of the
enterprise, such as inventory tracking, manufacturing process controls and customer service database. AI is having
major effect on the design, automation and overall economic of manufacturing operations.
Techniques of AI: AI application in manufacturing encompasses the following techniques.
• Expert System: An expert system is defined as an intelligent computer program that has the capability to solve
difficult real life problems by the use of knowledge substantial base and inference procedures. Expert systems
are computer based systems that apply the substantial knowledge of specialist to help to solve complex problem
without requiring a human to work through each one. In developing such systems, designers usually work with
expert to determine the information and decision rules that the experts use when confronted with particular type
of problems.
• Natural Language: These systems allow a user to obtain information by entering English language commands
in the form of simple, typed questions. Software shells are available, and they are used in such applications as
the scheduling of material flow in the manufacturing and analysing of information databases.
• Machine Vision: Compute and software implementing AI are being interfaced with camera and other image
process devices. The main purpose of machine vision is to provide the user graphic information about the parts
for the purpose of recognition. These machines can perform operation such as inspection, identifying, sorting of
parts and guiding of robots.
• Fuzzy Logic: Some time in manufacturing, decision are made on the basis of vagueness and imprecise
information or without reasoning. In such a situations fuzzy logic provide better solution. These models
have the capability to recognize, represent, manipulate, interpret and utilize data and information that are vague
or lack precision.
• Artificial Neural Network: Neural network go one step further than expert system in bringing stored knowledge
to bear on practical problems. Instead of just leading the user to the appropriate piece on knowledge that has
been captures in the system, neural networks process patterns of information to arrive at new abilities they were
not equipped with on day one. In a sense, they learn to do things for the user based on special preparation that
involves feeding the system data which it then analyzes for patterns. These are being used in robotics, object
preconisation, speech recognition and process control.
Lean Manufacturing:
Lean Manufacturing can be defined as: a systematic approach to identifying and eliminating waste through
continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. Lean is
philosophy that seeks to eliminate waste in all aspect of a firm’s product activities: human relation, vendor relation,
technology, and management of material and invent.
Lean manufacturing is simply the elimination of waste in the manufacturing process. Waste can be in the form
of material, time, ideal equipments, or inventory. Lean manufacturing helps to improve material handling, inventory,
quality, scheduling, and personal and customer satisfaction. A lean manufacturing process is one that continuously
strives to eliminate waste, thereby increase the percentage of time devoted to value adding activities.
Waste in Lean Manufacturing: There are different kinds of waste identified in lean manufacturing.
• Over Production:
• Waiting:

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 • Transportation:
• Non Value Added Process:
• Excess Inventory:
• Defects:
• Excess Motion:
• Underutilize People:
Principles of Lean Manufacturing: To achieve the lean level, industries have to follow some principles.
These principles are as follow:
• Perfect first time quality: Quest for zero defects, revealing and solving problems at the source.
• Waste minimization: Eliminating all activities that do not add value and safety nets, maximize use of scare
resource.
• Continuous improvement: Reducing cost, improving quality, increasing productivity and information
sharing.
• Pull processing: products are pulled from the consumer end, not pushed from the production end.
• Flexibility: producing different mixes or greater diversity of products quickly, without sacrificing
efficiency at lower volume of production.
• Building and maintaining a long term relationship with supplier through collaborative risk sharing, cost
sharing and information sharing arrangements.
Techniques Used for Lean Manufacturing: Few techniques are used for lean manufacturing as under:
• Work Flow Analysis
• Kanban
• Kaizen
Benefits of Lean Manufacturing: the benefits derived by adopting the lean manufacturing system are given
as:
• Increased productivity and asset utilization.
• Increase flexibility.
• Significant cost reduction in short span time.
• Significant improvement in delivery time.
• Stronger focus on performance.
• Reduces waste and inventory.
• Reduction in cycle time and lead time.
• Reduces unplanned maintenance.
• Reduction in scrap.
• Greater sensitivity to market change.
• Improve buyer supplier relationship.
• Increased customer satisfaction.
• Lesser setup time.
• Better communication between departments.
• Increased and improve competitiveness.
Questions

1) Write a short note on Coordinate Measuring Machine (CMM).

2) Write a short note on Artificial Neural Network (ANN).

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