1. What is process planning?

Process planning comprises the selection and sequencing of processes and

operations to transform a raw material into a finished component; the act of
preparing detailed work instructions to produce a component, including the
selection of manufacturing processes and operations, production equipment,
tooling and jigs and fixtures.

2. What is the relationship between process planning and the type of manufacturing
environment employed?
The level opf detail incorporated intop the process plans depends on the type of
environment employed.

3. What are the main activities undertaken during process planning?

Drawing interpretation, Material evaluation and process selection, Selection of
machines and tooling, Setting process parameters, Workholding devices,
Selecting quality assurance methods, Costing, Preparing the process planning
documentation.

4. What functions are involved in the design and manufacture of a product and what
do they contribute?
Marketing: After sales data, New product idea; Design: R&D, Product
specification, Concept design, Detail design, Modify design; Manufacturing:
Prototype, Pilot & test run, Production planning, Manufacturing.

5. Why is there so much emphasis on the integration of the design and manufacture
functions and how is this being achieved?
Integration of the design and manufacture functions is emphasized because it is
estimated and between 70 to 80 % of the cost of a product is committed at the design
state. This is done by ensuring the understanding of all team members about the
product functions, determining the appropriate design and manufacturing
methods to use, and relating all product functions to manufacturing methods.

6. What sort of information can the process planner obtain from the engineering
drawings of a component?
Geometry, Dimensions and tolerances, Geometric tolerances, Surface finishes,
Materials, Number of parts.

7. Why is it important for the process planner to have a good knowledge of materials
used in manufacturing?
Because the process planner will, on occasion, have to enter into a meaningful
dialogue with the design engineer about the materials specified based on the
manufacturing processes.

8. What is considered the most critical element in machining?

9. What are workholding devices and why are they used?
Workholding devices are devices used to hold the product during the manufacturing
processes, they are used to increase precision during manufacturing and to ease
the processes done on the product.

10. What process planning decisions can cost contribute to?

Cost can contribute to material used, manufacturing processes used, the batch size
employed, and to decide whether to make or buy a product or component.

11. What are the main inputs and outputs for process planning activity?

12. How does the industrial engineering function contribute to the process planning
activity?
The industrial engineering function generates various sources of internal
information used by the process planner, and is responsible for work measurement.

13. What is a flow process chart and how would it be used to help formulate a
process plan?
A flow process chart is a chart containing the processes, aspects involved, and the
time required. It is used as consideration in process planning, as it details not only
the value-added activities, but the non-value-added activities such as transportaion
and handling.

14. What is the relationship between quality engineering and process planning?
The relationship between quality engineering and process planning is that the QA
function specifies the details of the quality aspects of the process plan often in
conjunction with the process planner, including the inspection location, tools, and
methods employed.

15. How is processs planning related to production planning and to what planning
and control functions does it directly contribute?
Process planning is part of the production planning and control functions.

16. What are the main approaches to process planning?

Traditional approach and workbook approach.
17. What are the general guidelines for process planning?
Establishing one datum as soon as processing commences and using this as a
reference for all operations; creating as many surfaces as possible at the same
setting; avoiding the use of secondary surface data; precision operations should be
carried out last; inspection operations should be included at appropriate intervals.

18. What are the advantages and disadvantages of manual process planning?
Advantages: Low-cost and flexible.
Disadvantages: Excessive paperwork; Lack of consistency in planning; Late design
modifications; Changing technology.

19. How are a process, an operation and a cut defined in terms of process planning
and how are they related?
Cut is the sub-unit of an operation, operation is the sub-unit of a process. A process
will consist of a number of operations, some operations may require several cuts
or in some cases only one cut.