CIMS

PRESENTATION
Performed by: (Div. 1 Batch: T15)
Aaryan More PA59
Sarthak Gawande PA58
Ayush Pawar PA63
Bakhtawar Khan PA61
Vikram Kulkarni PA64
Computer-Aided Process
Planning
 Table of contents

01 INTRODUCTION 02 STRUCTURE

03 OPERATION OF A
SOFTWARE
04 METHODS
 01
INTRODUCTION
The first task in planning is the design of the
processes. Process planning is a vital link
between design and manufacturing functions.
This is an important task as the cost of the part
depends on the process. One of the active
research areas in CIMS is Computer Aided
Process Planning.
• In conventional production system, a process plan is created by a
process planner. It requires a significant amount of time and
expertise to determine an optimal routing for each new part
design. Different process planners have different experiences,
skills, and knowledge of the available processes in the plant.
• This leads to variations and inconsistencies in the process plans
in the plant. As a result of these issues, manufacturing firms are
interested in automating the task of process planning using
computer-aided process planning (CAPP).
 Why do firms need CAPP?
• However, individual engineers will have their own opinions about what constitutes the best
routing. Accordingly there are differences among the operation sequences developed by
various planners. Efficient process planning requires the service of experienced process
planners.

• Because of the problems encountered with manual process planning, attempts have been
made in recent years to capture the logic, judgment and experience required for this
important function and incorporates them into computer programmes.

• Based on the features of a given part, the program automatically generates the sequence of
manufacturing operations. The process planning software provides the opportunity to
generate production routings which are rational, consistent and perhaps even optimal.
 Advantages

Skill Requirement Planning Time Cost

Reduces the skill required of Reduces the process planning Reduces the process planning
a planner. time. and manufacturing cost.

Consistency Accuracy Productivity

Creates more consistent Produces more accurate
Increases productivity.
plans. plans.
 Benefits
Process rationalization and Automated process planning leads to more logical and
standardization consistent process plans than manual process planning.

Increased productivity of The systematic approach and the availability of standard process
plans in the data files permit more work to be accomplished by
process planners
the process planners.

Reduced lead time for Process planners working with a CAPP system can
process planning provide route sheets in a shorter lead time compared to
manual preparation.
Computer-prepared route sheets are neater and
Improved legibility easier to read than manually prepared route
sheets.
Incorporation of other The CAPP program can be interfaced
application programs with other application programs,
such as cost estimation and work
standards.
02
STRUCTURE
STRUCTURE OF A PROCESS PLANNING
SOFTWARE

Figure represents the structure of a computer

aided process planning system. In figure 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.
03
OPERATION
OPERATION OF A TYPICAL COMPUTER
AIDED PROCESS PLANNING SOFTWARE
A typical process planning software may provide the following basic
functions:

Process Planning Report generation

Initialization function
Brief descriptions of functions mentioned in previous slide are given below:

1. PROCESS PLANNING:
The structure of a process planning module will include modules to:
• Create a new plan
• Retrieve a plan and edit
• Delete a plan
• Display plan on monitor
• List summary information

2. CREATING A NEW PLAN:

Creation of a new plan involves several stages. Figure shows the header of a typical process plan
format. The user has to enter various data as per the above format. The manufacturing sequence
is entered in a suitable format. A typical format is given in Table. The process plan gives each
operation to be performed in sequence. The example given is for turning and drilling a
workpiece. The machine, tool and the technology parameters are in the process plan.
3. RETRIEVAL OF PLANS:
A process plan can be retrieved using any of the data fields contained in its
header. A single field or a combination of fields may be necessary. Some times
if we know a word in the description of the part (NOTE) the process planning
systems may come up with the plan numbers or related parts. For example if
we are looking for gearbox parts, by searching notes we may get:

If the user wants to retrieve the plan for Sl. No. 1 he/she can type 1 and get the
plan.
4. SUMMARY INFORMATION:
• Summary information will include Account information, Machine information,
Material information etc.
• Process planning software will have several modules. One such module is the
automatic time standards system. Time standards are based on cutting conditions used
and therefore calculation of machining time requires selection of cutting parameters.
Typical input data for such a system is:
Material : C45
Material hardness : 220 BHN
Work Centre Number : L 120
• The module then goes through the operation description looking for a work element
(say, a machining operation). It then displays available tool materials:
i. Coated Carbide
ii. Ceramic
iii. Cubic Boron Nitride
iv. Diamond coated tools
• From the operation description, pertinent dimensions will be retrieved (like starting
diameter, finish diameter, cut length and depth of cut).
• It also calculates number of passes, displays recommended values of depths, spindle
speeds, power required and machining time. These data can be edited manually if
necessary.
• Similarly there may be modules for time calculation for loading and unloading.
Facilities for archiving the plan are also incorporated in a process planning software.

5. REPORT GENERATION:
Computer aided process planning (CAPP) software packages have normally SQL
capabilities incorporated. Reports can be compiled for:
i. Parts with identical classification
ii. Parts using specific machine type
iii. Parts machined using specific tool materials
iv. Bill of materials
 4
METHODS
Computer-aided process planning systems are designed around two
approaches: (1) Retrieval CAPP systems and (2) Generative CAPP
systems. Some CAPP systems combine the two approaches in what is
known as semi-generative CAPP.
 Retrieval CAPP Systems
• A retrieval CAPP system, also called a variant CAPP system, is based on the principles
of group technology (GT) and parts classification and coding. In this form of CAPP, a
standard process plan (route sheet) is stored in computer files for each part code number.
The standard route sheets are based on current part routings in use in the factory or on an
ideal process plan that has been prepared for each family.
• Before the system can be used for process planning, a significant amount of information
must be compiled and entered into the CAPP data files. This is refer to as the preparatory
phase. It consists of
I. Selecting an appropriate classification and coding scheme for the company,
II. forming part families for the parts produced by the company, and
III. preparing standard process plans for the part families.

Steps (II) and (III) are ongoing as new parts are designed and added to the company’s design
database.
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. This system is used in a machine shop that produces a
variety of small components.
 Generative CAPP Systems
• Generative CAPP systems represent an alternative approach to automated process
planning. Instead of retrieving and editing an existing plan contained in a computer
database, a generative system creates the process plan based on logical procedures
similar to those used by a human planner.

• 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.
Advantages of Generative
CAPP System

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.
Thanks!

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