Computer Aided Process

Planning (CAPP)
 What is Process Planning?
Process planning includes the activities and
functions to prepare a detailed set of plans and
instructions to produce a part. Planning begins
with engineering drawings, specifications, part
list and a forecast demand.
Process planning translates design information
into the process steps and instructions to
efficiently and effectively manufacture the
product.
 Introduction to CAPP:
Main idea to develop computer aided process
planning is to structure the data concerning part
design, manufacturing facilities and capabilities
into categories.
CAPP is the method of automatically generating
the sequence of manufacturing operations.
CAPP provides the opportunity to produce
manufacturing routings which are rational,
consistent and even optimal.
 Characteristics of CAPP:
CAPP capable of understanding and
analyzing the part characteristics.
It possess knowledge about machine
tools, cutting tools, etc..
It possess the capabilities of analyzing the
interdependencies between part,
machining process, quality, cost.
It possess multiple calculating capabilities.
 Structure of CAPP:

Input based on Output as a

Processing
Solid model Process plan
 Types of CAPP:
Variant process planning
Generative process planning
 Variant Process Planning:
This system works on the basis of group
technology and parts classification and coding.
Parts are grouped into the part families on the
basis of design and manufacturing attributes.
This parts are called master parts.
Process plan for the part is created by recalling,
identification and retrieving an existing plan for
identical parts and making needful modifications
for a new part.
A standard process plan is stored in computer
files for each code number. The database of
these files is prepared and maintained.
Then appropriate standard plan is retrieved as
per the part or component.
The procedure of variant process plan consist
of:
1. Classify the parts and label the parts as
per the appropriate code.
2. Prepare the part families on the basis of
design and manufacturing attributes.
 3. Prepare the route sheet for each
part families.
 The above steps are the preparatory
steps which are required to make up the
database of standard process plans. This
is called preparatory stage.
 The next stage is production stage where
standard process plans are retrieved from
the database.
The steps are:
1. Enter the new part with part code
to get the process plan.
2. The CAPP program will search the
part family. If files contain identical
code then standard process plan is
retrieved.
 Diagram of Variant process plan:
Preparatory stage

Standard
Process plans
Part coding & Formation of Preparation of
classification Part family Standard plan
Part family matrix file

Machine routing file

Operations sequence file

Standard Process plan Other applications file

Part family Standard M/c
Operation retrieval editor
search Route retrieval
And edit

Production stage
Final
process
plan
Generative process planning:
It is the system which creates 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 plans.
Input to the system includes the description of
the part in the form of part code number.
After retrieving this information, the system can
generate the required processes and process
sequences for the work part.
Then it synchronizes this process
information in order to create a process
plan for this new component by using the
decision logic.
This system is comprised of mainly two
components:
1. geometry description and coding component:
it involves all the geometric features for all the process
related surfaces together with feature dimensions,
locations, tolerances and surface finish.
2. process knowledge database & 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, mfg. equipments, work
holding devices, jigs & fixtures, inspection instruments,
etc.
Diagram of Generative process Plan:
M/C specification
Geometric definition
& capability
From CAD

Knowledge
Part interrogation Acquisition
Feature extraction
Feature recognition

Interference system
Selection of
process
Knowledge
Base
Selection of
M/C tool

Final
Process Operations and
Plan Time calculations
 Benefits of CAPP:

Consistency Accuracy of Capacity

Productivity Ability to
of plans plans utilization Introduce
New technology

Increases

Skill requirement
Reduces Of planner

Lead time of Routine clerical Mfg. and process

Process plan work Work in progress
Planning cost