Computer Aided Process Planning (CAPP)

Process planning is concerned with

Determining the sequence of individual manufacturing operations needed to

produce a given part or product. The resulting operation sequence is
documented on a form typically referred to as route sheet.
Determining appropriate cutting conditions needed for the desired
manufacturing operations like spindle speed, feed rate etc
Setting up the time standard for the operations.

Traditional Process Planning

The traditional approach or the manual approach used for Process Planning involves
examining engineering part drawings and developing manufacturing process plans
and instructions based on knowledge of process and machine capabilities, tooling
materials, related costs and shop practices. This approach depends heavily upon
the experience of the manufacturing analyst to develop the process plans which are
feasible, low cost and consistent with plans for similar parts.
Drawbacks

This task is very tedious when the number of parts manufactured in an

industry is more. The effort required to manage the planning by human
becomes too huge.
Manually generated plans will always vary from person to person, as it
depends solely on the experience, judgment and knowledge of the analyst.
The plan prepared manually may not be always optimal
This process is more time consuming when compared to computer aided
process planning

Computer Aided Process Planning

In computer aided process planning, the planning elements such as route sheet,
cutting conditions and the time standards are determined by the computers itself.
They address all the drawbacks of manual methods. Based on the characteristics of
a given part, the program automatically generates the manufacturing operation
sequence. The process plans generated by CAPP are rational, consistent and
optimal.
The two different types of CAPP are
1. Retrieval type CAPP
2. Generative type CAPP
Retrieval type CAPP (also called variant type)

Retrieval type CAPP system uses parts classification and coding system and group
technology as the foundation. In this approach, the parts produced in the plant are
grouped into part families, distinguished according to their manufacturing
characteristics. For each process plan a standard process plan is established. The
standard process plan is stored in computer files and then retrieved for new
workparts which belong to the same family. Some form of part coding and
classification system is used to organize the computer files and to permit efficient
retrieval of the existing process plans as required.
When a new workpart is to be manufactured. First the workpart is coded using any
of the coding systems used in the industry, and then the code for the new part is
entered into the computer. The computer then compares this code with the already
existing part codes to identify the part family. If an exact match is not found, then
the machine routing file and the operation sequence file is searched to identify
similar parts.
Once a similar process plan is retrieved, then alterations can be made to make it
suitable for the manufacture of the new product. Since this process involves the
retrieval and editing of the already existing process plan, it is known as Retrieval
type process planning.

User enters
part code
no

Process plan

Part family
search

Part family
matrix file

Standard
machine routing
retrieve

Machine
routing file

Standard
operation
retrieve

Operation
sequence
file

Process plan
formatter

Operation
sequence
file

Fig: Retrieval type CAPP system

Some of the software available for variant CAPP system are MIPLAN and COMCAPP V
by MDSI.

Generative CAPP system

In generative CAPP, the computer creates the individual process plan from the
scratch, automatically, without any human assistance.
The process plans are generated by means of decision logics, formulae, technology
algorithms and geometry based data to perform uniquely the many processing
decisions needed to convert the part from raw material to the finished state.
The rules of manufacturing and the equipment capabilities are stored in a computer
system. When using the system, a specific process plan for the specific part can be
generated without any involvement of a process planner.
The inputs to the system would include a comprehensive description of the
workpart. This may include the use of some form of part coding to summarize the
workpart data. This does not include the retrieval of any standard process plan as in
retrieval type system.
Commonly used generative CAPP software is GENPLAN developed by LockheedGeorgia Company.

Benefits of CAPP

Process rationalization Computer generated routings are more consistent,

logical and optimal than the ones prepared manually. The process plan will be
consistent as the same software is being used by all the process planners.
The process plans tend to be more logical and optimal because the company
can incorporate the knowledge and experience of the best manufacturing
people into the process planning software.
Increased productivity of process planners Computer aided process
planning reduces clerical effort, fewer errors are made and the planners have
immediate access to planning database. This increase productivity of the
planners.
Reduced turn around time using CAPP, the planner will be able to generate
the route sheet for a new part in less time compared to manual preparation.
This leads to overall reduction in manufacturing lead time.
Improved legibility The computer-prepared document is neater and easier to
read than manually written route sheets.
Incorporation of other programs The process planning system can be used
in conjunction with other software packages which helps to automate the
time consuming manufacturing functions.

Group Technology
Group technology is the manufacturing philosophy in which similar parts are
identified and grouped together to take advantage of their similarities in
manufacturing and design. Similar parts are arranged into part families. Example, a
plant producing 10,000 part numbers may be able to group the vast majority of the
parts to 50 or 60 part families. Each family would possess similar design and
manufacturing characteristics. Hence, the processing of each member of a given
family would be similar, and this results in manufacturing efficiencies.
Part families

Design Part Family

A design part family is a collection of parts which are similar either because
of their similarities in their geometric shape and size
Design attributes > Dimensions > Shape > Material > Tolerances > Surface
finish > Function.

They are placed in the same design part family because they have the same
shape and size, but they differ in their production processes.

Manufacturing Part Family

A manufacturing part family is a collection of parts which have similar

processing or manufacturing steps required for their manufacture.

Manufacturing attributes > Production process > Operational sequence >
Production time > Tools required > Batch size > Machine tool > annual
production

Although their design characteristics are entirely different, a closer examination

would reveal that they are similar in the manufacturing process used for its
production.
The general method of classification into part families are

Visual inspection
In this method, the analyst groups the part by visually inspecting them
Route Sheet Analysis
The parts care classified by studying the various route sheet similarities, ie,
the similarities in the manufacturing processes.
Par t Classification and Coding System
In this system, the classification is done based on certain standard coding
systems used such as OPITZ coding, MICLASS coding and CODE system.

Coding system structure

Hierarchial
Chain type
Hybrid

Coding systems
1. OPITZ CODING SYSTEM

This coding system was developed by H. Opitz. The Opitz coding system has the
following digit sequence
12345 6789 ABCD
The first five digits (12345) code the design attributes of the part and are called the
form code. The next four digits (6789) are for coding manufacturing related
attributes and are called the supplementary code. The letters (ABCD) code the
production operation and sequence and are referred to as the secondary code.
The secondary code can be designated by the firm to serve its own particular
needs.

2. MICLASS CODING SYSTEM

The MICLASS (Metal Institute Classification System) classification number can range
from 12 to 30 digits. The first 12 digits are a universal code that can be applied to
any part. Upto 18 additional digits can be used to code data that are specific to the
particular company or industry
The workpart attributes coded in the first 12 digits of the MICLASS number are as
follows
Digit
Digit
Digit
Digit
Digit
Digit
Digit
Digit

no
no
no
no
no
no
no
no

1
2 and 3
4
5 and 6
7
8
9 and 10
11 and 12

Main Shape
Shape Elements
Position of Shape Elements
Main dimension
Dimension ratio
Auxiliary dimension
Tolerance codes
Material codes

One of the main feature of MICLASS system is that the parts can be coded using a
computer interactively. To classify a given part design, the user responds to a series
of questions asked by the computer. The number of questions depends on the
complexity of the part. On the basis of the response to the questions, the computer
assigns a code number to the part.
3. CODE SYSTEM
This system was developed by Manufacturing Data Systems Inc (MDSI). The code
system has eight digits. For each digit there are 16 possible values ( 0 to 9 and A to
F ) Which are used to describe the parts design and manufacturing attributes. The
initial digit position indicates the basic geometry of the part and is called the Major
Division of the CODE System. This digit would be used to specify whether the shape
was cylindrical, flat piece, block or others. The interpretation of the remaining seven
digits depends on the value of the first digit, but these remaining digits for a chain
type structure. Hence the chain system possess a Hybrid structure.
2nd and 3rd digits
5th, 5th and 6th digits
7th and 8th digits

Basic geometry and principal

manufacturing process
Secondary manufacturing process, e.g.
threads, grooves, slots, etc
Overall size of the part

Process Layout and Group Technology layout

Benefits of Group Technology

Product Design
When a new part is to be designed; the engineer can devote a few minutes to
create the code of the required part, and then can search the database of
already existing parts to get a similar design. Once the suitable design is
found, a few modifications can be made to it to get the desired part. A few
minutes taken for coding can save a lot of hours that must be spent for
designing. It also helps in standardization of the parts produced in an
industry.
Tooling and setup
In tooling, group jigs and fixtures are designed for Group technology in order
to accommodate every member of the part family. The machine tools in
Group Technology do not require drastic changeovers in setup because of the

similarity in the workparts processed on them. Hence setup time is saved.

(upto 69 percent reduction in setup time is observed in GT)
Material Handling
In group technology layout, there is very efficient flow of materials and parts
between the machines through the shop floor when compared to process
layout. Hence minimum material handling and waiting time.
Production and inventory control
Production scheduling is simplified with group technology. The machines are
grouped into cells in Group technology and it reduces the number of
production centers that must be scheduled. Grouping of parts into families
reduce the complexity and size of the scheduling problem. Since the work
flow is uninterrupted, the inventory level can be reduced considerably.
Employee satisfaction
The machine cell allows the part to be processed from raw material to
finished state by a small group of workers. The workers are able to visualize
their contributions to the firm more clearly. This tends to cultivate an
improved worker attitude and higher level of job satisfaction. This also
increases the quality of the product being manufactured.
Process planning procedures.
Time and cost of process planning procedures can be reduced through
standardization associated with group technology. A new design is identified
by its code number as belonging to a part family, for which the general
process routing is already known and readily available. This helps in cutting
down many time consuming process planning procedures.

Flexible Manufacturing Systems (FMS)

A flexible manufacturing system (FMS) consists of a group of programmable
production machines interconnected by means of an automated material handling
and storage system, and controlled by an integrated computer system to produce a
variety of parts at non-uniform production rates, batch sizes and quantities. A
flexible manufacturing system combines the concept of Flexible automation, Group
technology, CNC machine tools, Automated material handling and Computer control
of machines (DNC) and material handling.

Components of FMS

Processing stations
These workstations are typically CNC machine tools that performs machining
operations on families of parts. The processing stations also include
inspections stations, assembly workheads, and sheet metal presses.
The machining system is capable of performing several of the operations on
the workpiece automatically. Machining centers consists of automatic tool
changing and tool storage, pallet changer, CNC control and DNC control.

Material Handling and Storage

various types of automated material handling equipments are used to

transport the workparts and subassemblies between the processing stations,

sometimes incorporating storage into the function.
This system facilitates the timely supply of unmachined workpieces from the
storage to the machining centers and transport of the machined parts from
the machining centers to the desired locations.
o Random, independent movement of the workpieces between
workstations
o Accomodation of different part configurations Parts of various
configurations and sizes must be handled by the system.
o Compatibility with computer control- The handling system is
allowed to control directly by the computer to direct to work
stations, load and unload workstations.
AGVs are used very commonly in material handling in FMS. AGV
Automated Guided Vehicle is a material handling system which uses
independently operated, self-propelled vehicles that are guided along defined
pathways in the floor. The vehicles are powered by onboard batteries and
guidance is achieved by sensors on vehicle which can follow the guide wires
or paints.

Tool Handling and Storage

In flexible manufacturing system, various cutting tools are loaded onto the
machines at intervals depending on the machining operations. An automatic
tool handling system is used in FMS. The cutting tools are stored in auxiliary
tool storage from where the required tools can be transferred to the main tool
magazine. The limit to maximum number of tools in a machine are from 20 to
120.
Computer control system
Computer control coordinates the overall activities of the processing stations
and the material handling system in FMS. The main functions of computer are
o Control of workstations monitoring and controlling all the processing
stations
o Production control real time control of workstations, load/unload
stations, pallets, volume of raw material available, production rate etc.
o Traffic control loading, unloading, pallet control
o Tool control This includes supplying the correct tool to the machines
at the right time and also the monitoring of tool life.
o Scheduling creates actual sequence of parts and operations.
o Performance monitoring FMS can create reports on the performance
of the system

Benefits of FMS

Greater flexibility
Capability to cope with changes in production design and volumes, and in
rapid response to markets.
Higher machine utilization
More efficient work handling, offline setups, and better scheduling contribute
to FMS machine utilization of 80 percent or more.
Reduced work in progress
Since different parts are processed together rather than separately in
batches, the number of parts being processed at any moment tends to be
less than in a batch production mode.
Lower manufacturing lead time
Closely correlated with reduced work in progress is the time spent in process
by the parts. This means faster customer deliveries.
Higher labor productivity.
The higher production rate capacity of the FMS and its lower reliance on
direct labor means that the productivity per labor is significantly greater than
that obtained with conventional production methods. All tool changing and
material handling systems are fully automated.