UNIT 1

INTRODUCTION TO PROCESS PLANNING

PART- A
1. Define Process Planning
It is defined as an Act of preparing a detailed work instructions for the manufacture and
assembly of components into a finished product in discrete part manufacturing
environments
It is the systematic determination of the methods by which a product is to be manufactured
economically and competitively.
It is an intermediate between design and manufacturing.
Route sheet and operation are the two outputs of process planning activity.
2. What is a route sheet?
A route sheet is one which lists the productions operations and associated machine tools for
each component and subassembly of the product.
3. What are the material selection parameters?
1. Function 2. Service 3. Appearance 4. Environment 5. Reliability 6. Compatibility
4. List out the various approaches to process planning
1. Manual approach
(a) Traditional Approach (b) Workbook Approach
2. Computer Aided Process Planning
(a) Retrieval CAPP system (b) Generative CAPP system
5. What is CAPP?
In computer aided process planning (CAPP) , the process plan is prepared with the use of
computers by various methods. CAPP overcomes the drawbacks of manual process planning.
6. What are the three main areas focused upon during the material evaluation?
The materials considered for selection are to be evalauated based on the following three
considerations :
Shape or Geometry considerations
Material Property Considerations
Manufacturing considerations

7. List out the factors to be considered in the selection of manufacturing process

The factors to be considered are :

Material form
Component Size and Weight
Economic Considerations
Dimensional and Geometric accuracy
Surface finish specification
Batch size
Production rate

8. What are the various steps involved in process selection

Stage I Drawing Intrepretation
Stage II Identification of critical processing factors
Stage III - Comparision of potential manufacturing processes
Stage IV Identification of suitable processes
9. What are the factors considered in machine selection?
1. Technical Factors
Physical size of the workpiece
Machine accuracy
Surface Finish
Cutting forces
Power of the machine
2.

Operational Factors
Batch Size
Capacity
Availability

10. What are the stages of machine selection process

The machine selection involves the following four stages:
Stage I First cut-selection
Stage II Power/Force analysis
Stage III - Capability analysis
Stage IV Operational analysis

11. List the various factors considered for tooling selection

1. Constraints on tool selection
(a) Manufacturing practice (b) Manufacturing process (c) Machine tool characteristics

(d) Capability (e) Processing time (f) Cutting tool availability

2. Operational requirements for tool selection
(a) Workpiece material (b) Operation (c) Part geometry (d) Tooling data
3. Factors affecting tooling performance
(a) Cutting tool materials (b) Cutting tool geometry (c) Cutting fluids
12. What are the constraints influencing tool selection decision?
The six constraints influencing tool selection decision are :

Manufacturing practice
Manufacturing process
Machine tool characteristics
Capability
Processing time
Cutting tool availability

13. List out the stages of tool selection process

The five stages of tool selection process are
Stage I Evaluation of process and machine selection
Stage II Analysis of machining operations
Stage III - Analysis of workpiece characteristics
Stage IV tooling analysis
Stage V - Selection of tooling

14. What are the information that a route sheet can provide?

Part identification of the processing steps in each operation

Description of the processing steps in each operation
Operation Sequence and machines
Standard Setup and cycle times
Tooling requirements for each operation

15. List out any four information that the process planner can obtain from the engineering drawing of a
component

Geometric and Dimensions

Material Specifications
Notes on special material treatments
Dimensional tolerances specifications

 Geometrical tolerance specifications

Surface finish specifications
PART-B
1.
2.
3.
4.

Explain in detail the process planning activities

Explain in detail about the various methods of process planning
List and explain the various factors considered for tooling selection
Explain the responsibilities of a process planning engineer

UNIT II
PROCESS PLANNING ACTIVITIES
PART- A
1. What are the main process parameters that can influence the success of the machining?
(a) Cutting Speed (b) Feed rate (c) Depth of cut
2. List any four factors that are to be considered during selection of cutting speed.
Nature of the cut
Work material
Cutting tool material
Cutting fluid application
Purpose of machining
3. List the major factors that are to be considered during the selection of feed rate.
Work material (Type,strength,hardness, etc)
Capacity of the machine tool (Power,Rigidity,etc)
Cutting tool (Material, Geometry and configuration)
Cutting fluid application
Surface finish desired
Type of operation
Nature of cut

4. What is the recommended depth of cut for turning, boring shaping and planning operation?
For turning and boring 6mm for roughing
0.4mm for finishing
For Shaping and Planing 1-4mm

5. List any four factors that influence the design or selection of a workholder

Physical Characteristics of the workpiece

Physical Characteristics of the finished component
Type and capacity of the machine, its extent of automation
Provision of locating devices in the machine

6. What is meant by statistical quality control?

Statistical quality control (SQC) is about employing inspection methodologies derived from statistical
sampling theory to ensure conformance to requirements.
7. What are two basic quality strategies?
The two basic quality strategies are
1. Detection Strategy
2. Prevention Strategy
8. List the seven statistical tools of quality that are used in quality control
1. Flow Chart 2. Check Sheet 3. Histogram 4. Pareto diagram 5. Cause and effect diagram 6. Scatter
diagram 7. Control chart
9. What is a control chart?
A control chart is a graph that displays data taken over time and the variations of this data.
10. What are the uses of control charts?
To check whether the process is controlled statistically or not
To determine process variability
To establish the process capability of the production process
To identify the type of variation that occurs
To determine the effects of process changes.
11. List the commonly used control charts for variables for quality control
Average charts
R- or Range charts
s- or Standard deviation charts

12. What is meant by process capability?

Process capability may be as the the minimum spread of a specific measurement variation which will
include 99.7% of the measurements from the given process.
13. List any six documents that are required for process planning
Assembly and component drawing of the product and bill of materials
Specification of various machine tools
Machining /Machinability data handbook
Catalogues of various cutting tools and tool inserts
Sizes of standard materials
Charts of limits,fits and tolerances

14. What do you understand by Break even analysis?

Break even analysis , also known as Cost-Volume Profit analysis , is the study of interrelationship
among a firms sales, costs and operating profit at various levels of output.
15. What is meant by Break-even point?
The breakeven point may be defined as the level of sales at which total revenues and total costs are
equal. It is a point at which the profit is zero.

PART-B
1.
2.
3.
4.

List out the set of documents /information that are required for process planning
Explain the various principles of jigs and fixture design
List and explain the various factors to be considered for selection of measuring instruments
List and explain the major factors are to be considered during selection of cutting speed