Computer Aided Process Planning CAPP

Computer Aided Process Planning (CAPP) 1
1. INTRODUCTION
Technological advances are reshaping the face of manufacturing, creating

paperless manufacturing environments in which computer automated process planning
(CAPP) will play a preeminent role. The two reasons for this effect are: Costs are
declining, which encourages partnerships between CAD and CAPP developers and
access to manufacturing data is becoming easier to accomplish in multivendor
environments. This is primarily due to increasing use of LANs; IGES and the like are
facilitating transfer of data from one point to another on the network; and relational
databases (RDBs) and associated structured query language (SQL) allow distributed
data processing and data access.
.
With the introduction of computers in design and manufacturing, the process
planning part needed to be automated. The shop trained people who were familiar with
the details of machining and other processes were gradually retiring and these people
would be unavailable in the future to do process planning. An alternative way of
accomplishing this function was needed and Computer Aided Process Planning (CAPP)
was the alternative. Computer aided process planning was usually considered to be a
part of computer aided manufacturing. However computer aided manufacturing was a
stand alone system. Infact a synergy results when CAM is combined with CAD to
create a CAD/CAM. In such a system CAPP becomes the direct connection between
design and manufacturing.
Moreover, the reliable knowledge based computer-aided process planning

applicationMetCAPP software looks for the least costly plan capable of producing the
design and continuously generates and evaluates the plans until it is evident that non of
the remaining plans will be any better than the best one seen so far. The goal is to find a
useful reliable solution to a real manufacturing problem in a safer environment. If
alternate plans exist, rating including safer conditions is used to select the best plans
1.1 COMPUTER AIDED DESIGN (CAD)
A product must be defined before it can be manufactured. Computer Aided

Design involves any type of design activity that makes use of the computer to develop,
analyze or modify an engineering design. There are a number of fundamental reasons
for implementing a computer aided design system.
a. Increase the productivity of the designer: This is accomplished by helping
the designer to visualize the product and its component subassemblies and parts; and
by reducing the time required in synthesizing, analyzing, and documenting the
design. This productivity improvement translates not only into lower design cost but
also into shorter project completion times.
b. To improve the quality of the design: A CAD system permits a more
thorough engineering analysis and a larger number of design alternatives can be
investigated. Design errors are also reduced through the greater accuracy provided
by the system. These factors lead to a better design.
c. To improve communications: Use of a CAD system provides better
engineering drawings, more standardization in the drawings, better documentation
of the design, fewer drawing error, and greater legibility.
d. To create a database for manufacturing: In the process of creating a the
documentation for the product design (geometries and dimensions of the product
and its components, material specification for components, bill of materials etc),
much of the required data base to manufacture the product is also created.
Design usually involves both creative and repetitive tasks. The repetitive tasks within
design are very appropriate for computerization.
1.2 COMPUTER AIDED MANUFACTURING (CAM)
By the time computer use in design began, numerical control technology (NC
technology) had matured to become cost effective for applications in machining. An
important in numerical control is part-programming. A part-program is simply a set of
statements comprehensible to the machine control unit (MCU) , that oversees slide and
tool movements and other auxiliary functions. In the case of components with complex
geometries, part-programs had to carry out lengthy calculations for which it was logical
to use computers. This gave rise to machine control units (MCU’s) with built in
microprocessors- the building blocks of computers. The use of computers in extending
the applications of NC technology, especially to part-programming was earlier termed
Computer Aided Machining (CAM) and the associated technology was called Computer
Numerical Control (CNC). Later Computer Aided Machining became an acronym for
Computer Aided Manufacturing (CAM). Earlier Computer Aided Manufacturing used
to denote computer use in part-programming only. Today it means any non design
function of manufacturing that is computer aided.
1.3 CAD/CAM
As the use of computers in design and manufacturing broadened under CAD and
CAM, it became evident that certain tasks were common to both, eg:-both design and
manufacturing require data on tolerances. Part geometries created during CAD can
readily be saved in the database for latter use. The forward slash (/) between CAD and
CAM was meant to reinforce the shared functions of design and manufacturing.
2. PROCESS PLANNING
The product design is a plan for the product and its components and
subassemblies. To convert the product design into a physical entity, a manufacturing
plan is needed. The activity of developing such a plan is called process planning. It is a
link between product design and manufacturing. Process planning involves determining
the sequence of processing and assembly steps that must be accomplished to make the
product. It is concerned with the engineering and technological issues of how to make
the product and its parts. What types of equipment and tooling are required to fabricate
the part and assemble the product. It involves determining the most appropriate
manufacturing and assembly process and sequence in which they should be
accomplished to produce a given part or product according to the specifications set forth
in the product design documentation. All the related information is documented on a
Route Sheet .The planning begins with engineering drawings, specifications, parts or
material lists and a forecast of demand. The scope and variety of processes that can be
planned are generally limited by the available processing equipment and technological
capabilities of the company or the plant.
Process planning is usually accomplished by manufacturing engineers. Based on

process planner’s skill, knowledge, and experience, the processing steps are developed
in the most logical sequence, to make each part.
The following are the list of many decisions and details usually included within the
scope of process planning.
• Interpretation of design drawings: The part or product design must be
analyzed (materials, dimensions, tolerances, surface finishes etc) at the start of the
process planning procedure.
• Processes and sequences: The process planner must select which processes are
required and their sequence. A brief description of all processing steps must be
prepared.
ORGANISATION FOR INDUSTRIAL

S/O#RESEARCH,
PRJ# INC
ORDER MIN. FACILITY-F1
DUE
PART NUMBER:A63799 QTY QTY DATES
PR#
PART NAME:SHAFT, ARM
PLNG REV: 02 DWG REV:0 A34UB 45D3 1000
935 249
2
PLANNRER: ADAMS
INSPECTIONS CODE#: 1310-1181-2111-0000-0100-0000-0000-00
#1 #2 #3
SPECIAL INSTRUCTIONS / HANDLING:
MFG FHB
½” DIA MS-500 H.R. STEEL (2” LENGTH)
ENG PC
Q/A AH
OPER MACH OPER DESCRIPTION- SET UP PIECE OPR

NO: TOOL ASSY INSTRUCTIONS TIMES TIMES
0010 5145 S/U COLLET 2.00 0.173

ROUGH TURN M/C PER TAPE NO: LS982A
0 .440 DIA BY1.7500 LENGTTH
FINISH 3/64 GROOVES (TYP) AND CHAMFERS
0.270 DIA.BY 0.375 LENGTH
CHAMFER CUTOFF TO 1.960
0015 1026 #2 CENTERS BOTH ENDS 0.25 0.004
0020 9401 CARBURIZE AND HARDEN 0.50
0030 4063 S/U BETWEEN CENTERS 1.25 0.0983
GRIND OD HOLD CONCENTRICITY
HOLD 0.4200 DIM. HOLD 0.2600 DIM.
HOLD 0.2815 DIM. HOLD 0.2712 DIM.
0040 9501 BLAST TO CLEAN 0.001
0050 9201 CHROME PLATE PER PRINT 0.38
0060 9805 FINAL INSPECT
ROUTE SHEET GENERATED BY MIPLAN

• Equipment selection: In general, process planers’ must develop plans that

utilize existing equipment in the plant. Otherwise, the component must be purchased
or an investment must be made in new equipment.
• Tools, Dies, Moulds, Fixtures and gauges: The process planner must decide
what tooling is required for each processing step. The actual design and fabrication
of these tools is usually delegated to a tool design department and tool room or an
outside vendor specializing in that type of tool is contracted.
• Method analysis: Workplace layout, small tools, hoists for lifting heavy parts
even in some cases hand and body motions must be specified for manual operations.
The industrial engineering department is usually responsible for this area.
• Work standards: Work measurement techniques are used to set time standards
for each operation.
• Cutting tools and cutting conditions: These must be specified for machining
operations often with reference to standard handbook recommendations.
The results of planning are:
• Routings which specify operations, operation sequences, work centers,

standards, tooling and fixtures. This routing becomes a major input to the
manufacturing resource planning system to define operations for production activity
control purposes and define required resources for capacity requirements planning
purposes.
• Process plans which typically provide more detailed, step by step work
instructions including dimensions related to individual operations, machining
parameters, set-up instructions, and quality assurance check points
• Fabrication and assembly drawings to support manufacture.
Manual process planning as mentioned earlier is based on a manufacturing engineer’s

experience and knowledge of production facilities, equipment, their capabilities,
processes and tooling. Process planning is a time-consuming process and the results
vary based on the person doing the planning.
3. COMPUTER-AIDED PROCESS PLANNING ( CAPP)
Process planning translates design information into the process steps and
instructions to efficiently and effectively manufacture products. As the design process is
supported by many computer aided tools, computer aided process planning has evolved
to simplify and improve process planning and achieve more effective use of
manufacturing resources.
3.1 CAD/CAM INTEGRATION AND CAPP FEATURES
A frequently overlooked step in the integration of CAD/CAM is the process

planning that must occur. CAD systems generate graphically oriented data and may go
so far as graphically identifying metal etc to be removed during processing. In order to
produce such things as NC instructions for CAM equipment, basic decisions regarding
equipment to be used, tooling and operating sequence need to be made. This is the
function of Computer aided process planning. Without some elements of CAPP there
would be no such thing as CAD/CAM integration. The CAD/CAM systems that
generate tool paths and NC programs include limited CAPP capabilities or imply a
certain approach to processing.
CAD systems also provide graphically oriented data to CAPP systems to use to
produce assembly drawings etc. Further, this graphically oriented data can then be
provided to manufacturing in the form of hardcopy drawings or work instruction
displays. This type of system uses work instruction displays at factory workstations to
display process plans graphically and guide employees through assembly step by step.
The assembly is shown on the screen and as a employee steps through the assembly
process with a footswitch, the components to be inserted or assembled are shown on the
CRT graphically along with text instructions and warnings at each step.
If NC machining processes are involved, CAPP software exists which will select tools,
feeds, and speeds and prepare NC programs.
3.2 COMPUTER-AIDED PROCESS PLANING : TYPES
Computer aided process planning systems are designed around two approaches.
These approaches are called:
1. Retrieval CAPP systems or Variant Approach

2. Generative CAPP systems or Generative Approach
Some Computer aided process planning systems combine the two approaches in what is
known as Semi Generative Approach.
1. Retrieval CAPP System or Variant Approach
The retrieval type is suitable for a family of parts. This system draws a standard
process plan and stores it in the database. Whenever a different part from the family is
to be processed, the standard process plan is retrieved and appropriately modified –
hence the retrieval to this system. The retrieval system relies on the concept of group
technology for part coding and classification. It is also compatible with the concept of
cellular manufacturing in which cells are designed and laid out for family-of-parts
production. In this type, as mentioned earlier a standard process is stored in computer
files for each part code number called the Route Sheet.
The retrieval CAPP system operates as given in figure 2 . 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 referred to as the “preparatory step”. It consists
of the following steps:
i. Selecting an appropriate classification and coding scheme for the company

ii. Forming part families for the parts produced by the company
iii. Preparing standard process plans for the part families
Steps (ii) and (iii) continue as new parts are designed and added to the company’s
design database.
New part design
Derive GT code
number for part
Selecting coding
Search part family system and form part
file for GT code Part family file families
number
Retrieve standard Standard process Prepare standard

process plan plan file process plans for
part families
Edit existing plan

or write new plan
Process plan Other application

formatter programs
Process plan
(route sheet)
GENERAL PROCEDURE FOR RETRIEVAL CAPP SYSTEMS
After the preparatory phase has been computed, the system is ready for use. For
a new component for which the process plan is to be determined, the first step is to
determine the GT code number for the part. With this code number a search is made for
the part family file to determine if a standard route sheet exists for the given part code.
If the file contains a process plan for the part, it is retrieved (hence the word “retrieval”
for this CAPP system) and displayed for the user. The standard process plan is
examined to determine whether any modifications are necessary. It might be that
although the new part has the same code number, there are minor differences in the
process required to manufacture it. The user edits the standard plan accordingly. This
capacity to alter an existing standard process plan is what gives the retrieval system its
alternative name: “variant” CAPP system.
If the file does not contain a standard process plan for the given code number,
the user may search the computer file for a similar or related code number fro which a
standard route sheet does exists. Either by editing an existing process plan or by starting
from scratch the user prepares the route sheet for the new part. This route sheet becomes
the standard process plan for the new part code
The process planning session concludes with the process plan formatter, which
prints out the route sheet in the proper format. The formatter may call other application
programs into use. For eg: -To determine machining conditions for the various machine
tool operations in the sequence, to calculate standard time for the operations or to
compute cost estimates for the operations.
One of the commercially available Retrieval CAPP systems is MultiCapp, from

OIR, the Organization for Industrial Research. It is an online computer system that
permits the user to create new plans, or retrieve and edit existing process plans as
explained earlier.
Generative CAPP System or Generative Approach
The generative method of developing process plans involves starting from

scratch every time a different part is to be processed; no plans are available as the
baseline. The basic requirement for a generative process planning system is that the
given component model/drawing is to be interpreted in terms of manufacturability. Here
instead of retrieving and editing an existing plan contained in the computer database,
generative system creates the process plan based on logical procedures. In a fully
generative CAPP system the process sequence is planned without human assistance and
without a step of predefined plans.
A generative CAPP system is usually considered part of the field of expert
systems, a branch of artificial intelligence. An expert system is a computer program that
is capable of solving complex problems that normally require a human with years of
education and experience. Process planning fits within the scope of this definition.
There are several ingredients required in a fully generative process planning system:
i. First the technical knowledge of manufacturing and the logic used by successful
process planners’ must be captured and coded into a computer program. In expert
systems applied to process planning, the knowledge and logic of human process
planners’ is incorporated into a so called “knowledge base”. The generative CAPP
system then uses that knowledge base to solve process planning problems (ie create
route sheets)
ii. Second ingredient in process planning is a computer compatible description of
the part to be produced. This description contains all the pertinent data and
information needed to plan the process sequence. Two possible means of providing
this description are:
a. the geometric model of the part that is developed on a CAD system
during product design and
b. a GT code number of the part that defines the part features in significant
detail.
iii. The third ingredient in a generative CAPP system is the capability to apply the
process knowledge and planning logic contained in the knowledge base to a given
part description. In other words, the CAPP system uses its knowledge base to solve
a specific problem – planning the process for a new part. This problem solving
procedure is referred to as the “inference engine” in the terminology of expert
systems. By using its knowledge base and inference engine, the CAPP system
synthesizes a new process plan from scratch for each new part it is presented.
4. GROUP TECHNOLOGY
Group technology is a 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. Each family would possess
similar design and manufacturing characteristics. Hence processing of each member of a
given family would be similar and this results in manufacturing efficiencies. These
efficiencies are achieved in the form of reduced set-up times, lower in-process
inventories, better scheduling, improved tool control and the use of standardized process
plans. The design retrieval system is a manifestation of group technology principle
applied to the design function. To implement such a system some form of parts
classification and coding is required.
Part classification and coding is concerned with identifying the similarities

among parts and relating these similarities to a coding system. Part similarities are of
three types:
i. Design attributes (such as geometric shape and size)

ii. Manufacturing attributes (sequence of processing steps required to make
the part)
iii. Design and manufacturing attributes (combination of the design and
manufacturing attributes)
When implementing a parts classification and coding system most companies elect to
purchase a commercially available package rather than develop their own. The
following factors are considered in selecting a parts coding and classification system:
• Objective
• Scope and application
• Costs and time
• Adaptability to other systems
• Management problems
4.1 BENEFITS OF GROUP TECHNOLOGY
 Product Design Benefits: When a new part design is required, the engineer or
draftsman can devote a few minutes to figure the code of the required part. Then
the existing part designs that match the code can be retrieved to see if one of them
will serve the function desired. The few minutes spent searching the design file
with the aid of the coding system may save several hours of the designers’ time. If
the exact part design cannot be found, perhaps a small alteration of the existing
design will satisfy the function. Use of the automated design-retrieval system
helps to eliminate design duplication and proliferation of new part designs. Other
benefits of group technology in design are it improves cost estimation procedures
and helps to promote design standardization. Design features such as inside corner
radii, chamfers, and tolerances are more likely to become standardized with group
technology.
 Tooling and Set-ups: In tooling, an effort is made to design group jigs and
fixtures that will accommodate every member of a parts family. Work holding
devices are designed to use special adapters which convert the general fixture into
one that can accept each part family member. The machine tools in a GT cell do
not require drastic changeovers in set-up because of the similarity in the workparts
processed on them. Hence setup time is saved. It has been estimated that the use of
group technology can result in 69% reduction in setup time.
 Materials Handling: Another advantage in manufacturing is a reduction in the
workpart move and waiting time. The group technology machine layouts lend
themselves to efficient flow of materials through the shop.
 Production and Inventory Control: Grouping of machines into cells reduces the
number of production centers that must be scheduled. Grouping of parts into
families reduces the complexity and size of the parts scheduling problem. Because
of the reduced set-ups and more efficient materials handling with machine cells,
production lead times, work-in-process, and late deliveries can all be reduced.
 Employee Satisfaction: The machine cell often allows parts 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. Here
more attention tends to be given to product quality. Also the workers are more
responsible for the quality of work they accomplish.
 Process Planning Procedures: The time and cost of process planning function
can be reduced through standardization associated with group technology.
5. CAPP LITERATURE AND CAPP METHODOLOGY
The developed CAPP system consists of feature recognition module and other
modules for selecting machines, tools, machining parameters and optimization modules.
The feature recognition module has been developed by SolidWorks as modeling
software and features are interpreted using a programme written in Visual Basic 6.0.
The Oracle 7.3 has been used for database management. The highlight of the
system is that it has got excellent user interface by which user can interact with the
system at different levels while generating a process plan.
METHODOLOGY
Various modules used for generating process plan are described as follows:
Feature Extraction Module
The Solid modelling software plays an important role in providing features data.
The solid modelling software package used in this work is SolidWorks 98 Plus windows
based software. The software coding to extract feature along with its attributes has been
implemented in Visual Basic 6.0 and database is created in Oracle 7.3 as backend.
Using the Application Programme Interface (API) of SolidWorks 98 Plus, it is possible
to fetch any of the functions that are used for the modelling.
Blank Selection Module
After extracting the features information from the feature extraction module, the
next step is to find out the overall dimensions of the raw materials required. Overall size
of the component is required for the selection of the raw material from the raw material
database.
Once the component is modelled in SolidWorks modelling software, it is

possible to find out the overall size of the component directly from SolidWorks
Application Program Interface. The system automatically adds the machining
allowances on each face. Provisions are also made so that the user can also customize
the machining allowances according to requirements.
Set-Up Planning
Once the features are recognized, the next step is to group the features into set-
ups. Set-Up planning deals with the selection and sequencing of the processes required
for generating the final shape of a component. It is a mixture of complex and inter-
related tasks. Set-Up planning also includes the orientation in which the component is to
be placed on the work-table for machining. It covers work-holding criteria as well.
Set-Up Planning Methodology
The input for this particular module comes from the feature extraction module.
All the features identified from the CAD model are given to this module for further
processing. Here, different features have different possible directions of approach. One
of the possible directions of approach is perpendicular to the location face. The user
decides this by interfacing with the system and entering the location face details for
each and every feature. Any feature, which lies in the particular orientation, is given the
location face accordingly.
The feature tree holds the information about its nodes, dimensions, location and
tolerance information. If the user selects a particular node, then information about the
feature can be viewed. The algorithm developed searches through all the features and
checks for each face the number of features that can be machined. The feasible faces are
then ordered accordingly and then grouped. The desired set-up planning is the one in
which maximum number of features like tolerances, location is to be given manually
prior to sep-up formation.
Routing
Routing is the method of directing the blank through various stages to get the
required feature. In this module the following information is generated.
• Possible route identification

• Selecting the optimum route
• Calculating the intermediate dimensions for the route selected
Possible Route Identification
The process selection is done taking into consideration the following details:
• The geometric and technological information of the features.
• Each and every feature and its associated accuracy and surface finish
requirement are taken into consideration.
• Based on the surface finish requirement specified and the accuracy indicated, the
various possible routes available in the feature-process-route database are
identified.
The method adopted gives various options or routes for a given feature. An
exclusive feature-process-route table is maintained in the database and routes are
selected based on the accuracy that can be attained using the specific route for a given
feature.
A feature may have one or more number of routes and the user is allowed to
change the routes according to his requirement. A process route can be divided based on
the final finish requirement
Eg: - To mill a block of accuracy IT 8, may be done in the following two ways:
Rough Milling  Semi-finish Milling Finish Milling

Rough Milling  Semi-finish Milling Rough-grinding
Many routes are possible similar to these and should be considered before
selecting the final route. The dimensional variations that are allowable for the features
on a part to be machined will affect the operations, tools, and set-ups that are required to
machine the parts. Stringent tolerance specifications between features will require more
accurate operations, tools and additional set-ups for machining them. At this stage itself,
feature sequencing is carried out.
Cutting Tool Selection
The main concerns in tool selection include tool type, material, geometry, and
tool dimensions. Selection of tool type is based mainly on operations to be carried out
and the machine tools involved. A criterion for selecting tools for rough machining, for
eg: - is to minimize the tool changes and to maximize the number of features machined.
Several other factors also influence productivity such as tool material and size.
The process generation module of the CAPP system decides the process to be
carried out to finish the part by means of feature process correlation. Based on the tool
process correlation the cutting tool is decided. The tool process correlation holds all the
information regarding tools and their operations. If the feature is a hole, then a drill is to
be used.
But based on the feature dimension, the best matching tool is to be selected from
the corresponding database, providing data like tool code, tool length, diameter, and
insert material, separate databases are developed and maintained for drill tools, milling
cutters, and grinding wheels. The tool selection is facilitated with dual methods, namely
automatic selection and manually.
Machine Selection For Individual Process
Machine selection is based on the blank size and process capability of the
machine. For each and every process one or more number of machines are possible.
This is added in a list where it is identified by a key. The list contains the following link
information:
• Set-Up number
• Feature name
• Process
After selecting the various possible machines, redundant machines are eliminated and
only machines, which are unique, are identified and it is retained for further processing.
The information is available as a list structure where the set-up is the main link.
6. CAPP APPLICATIONS: CASE OF METCAPP

SOFTWARE
MetCAPP is a knowledge –based process planning and cost estimating system

targeted at providing:
• Improved productivity by reducing process time and variability
• Reduced inventories
• Consistent and higher product quality levels
MetCAPP provides the link between design and manufacturing floor. It provides the
ability to take CAD generated solid models and use them to generate process plans
based on the best :
• Machines
• Tools
• Sequence of steps
• Timing
• Routing/cost combinations
• Provision for alternate and concurrent operations
The technology modules are:
• Feature recognition
• Milling
• Turning
• Hole Making
The user effectively manages the system via the technology module manager as
illustrated in the figure.
MetCAPP, which is a knowledge-based manufacturing process planning and

cost estimation system, uses the Step Optimisation to recognize the machining steps, to
optimise the time and resources. The Step Optimisation should be used only after
calculating the steps for all features, either manually or by technology modules. Once
the optimisation is generated, any changes to the features are reflected in step
optimisation data.
Though, the inclusion of a process plan in the problem requires optimisation

criterion. Process planning is connected with optimising the resources and processing
costs as well as
Knowledge Based Machining
Technology Module Manager
Milling Module
Manufacturing
Technology
Database
Turning
Rules
Module
Features
Hole making
Module
Fig 3. MetCAPP : TECHNOLOGY MODULE MANAGER AND TECH.

FEATURES
processing time. Consequently, the object function used in process planning and its
optimisation is to minimize the number of rejects and the total processing costs, as well
as minimizing the time required to complete all operations.
Moreover, MetCAPP develops a process plan based on specific elemental

manufacturing features. This approach can be used to decompose a very complex part
into a number of separate manufacturing features. The process planner still has a full
control over the plan by determining the order in which the features are selected and
included in the process plan.
Process planning is the glue between product, process, and resources. It is

necessary ability to manipulate, view, and deliver multiple data formats and types.
Today’s solutions are, at best, short term. Systems should be designed to reflect this, or
allow incremental changes. MetCAPP Software analyses the manufacturability of
proposed design as follows:
1) Finding Machining Features:

Many aspects of feature recognition problem are still open and active areas of
research. Among these are: recognizing and representing interactive features,
incremental recognition of features, and incorporation of user customizable feature
classes. As an input, MetCAPP takes solid models (for instance from SolidWorks- a 3D
software) of a part P and stock S, along with tolerance specifications for P. The
tolerance specifications tell how much variation from the nominal geometry is
allowable in any physical realization of a part P.
An operation plan is a sequence of machining operations capable of creating P

from S. A workpiece is the intermediate object produced by starting with S and
performing zero or more machining operations. The machining operations in MetCAPP
currently considered are (end milling, side milling, face milling and drilling). Each
machining operation will create either a primary feature or a truncation of primary
features from P and S. MetCAPP generates F automatically from solid models of P and
S.
2) Generating Feature Based Models (FBM’s):

A Feature Based Model (FBM) is any irredundant subset of features F⊆Φ such
that P can be produced from S by removing the features in F. Each operation plan O of
interest corresponds to an FBM, in the sense that each machining operation in O will
create either a feature in F or a truncation of a feature in F. Since each FBM is a subset
of Φ , FBM can be generated using set-covering techniques.
3) Generating Operation Plans:
Each FBM can lead to several operation plans, of which some are better than
others. Thus, to generate operation plans from a given FBM, MetCAPP again does a
depth-first-branch-and-bound search. Due to various types of interactions (accessibility,
set-up, etc.) among the features in a FBM F, these intersections introduce precedence
constraints requiring that some features of F be machined before or after other features.
MetCAPP generates a total orderings on F consistent with the precedence constraints.
4) Operation Plan Evaluation:
Designers give design tolerance specifications to specify how far the design can
vary from its nominal geometry. To verify whether a given operation plan will satisfy
the design tolerances, MetCAPP must estimate what tolerances the operations can
achieve. Unlike typical approaches for computer-aided tolerance charting, which are
computationally very intensive and only consider limited types of tolerances, MetCAPP
evaluates the manufacturability aspects of a wide variety of tolerances.
In manufacturing planning the goal to be achieved is represented by a design

specification. In planning a sequence of machining operations it is physically impossible
to produce the exact nominal geometry of the design, so the objective is to find any
reliable plan which can produce an approximation of the design geometry that satisfies
various design tolerances. In addition, it is advantageous to have a highly differentiated
view of the production costs.
CAD SYSTEM CAD models of the part P

and stock S
Designer
Find all primary
1.Identify Features
machining features for P.
Call this set φ .
2.Generate FBM Generate the feature-based

model F⊆ φ .
Generate an operation
3.Generate Plan plan O for F. If O can
satisfy P’s machining
tolerances, then
estimate its cost and
4.Evaluate Plan time
5.Feedback Information about P’s

manufacturability
THE BASIC APPROACH USED IN MetCAPP

6.1 THE MetCAPP FEATURES
• Automated Feature Recognition: generates the flow of data from solid models
directly into MetCAPP. This module allows users to import 3D solid CAD models
into MetCAPP and then automatically analyzes the part to extract manufacturing
features for sequencing and process plan generation.
• Process Documentation. MetCAPP’s report writer: allows users to merge texts
and graphics, including CAD drawings, photographs, electronic documents and
bar codes into a single document. This can be printed, sent to the floor
electronically or through Application Programme Interface (API) to other parts of
the IP system (eg:- NC tape generation, MRP or order entry)
• Graphics. MetCAPP’s redline capability: allows the user to add layers of
annotations to a file without changing the original drawing/graphic. MetCAPP
supports over 40 different graphic file types for viewing, printing, and
redline/markup.
• The MetCAPP Technology Modules: These contain rules and data to support a
wide range of features. These automatically select a process sequence, tools for
each step and speeds/feeds for each machining pass. The technology modules
evaluate the capabilities of the machine and utilize as much machine horsepower
as is available at the selected speed range.
• Templates and Formulas: provide MetCAPP users the flexibility to define tasks
and work procedures specific to their operations. Recall and replication of these on
demand further enhances planner productivity.
• Cost Estimating: Costed routings with accurate tooling, fixturing, and materials
provide the estimator with strong quotation support.
• Group Technology: MetCAPP provides the ability to interrogate a standard
database of process plans and identify parts and assemblies by their characteristics.
This enables identification of similar parts for more rapid plan generation as well
as strong support for configuring products in order entry.
6.2 MetCAPP BENEFITS
 50% increase in process planner productivity.

 40% increase in existing equipment’s capacity.
 25% reduction in setup costs.
 12% reduction in tooling requirements
 10% reduction in scrap and rework
 10% reduction in shop floor labor
 6% reduction in work-in-process
 4% reduction in material usage
These are in addition to the overall gains resulting from:
 Connecting process planning to their CAD systems for swift feedback, rapid and
accurate data transfer, plus work-in-process images when desired.
 Linking process planning to CAM systems
 Linking process planning to Enterprise Planning System, MRP/ERP, yielding a
single point of entry.
Today process planning and workshop scheduling in industry are carried out as
sequential, non-collaborative tasks. This has several disadvantages and can be improved
by making these activities partly concurrent or at least collaborative. The integration or
collaboration of scheduling and process planning has been the focus of extensive
international research efforts in recent years. To achieve the overall goals is necessary to
be followed the specific technical objectives with consideration of reliability,
maintainability, and supportability. A reliable and user-friendly interface to standard
CAD systems used in industry is urgently required to close the gap in the CAD-CAM
information chain. The MetCAPP system highlights the requirements that a nowadays
CAPP system must meet, namely: flexibility, modularity, interoperability, autonomy,
and scalability. These have been selected based on weaknesses of the current available
CAPP systems.
1) Automated transfer of geometry and technology information from CAD which

reduces the effort spent on entering CAD data into a CAPP system, and
2) Powerful CAPP modules for interactive, semi-automated and generative process
planning and full support for time and cost calculation.
Non-linear concept used, for instance in MetCAPP, is especially suited for production
environment like mechanical manufacturing of discrete parts of the pilot user.
The use of powerful CAPP tools that meet the performance requirements will
improve process-planning quality with respect to applied manufacturing technology and
accuracy of time and cost calculation. This will result in better utilization of the
available manufacturing resources, more exact product costing, improved product
quality and generally speaking towards a safer world. Collaboration between process
planning and scheduling will improve the logistical quality of process plans through
feedback of loading information
As a computer aided process planning system, enables the process engineer

and/or the cost estimator to more effectively and safely plan the manufacturing process.
MetCAPP users realize improved productivity in reduced process time and variability,
reduced inventories and higher product quality levels, and in general safer production.
Manufacturing can use MetCAPP for more reliable planning, estimation and shop floor
control of manufacturing operation leading towards reduction in number of poor parts
and hence guarantee better future performance, as well as improved competitiveness
and productivity in a safer environment.
7. CAPP BENEFITS
Significant benefits can result from implementation of Computer Aided Process

Planning. In a detailed survey of twenty-two large and small companies using
generative type CAPP system, the following estimated cost savings were achieved.
 58% reduction in process planning effort

 10% savings in direct labor
 4% savings in material
 10% savings in scrap
 12% savings in tooling
 6% reduction in work in process
In addition there are intangible benefits as follows:
 Process rationalization and standardization

 Increased productivity of process planners
 Reduced process planning and production lead time; faster response to
engineering changes
 Greater process plan consistency, access to up to date information in a central
database
 Improved cost estimating procedures and fewer calculation errors
 More complete and detailed process plans
 Improved legibility
 Improved production scheduling and capacity utilization
 Improved ability to introduce new manufacturing technology and rapidly update
process plans to utilize the improved technology
8. CONCLUSION
CAPP is a highly effective technology for discrete manufacturers with a

significant number of products and process steps. Rapid strides are being made to
develop generative planning capabilities and incorporate CAPP into a computer
integrated manufacturing architecture. The first step is the implementation of GT or FT
classification and coding. Commercially available software tools currently exist to
support both GT and CAPP. As a result, many companies can achieve the benefits of
GT and CAPP with minimum cost and risks. Effective use of these tools can improve a
manufacturers competitive advantage too.
REFERENCES
 Mikell P. Groover & Emory W. Zimmres. Jr, “Computer Aided Design and
Manufacturing”, Prentice Hall Publication, 1994.
 “CAPPturing Manufacturing”, The Machinist, May-June 2003
 http://www.cimplex.com/metcapp.hmt
 “Computer aided process planning based on Information Management”,

Journal of Materials Processing Technology 103 (2000) 120-127.
 “Computer aided Process Planning”, Kenneth Crow, DRM Associates
 “A Reliable Knowledge Based Computer aided Process Planning

Application-Case of MetCAPP Software”, Galia Novakova, PhD student,
Polytechnical University of Turin, Department of Production Systems and
Economics
 Mikell P. Groover “Automation Production Systems and Computer
integrated Manufacturing”, Prentice Hall India Pvt Ltd, 1997
 James.a.Rehg and H.W. Kraebber, “Computer Integrated Manufacturing”,

Pearson Education Asia, 2002

Computer Aided Process Planning CAPP

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Computer Aided Process Planning (CAPP) 1

Technological advances are reshaping the face of manufacturing, creating

Moreover, the reliable knowledge based computer-aided process planning

1.1 COMPUTER AIDED DESIGN (CAD)

A product must be defined before it can be manufactured. Computer Aided

1.2 COMPUTER AIDED MANUFACTURING (CAM)

Process planning is usually accomplished by manufacturing engineers. Based on

ORGANISATION FOR INDUSTRIAL

OPER MACH OPER DESCRIPTION- SET UP PIECE OPR

0010 5145 S/U COLLET 2.00 0.173

ROUTE SHEET GENERATED BY MIPLAN

• Equipment selection: In general, process planers’ must develop plans that

The results of planning are:

• Routings which specify operations, operation sequences, work centers,

Manual process planning as mentioned earlier is based on a manufacturing engineer’s

3. COMPUTER-AIDED PROCESS PLANNING ( CAPP)

3.1 CAD/CAM INTEGRATION AND CAPP FEATURES

A frequently overlooked step in the integration of CAD/CAM is the process

3.2 COMPUTER-AIDED PROCESS PLANING : TYPES

1. Retrieval CAPP systems or Variant Approach

1. Retrieval CAPP System or Variant Approach

i. Selecting an appropriate classification and coding scheme for the company

New part design

Retrieve standard Standard process Prepare standard

Edit existing plan

Process plan Other application

GENERAL PROCEDURE FOR RETRIEVAL CAPP SYSTEMS

One of the commercially available Retrieval CAPP systems is MultiCapp, from

Generative CAPP System or Generative Approach

The generative method of developing process plans involves starting from

Group technology is a manufacturing philosophy in which similar parts are

Part classification and coding is concerned with identifying the similarities

i. Design attributes (such as geometric shape and size)

4.1 BENEFITS OF GROUP TECHNOLOGY

 Employee Satisfaction: The machine cell often allows parts to be processed

5. CAPP LITERATURE AND CAPP METHODOLOGY

Feature Extraction Module

Blank Selection Module

Once the component is modelled in SolidWorks modelling software, it is

Set-Up Planning Methodology

• Possible route identification

Possible Route Identification

Rough Milling  Semi-finish Milling Finish Milling

Cutting Tool Selection

Machine Selection For Individual Process

6. CAPP APPLICATIONS: CASE OF METCAPP

MetCAPP is a knowledge –based process planning and cost estimating system

MetCAPP, which is a knowledge-based manufacturing process planning and

Though, the inclusion of a process plan in the problem requires optimisation

Knowledge Based Machining

Technology Module Manager

Fig 3. MetCAPP : TECHNOLOGY MODULE MANAGER AND TECH.

Moreover, MetCAPP develops a process plan based on specific elemental

Process planning is the glue between product, process, and resources. It is

1) Finding Machining Features:

An operation plan is a sequence of machining operations capable of creating P

2) Generating Feature Based Models (FBM’s):

In manufacturing planning the goal to be achieved is represented by a design

CAD SYSTEM CAD models of the part P

2.Generate FBM Generate the feature-based

5.Feedback Information about P’s

THE BASIC APPROACH USED IN MetCAPP

6.1 THE MetCAPP FEATURES