DILLA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

Department of Mechanical Engineering
Course Title: Process Planning and Product Costing
(Manufacturing Stream)
Course Code: MEng5381
Individual Assignment
Name ID.NO
Biniam Getachew………RNS-1614/20
Instructor: Mr.Desalegn
Date: Nov 2024
Dilla,Ethiopia
1, Discuss in detail about ‘Opitz classification and
coding system’ (give at least two examples of Opitz
part coding system).
Answer
Opitz classification and coding system
Introduction to GT:
Group technology (GT) portrays a significant role in improving
productivity for the cellular manufacturing systems (CMS) which
classifies homogeneous parts and clusters them into part families
based on their manufacturing designs, attributes and geometric
shapes (Burbidge, 1963). It scrutinizes products, parts and
assemblies and then assembles homogeneous items to simplify
design, manufacturing, purchasing and other business processes.
Group Technology reduces the time required for practicing
engineering drawings for homogeneous parts, and the cost and time
required for designing supplementary machining apparatus such as
typically designed cutting tools, jigs and fixtures etc. A successful
implementation of GT can eventually minimize the engineering and
tooling costs, quicken product development, enhance costing
accuracy, simplify process planning and the overall purchasing
process (Galan et al., 2007). A major prerequisite in implementing
GT is the recognition of part families (Wemmerlov and Hyer, 1987),
a group of parts sharing homogeneous design and manufacturing
attributes. Early research in this domain has been dedicated
primarily on the formation of production-oriented part families.
However these methodologies are inadequate in achieving the needs
of other extents of manufacturing. For example, parts with
homogeneous shape, size, dimension or other design characteristics
are believed to be clustered in a single family for design justification
and elimination of part varieties. Therefore the scope of this domain
of investigation is believed to be expanded and examined to a wider
span of part similarities, which are assumed to be identified sooner
than the formation of part families based on shape, length/diameter
ratio, material type, part function, dimensions, tolerances, surface
finishing, process, operations, machine tool, operation sequence,
annual production quantity, fixtures needed, lot sizes (Groover and
Zimmers 1984). This paper proposes a state-of-the-art part family
identification technique called HPFOCS, to investigate the nature of
similarities and to describe the effectiveness of the technique in
solving the problem in hand.

Opitz Coding System:

This classification and coding system was initially proposed by Opitz
(1970) at Aachen Technology University in Germany. The basic code
comprises of nine digits that can be extended by additional four digits.
The general interpretations of the nine digits are as indicated
 Figure 1: Opitz part coding system

The interpretation of the first 9 digits is:

Digit 1: General shape of work piece, otherwise called ‘part-class’.

This is further subdivided into rotational and non-rotational classes and
further divided by size (length/diameter ratio.)
Digit 2: External shapes and relevant form. Features are recognized as
stepped, conical, straight contours. Threads and grooves are also
important.
Digit 3: Internal shapes. Features are solid, bored, straight or bored in
stepped diameter. Threads and grooves are integral part.
Digit 4: Surface plane machining, such as internal or external curved
surfaces, slots, splines.
Digit 5: Auxiliary holes and gear teeth.
Digit 6: Diameter or length of work piece.
Digit 7: Material Used.
Digit 8: Shape of raw materials, such as round bar, sheet metal,
casting, tubing etc.
Digit 9: Work piece accuracy.

All the 9 digits are interpreted numerically (0-9).

An example of square cast-iron flange is shown in Figure 2 in this
context.
The Opitz codes of square cast-iron flange is 65443 6070(Ham et al.,
1985).
The attributes are denoted as a1-a9,
a1=6 (Non-rotational, flat component with A/B<= 3, A/C > 4.)
a2=5 (Flat small deviations from casting.)
a3=4 (Main bores are parallel.)
a4=4 (Plane stepped surface.)
a5=3 (Drilling pattern for holes, drilled in one direction.)
a6=6 (400 mm. < length of edge <=600 mm.)
a7=0 (material is cast iron.)
a8=7 (Internal form: Casting.)
a9=0 (surface finish none.)
 Figure 2: Square cast-iron flange.

Part grouping problem deals with categorical data in the

vicinity of cellular manufacturing system. However linkage
clustering methods are developed to group the observations
(continuous items) rather than the categorical variables
(Anderberg, 1973). The issue of variable clustering generally
requires for dimension scaling. In order to utilize the linkage
methods such as average linkage (ALC) or single linkage
(SLCA) substantial modifications are assumed to be added
(Seifoddini and Wolfe, 1986). Therefore to achieve this goal
an improved similarity measure was proposed by Offodile
(1992) which is appropriate for the categorical data
presented by Opitz coding system. In present study
Offodile’s similarity measure is utilized to avoid such
drawbacks and the ALC and HPFOCS techniques are
modified accordingly which further can consider the
categorical data to group the parts using classification
and coding system. The next section elaborates these
methodologies.

The OPITZ classification system:

●it is a mixed (hybrid) coding system
●developed by Opitz, Technical University of Aachen, 1970
●it is widely used in industry
●it provides a basic framework for understanding the classification
and coding process
●it can be applied to machined parts, non-machined parts (both
formed and cast) and purchased parts
●it considers both design and manufacturing information
EXAMPLE 1
EXAMPLE 2
2,Explain the main components of Opitz coding system.
Answer
1. General Shape (Digit 1)
This digit classifies the general shape of the workpiece, also referred
to as the ‘part-class.’ It is further divided into rotational and non-
rotational classes and categorized by size, specifically the length-to-
diameter ratio.
2. External Shapes and Features (Digit 2)
This component focuses on the external shapes of the part,
identifying features such as stepped forms, conical shapes, straight
contours, threads, and grooves.
3. Internal Shapes (Digit 3)
This digit describes internal features of the part, which may include
solid forms or bored shapes with straight or stepped diameters.
Threads and grooves are also considered integral parts of this
classification.
4. Surface Machining (Digit 4)
This component pertains to surface plane machining characteristics,
including internal or external curved surfaces, slots, and splines.
5. Auxiliary Features (Digit 5)
This digit accounts for auxiliary holes and gear teeth present in the
part design.
6. Dimensions (Digit 6)
This component specifies either the diameter or length of the
workpiece, providing critical size information necessary for
classification.
7. Material Used (Digit 7)
This digit identifies the material from which the part is made, which
can significantly influence manufacturing processes and properties.
8. Raw Material Shape (Digit 8)
This component describes the shape of raw materials used in
production, such as round bars, sheet metal, castings, or tubing.
9. Workpiece Accuracy (Digit 9)
The final digit indicates the accuracy level required for the
workpiece, which is essential for ensuring that parts meet specified
tolerances during manufacturing.

3, Explain the benefits of ‘Group Technology’ in design

and manufacturing process-plan.
Answer

1. Definition of Group Technology (GT)

Group Technology (GT) is a manufacturing philosophy that involves
grouping similar parts or products into families based on their
design and manufacturing characteristics. This approach allows for
the optimization of production processes by leveraging similarities
among components, which can lead to increased efficiency and
reduced costs.
2. Enhanced Productivity
One of the primary benefits of GT is enhanced productivity. By
organizing similar parts into families, manufacturers can streamline
operations, reduce setup times, and minimize the need for extensive
retooling. This leads to faster production cycles as machines can be
set up to handle multiple similar parts without significant downtime.
3. Improved Quality Control
GT facilitates better quality control by standardizing processes for
similar items. When parts are grouped together, it becomes easier to
implement consistent quality checks and maintain high standards
across the production line. This uniformity helps in reducing defects
and improving overall product quality.
4. Reduced Lead Times
By utilizing GT, manufacturers can significantly reduce lead times
associated with production. The ability to produce similar items in
batches allows for quicker response times to market demands and
customer orders. This agility is crucial in today’s fast-paced
manufacturing environment where time-to-market can be a
competitive advantage.
5. Cost Efficiency
Cost savings are another significant benefit of GT. By minimizing
setup times, reducing waste through efficient use of resources, and
lowering inventory costs due to better planning and scheduling,
companies can achieve substantial cost reductions. Additionally,
economies of scale can be realized when producing larger quantities
of similar products.
6. Simplified Production Planning and Scheduling
Group Technology simplifies the planning and scheduling process by
allowing manufacturers to focus on families of products rather than
individual items. This simplification leads to more efficient resource
allocation, better utilization of machinery, and improved workflow
management.
7. Enhanced Communication Across Departments
Implementing GT fosters better communication between design and
manufacturing teams since both groups work with similar part
families. This collaboration ensures that design considerations align
with manufacturing capabilities from the outset, leading to fewer
misunderstandings and revisions during the production process.
8. Flexibility in Production Systems
GT provides flexibility within production systems by enabling
manufacturers to adapt quickly to changes in product design or
market demand without overhauling entire processes or systems.
The modular nature of grouped technologies allows for easier
adjustments while maintaining efficiency.
In summary, Group Technology offers numerous advantages that
enhance productivity, improve quality control, reduce lead times,
increase cost efficiency, simplify planning processes, foster
communication between departments, and provide flexibility within
manufacturing systems.
References:
1,"Definition from Business dictionary.com".
www.business dictionary.com. Retrieved 12 May 2013.
2, "Definition from All Data Labs". www.all data labs.com. Retrieved 1
Jan2016.