Process planning and

cost estimation
 Unit 1

INTRODUCTION
TO PROCESS
PLANNING
 Process Planning
Process planning also known as operations
planning, is the systematic determination of the
engineering processes and systems to manufacture
a product competitively and economically.
It can be defined as act of preparing a detailed
work instruction for the manufacturing and
assembly of the components into a finished
product in discrete part manufacturing
environments.
Production manufacturing cycle
Process planning
 Responsibilities of process planning
engineer
Interpreting part print analysis and symbols.
Gathering the fundamental details of product
design.
Selecting the machining processes.
Selecting proper machining with allied tooling.
Sequencing the operations.
Deciding on the inspection equipment in order
to meet the desired quality.
 Determining appropriate production
tolerances.
Determining proper cutting tools and cutting
conditions.
Calculating the overall times using work
measurement techniques.
 Process planning activity
Steps
Drawing interpolation
Material evaluation and process selection
Selection of machines, tooling and work holding
Setting process parameters
Selecting quality assurance methods
Cost estimating
Preparing the process planning documentation
Communicating the manufacturing knowledge to the
shop floor
 Process planning documentation
The alternatives and associated machines, the
next step in process planning is to document
clearly all the information in detail.
The resulting process plan is generally
documented as a job routing or operation
sheet. The operation sheet is also called
route sheet, instruction sheet, traveller
or planner.
 A route sheet provides the following
information
Part identification
Description of the processing steps in each
operation.
Operation sequence and machines
Standard setup and cycle times
Tooling requirements for each operation
Production control information showing the
planning lead time at each operation.
 Process planning methods
1. Manual process planning
I. Traditional approach
II. Workbook approach
2. Computer aided process planning (CAPP)
I. Retrieval (or variant) CAPP system and
II. Generative CAPP system.
 Benefits of CAPP
Process rationalization and standardization
Productivity improvement
Product cost reduction
Elimination of human error
Reduction in time
Reduced clerical effort and paper work
Improves legibility
Faster response to engineering changes
Incorporation of other application programes.
Retrieval (or variant) CAPP system
In this system a process plan for a new part is
created by recalling, identifying an existing
plan for similar part, and making necessary
modifications for the new part
 Generative CAPP system
In this approach the computer is used to
synthesize or generate each individual process
plan automatically and without reference to
any prior plan.
 Components of generative CAPP system

A part description
A substance to define the machining
parameters
A subsystem to select and sequence individual
operations
A database
A report generator
 Drawing interpolation
Types of drawing
Combined drawings
Assembly drawings
Single part assembled drawings
Collective assembled drawings
Detailed drawing
Single part drawings
Collective drawings
 Detail drawing
Information required for manufacturing of the
required component or product
 Assembly drawings
Drawing which shows the complete product
with all its components in their correct
physical relationship
 Collective drawing assembly
A combined detailed and assembly drawing
Information on the drawing sheet
Material selection and evaluation
The material selection for a component or
product is the responsibility of design
engineers, the process planner should
evaluate the materials specified along with
design engineers, based on the availability of
manufacturing processes.
Material selection process and methods
 Material evaluation methods
Shape or geometry considerations
Material property requirements
Manufacturing consideration
 Process selection
A process is method of shaping, joining or
finishing a material.
classification of process
Primary process
Molding
deformation
Secondary process
Machining
Heat treatment
 Factors in process selection
Material form
Component size and weight
Economic considerations
Dimensional and geometric accuracy
Surface finish specification
Batch size
Production rate
 Stages of process selection
Drawing interpolation
Identification of critical processing factors
Comparison of potential manufacturing
processes
Identification of suitable processes
Identification of critical processing factors
Production equipment and tooling selection

Process planner has selected the

manufacturing processes to be employed then
specific production equipment required for
carry out the selected processes should be
selected.
 Factors to be considered
During selection of production equipment
Component size
Component weight
Physical size of the machine
Construction of the machine
Power and torque of the machine
Number of tools available for the machine
Types of tools available for the machine
 Factors to be considered
During selection of appropriate tooling
Availability of tooling
Work piece material
Type of cut
Part geometry or size
Tool material
Machining data
Quality requirements
 Factors in equipment selection
Technical factors
Physical size of the work piece
Machine accuracy
Surface finish
Cutting forces
Power of the machine
Operation factors
Batch size
Capacity
Availability
 Factors in tooling selection
Constraints on tool selection
Manufacturing practice
Manufacturing process
Machine tool characteristics
Capability
Processing time
Cutting tool availability
 Operating requirements for tool selection
Work piece material
Operation
Part geometry
Tooling data
Factors affecting tooling parameters
Cutting tool materials
Cutting tool geometry
Cutting fluids
 Tooling selection method
Evaluation of the process and machine
selection
Analysis of machining operations
Analysis of work piece characteristics
Tooling analysis
selection of tooling
Any quries ?...
Thank you