Introduction To Process Planning: Chapter-1

Chapter-1
Introduction to
Process
Planning
By Simegn M
prepared by;-Simegn M 24/09/13 1

PROCESS PLANNING
(manufacturing planning, material processing, process engineering, and
machine routing).
 Defn: “Determining the most appropriate
manufacturing processes and the sequence
in which they should be performed to
produce a given part or product specified by
designed Engineering”.
 It can also be defined as “The systematic

determination of the processes by which a
product is to be manufactured economically
& competitively”. 2
prepared by;-Simegn M 24/09/13
PROCESS PLANNING
 The system or a process responsible for the
conversion of raw material into finished product
by the most economical way within the limit of
design specifications.
 The process parameters which is used to convert
the part into the final product.

 Process planning is the intermediate stage
between designing & manufacturing of the

product.

Defining Process Planning
In general, the inputs to Process Planning are:
 Design data
 Raw material data
 Facilities data (machining data, tooling data, fixture data etc.)
 Quality requirements data
 Production type data
The output of process planning is the process plan:

 Process Plan Sheet
 Process Sheet
 Operation Sheet
 Planning Sheet
 Route Sheet
 Route Plan
 Part Program prepared by;-Simegn M 24/09/13 4
FUNCTIONS OF PROCESS
PLANNING
Process Planning has the following important functions:
 To determine the basic manufacturing process.

 To determine the sequence of operations.
 To determine the equipment's and tooling required.

PROCESS PLANNING CONSITS OF:
Sequence of operations to be performed
Selecting the proper machines
Selecting the proper tools
Jigs & fixtures
Material to be used
Specifying the inspection stages
Details like speed, feed, depth of cut, etc.

 Depending on the production environment PP
can be
◦ Rough
◦ Detailed

A Rough Process Plan

A Detailed Process Plan

Components of Process Planning
 Selection of machining operations
 Sequencing of machining operations
 Selection of cutting tools
 Determining the setup requirements
 Calculation of cutting parameters
 Tool path planning and generation of
NC/CNC programs
 Design of Jigs/Fixtures

Step-by-step
operations in
a sample
part

The following information is needed to develop a process plan.
 Knowledge of various manufacturing process.

 Engineering component of drawing.
 Knowledge of various tools and fixture.
 Relation costs of various process ,tooling,
and raw materials.

 Resource available in factory.
 Ability to do computation on machine time
and cost.
 Knowledge to use reference books such as
machinablity data hand books.

PLANNING OF PROCESSES FROM RAW MATERIAL TO
FINISHED PRODUCT (steps)
 Part Print Analysis

 Make or buy decision
 To Select Basic Manufacturing Process
 To Determine the Sequence of Operation
 Combine the Operations
 Selection of Machine Tools and Equipment
 Inspection
 Miscellaneous Functions
 Preparation of Operation

FACTORS AFFECTING PROCESS PLANNING
Production Methods
Size and Type of raw
material
Process Capability
Quantity to be manufactured
Delivery dates of the
products
Surface finish and accuracy
required

COMBINED OPERATIONS
 The cost of processing can be reduced by eliminating unnecessary
operations.
 This can be achieved in number of ways and are accomplished
through proper planning.
Operations can be performed in two ways:

1. By Simulation
2. By Integration

By Simulation
Simulation involves those combinations
where two or more elements of an
operation, or two or more operations are
performed at the same time.
Example: series of hole to be drilled

simultaneously using a multiple spindle
drill press. Cuter are specially designed.

By Integration
 Where several individual elements of an
operation or group of operations are
combined in succession but not
simultaneously.
 Example: Taping is done after drilling hole

on the same set up by just changing the tool.

ADVANTAGES OF COMBINED OPERATIONS
 Improved accuracy
 Reduced labor cost
 Reduced plant fixed cost
 Less tooling required
 Less handling required
 Fewer setups
 Smaller in process inventory
 Less scrap
 Fewer inspection points required

DISADVANTAGES OF COMBINED
OPERATIONS
 Maintaining tool accuracy

 Possible higher tool costs
 Maintaining dimensions for several baselines
 More costly setups
 Sometimes scrap is increased
 Compromises on operational speed
 Chip disposal

Approaches to CAPP (computer aided
process planing)
1.Variant process planning.
2.Generative process planning.

1.Variant Process Planning
“based on the valid conjecture that similar
parts will have similar process plans”
 GT-based part coding
◦ Families of similar parts are created

◦ Family matrix

1.Generative process planning

INSPECTION
Quality related in-process inspection is an
essential part of quality control in
manufacturing.
 It includes measuring, examining or testing
one or more characteristics of a product or

process.
Inspection includes separation of defective
parts from the non-defective parts.

TYPES OF INSPECTION
CENTRALIZE
FLOOR
D
Special cell
Done at work
located in the
station itself
industry

PURPOSE OF INSPECTION
To distinguish good lots from bad lots.
To distinguish good pieces from bad pieces.
To determine if the process is changing.
To rate quality of product.
To rate accuracy of inspectors.
To measure precision of instruments.
To secure products design information.


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Chapter-1

prepared by;-Simegn M 24/09/13 1

 It can also be defined as “The systematic

the part into the final product.

between designing & manufacturing of the

prepared by;-Simegn M 24/09/13 3

The output of process planning is the process plan:

Process Planning has the following important functions:

 To determine the basic manufacturing process.

prepared by;-Simegn M 24/09/13 5

Selecting the proper machines

Selecting the proper tools

Jigs & fixtures

Specifying the inspection stages

Details like speed, feed, depth of cut, etc.

prepared by;-Simegn M 24/09/13 6

prepared by;-Simegn M 24/09/13 7

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 Knowledge of various manufacturing process.

and raw materials.

machinablity data hand books.

prepared by;-Simegn M 24/09/13 12

 Part Print Analysis

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 This can be achieved in number of ways and are accomplished

through proper planning.

Operations can be performed in two ways:

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Example: series of hole to be drilled

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 Example: Taping is done after drilling hole

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 Maintaining tool accuracy

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1.Variant process planning.

2.Generative process planning.

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◦ Families of similar parts are created

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one or more characteristics of a product or

parts from the non-defective parts.

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