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Introduction To Process Planning: Chapter-1

The document discusses process planning, which involves determining the most appropriate manufacturing processes and sequence to produce a part specified in a design. Process planning determines the basic manufacturing process, operation sequence, required equipment, tools, and inspection stages. It aims to convert raw materials into finished products economically through intermediate stages between design and manufacturing. Key factors in process planning include production methods, material size/type, process capabilities, and quality requirements.

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zelalem wegayehu
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78 views26 pages

Introduction To Process Planning: Chapter-1

The document discusses process planning, which involves determining the most appropriate manufacturing processes and sequence to produce a part specified in a design. Process planning determines the basic manufacturing process, operation sequence, required equipment, tools, and inspection stages. It aims to convert raw materials into finished products economically through intermediate stages between design and manufacturing. Key factors in process planning include production methods, material size/type, process capabilities, and quality requirements.

Uploaded by

zelalem wegayehu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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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.

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


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.

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


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.

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


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

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


A Rough Process Plan

prepared by;-Simegn M 24/09/13 8


A Detailed Process Plan

prepared by;-Simegn M 24/09/13 9


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

prepared by;-Simegn M 24/09/13 10


Step-by-step
operations in
a sample
part

prepared by;-Simegn M 24/09/13 11


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.

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


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

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


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

prepared by;-Simegn M 24/09/13 14


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

prepared by;-Simegn M 24/09/13 15


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.

prepared by;-Simegn M 24/09/13 16


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.

prepared by;-Simegn M 24/09/13 17


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

prepared by;-Simegn M 24/09/13 18


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

prepared by;-Simegn M 24/09/13 19


Approaches to CAPP (computer aided
process planing)

1.Variant process planning.

2.Generative process planning.

prepared by;-Simegn M 24/09/13 20


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

prepared by;-Simegn M 24/09/13 21


1.Generative process planning

prepared by;-Simegn M 24/09/13 22


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.

prepared by;-Simegn M 24/09/13 23


TYPES OF INSPECTION

CENTRALIZE
FLOOR
D

Special cell
Done at work
located in the
station itself
industry

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


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.

prepared by;-Simegn M 24/09/13 25


prepared by;-Simegn M 24/09/13 26

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