INTRODUCTION TO PROCESS PLANNING

1. 20ME706PE
PROCESS PLANNING
AND COST
ESTIMATION

2. • UNIT I INTRODUCTION TO PROCESS PLANNING
• UNIT II PROCESS PLANNING ACTIVITIES
• UNIT III INTRODUCTION TO COST ESTIMATION
• UNIT IV PRODUCTION COST ESTIMATION
• UNIT V MACHINING TIME CALCULATION

4. Design the
product
Manufacturing
Process
planning
Stages

6. PROCESS PLANNING ACTIVITIES:
1. Drawing interpretation:
• Analyse finished part in engineering design.component
drawings(features,dimensions,geometric tolerances,surface
finish,material specification,part required).
2. Material evaluation and process selection:
• (Function,appearance,reliability,life,environment,compatibility,produc
tivity,cost).Evaluate the materials, (features,dimensions,geometric
tolerances transform rough state to finished state).Process
evolution(rough to finished).Part evolution(final state to initial state).

7. 3. Selection of m/c,tooling,workholding devices:
• Economic considerations,production rate per unit cost,durability and
dependability,lower process rejection,minimum setup times,long life
of m/c,functional versatility.best m/c,make or buy,BEA .
4. Selecting process parameters:
• Machines selected,calculating operation setup time and cycle
time,tooling sequence,equipment capability,shop practice.
• Calculation of part processing time requires determination of
sequence of processing steps on each m/c as outplanning.
• Part loading,unloading,m/c indexing for 1 cycle.
• M/c cycle time allowances added to standard cycle time.Calculate
cycle time & m/c rates to find out cost.

8. 5. Selecting quality assurance methods:
• Inspection criterias(dimensional,geometric,surface finish),tools and
techniques,increases costs&time.
6. Cost estimating:
• Process of determining the probable cost of product before
manufacture.
• Material,labour,overhead costs-profit.
• Material,mfg processes,batch size,make or buy.

9. 7. Process planning documentation:
• Document clearly all the detail information.
• Documented as job routing or operating sheet.
• Production operations&associated m/c tools for component and
subassembly.
• Route sheet information as
part identification,processing,operation of m/c,std times,setup cycle
times,tooling requirements,production control information shows
planning lead time operation.
• Reasons: part process-design,job quote,cost estimate,std cost
systems,communication vehicle.
8. Communicate process knowledge:
• Mfg to shop floor,economy,consistent quality.

14. Computer Aided Process Planning

15. Retrieval (or variant) CAPP System

18. Selection of Process planning system
Major factors to be considered while selecting the
best process planning system are:
i. General Environment
ii. Organisational Structure
iii. Technical Expertise
iv. Needs and Objectives of the company

19. DRAWING INTERPRETATION

20. The following information can be obtained from the
interpretation of an engineering drawing:
i. Material of the product
ii. Number of parts to be produced
iii. Weight of the component
iv. Dimensions of the parts
v. Dimensional and geometric tolerances
vi. Size and Accuracy

21. TYPES OF DRAWINGS

22. 1)DETAIL DRAWINGS

23. 1.1) SINGLE –PART DRAWINGS

24. 1.2) COLLECTIVE SINGLE –PART
DRAWINGS

25. 2) ASSEMBLY DRAWINGS

26. 2.1) SINGLE –PART ASSEMBLY
DRAWINGS

27. 2.2) COLLECTIVE ASSEMBLY DRAWINGS

29. INFORMATION IN THE DRAWING SHEET
REQUIRED FOR PROCESS PLANNING
• DIMENSIONS

30. • MATERIAL SPECIFICATION
• SPECIAL MATERIAL TREATMENTS

31. • TOLERENCES, LIMITS AND FITS

32. • SURFACE FINISH

34. Material Selection Process

35. Material Evaluation Method
1. Shape or Geometry Consideration
2. Material Property Requirements
3. Manufacturing Considerations

36. Shape or Geometry Consideration
Some of the important shape or Geometry considerations are:
• Relative size
• Complexity
• Dimensional Tolerance
• Surface Finish
• Allowances
• Design for Assembly
• Design for Manufacturability

37. Some raw materials forms for common manufacturing processes

38. Material Property Requirements
i. Mechanical Properties
ii. Physical Properties
iii. Service Environment
Manufacturing Considerations
• Standard Components
• Ease of Manufacture
• Quantity and rate of components
• Minimum and Maximum
• Level of Quality
• QA and Inspection Requirements
• Ease of Assembly

40. Process Selection
Method

45. Factors considered for machine
selection

52. Steps in Machine Selection

53. Factors in tooling selection
• Manufacturing practice
• Manufacturing process
• Machine tool characteristics
• Capability
• Processing time
• Cutting tool availability

57. Operating requirements for tool
selection
• Workpiece material
• Operation
• Part geometry
• Tooling data

60. Factors affecting tooling performance
• Cutting tool materials
• Cutting tool geometry
• Cutting fluids