DESIGN PROCESS PLANNING & MANAGEMENT

1. Define
Empathy
Ideate Prototype
Launch
Test
 High Repeatability and Precision
e.g. Aircraft parts
 Volume of production is very high
 Complex contours/surfaces need to be machined.
E.g. Turbines
 Flexibility in job change, automatic tool settings, less scrap
 More safe, higher productivity, better quality
 Less paper work, faster prototype production, reduction in lead
times
ADVANTAGE
ADVANTAGE

2. Define
Empathy
Ideate Prototype
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 Costly setup, skilled operators
 Computers, programming knowledge required
 Maintenance is difficult
DISADVANTAGE
DISADVANTAGE

3. Define
Empathy
Ideate Prototype
Launch
Test
CNC MACHINING PROCESS
CNC MACHINING PROCESS
DECIDE ON MEASURING UNITS
 Inch/Metric
DECIDE ON Co-ordinate System
 Absolute
 Incremental
CALL UP THE TOOL
TURN ON THE SPINDLE
MOVE TOOL RAPIDLY TO A POINT CLOSE TO PART
START MACHINING
System Shutdown

4. Define
Empathy
Ideate Prototype
Launch
Test
• Part program
• Program input device
• Machine control unit
• Drive system
• Machine tool
• Feedback system
CNC SYSTEM ELEMENTS
CNC SYSTEM ELEMENTS

5. Define
Empathy
Ideate Prototype
Launch
Test
The part program is a sequence of instructions which
describe the work which has to be done on a part, in the
form required by a computer under the control of an NC
computer program.
PART PROGRAMMING
PART PROGRAMMING

6. Define
Empathy
Ideate Prototype
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Test
• A part program is a list of coded instructions which
describes how the designed component or part will be
manufactured.
• These coded instructions are called data.
• The part program can be further broken into separate
lines of data called blocks.
• A block of data contains words.
PART PROGRAMMING
PART PROGRAMMING

7. Define
Empathy
Ideate Prototype
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Test
CO-ORDINATE AXIS
CO-ORDINATE AXIS

8. Define
Empathy
Ideate Prototype
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Test
 Process planning
 Axes selection
 Tool selection
 Cutting process parameters planning
 Job and tool setup planning
 Machining path planning
 Part program writing
 Part program proving
PART PROGRAMMING FUNDAMENTALS
PART PROGRAMMING FUNDAMENTALS

9. Define
Empathy
Ideate Prototype
Launch
Test
 Manual
 Computer aided
TYPES OF PART PROGRAMING
TYPES OF PART PROGRAMING

10. Define
Empathy
Ideate Prototype
Launch
Test
 ISO standards for coding
 Co-ordinate function
 Feed function
 Speed function
 Tool function
 G Codes
 M Codes
MANUAL PART PROGRAMMING METHODS
MANUAL PART PROGRAMMING METHODS

11. Define
Empathy
Ideate Prototype
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Test
Basic Axes
X – axis ( Table left & Right)
Y – axis ( Table In & Out)
Z – axis ( Spindle)
MACHINE AXIS
MACHINE AXIS

12. Define
Empathy
Ideate Prototype
Launch
Test
Additional Axes
• A — axis (angular axis about X - axis)
• B — axis (angular axis about Y — axis)
• C — axis (angular axis about Z — axis)
• U — axis (secondary axis parallel to X)
• V — axis (secondary axis parallel to Y)
• W — axis (secondary axis parallel to Z)
• I - Circular cutting reference for X
• J - Circular cutting reference for Y
• K — Circular cutting reference fort
MACHINE AXIS
MACHINE AXIS

13. Define
Empathy
Ideate Prototype
Launch
Test
COMMON FORMAT OF A BLOCK
COMMON FORMAT OF A BLOCK
N50
G90 G01
X1 Y2
F10
S1500
T01
M03
Sequence
Preparatory Function
Dimension word
Feed rate
Spindle Function
Tool Function
Misc Function

14. Define
Empathy
Ideate Prototype
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Test
Modal command
Certain command remain active until cancelled by another
codes
Non Modal command
Command remain active in the block in which it is issued
MODAL / NON MODAL
MODAL / NON MODAL

15. Define
Empathy
Ideate Prototype
Launch
Test
• Linear interpolation
• Circular interpolation
INTERPOLATION
INTERPOLATION

16. Define
Empathy
Ideate Prototype
Launch
Test
• A Angular dimension around X axis
• B Angular dimension around Y axis
• C Angular dimension around Z axis
• F Feed function
• G Preparatory function
• H Unassigned
• I Distance to arc centre or thread lead parallel to X
• J Distance to arc centre or thread lead parallel to Y
• K Distance to arc centre or thread lead parallel to Z
• M Miscellaneous function
WORD ADDRESSES
WORD ADDRESSES

17. Define
Empathy
Ideate Prototype
Launch
Test
• N Sequence number
• O Reference rewind stop
• S Spindle speed function
• T Tool function
• U Secondary motion dimension parallel to X*
• V Secondary motion dimension parallel to Y*
• W Secondary motion dimension parallel to Z*
• X Primary X motion dimension
• Y Primary Y motion dimension
• Z Primary Z motion dimension
WORD ADDRESSES
WORD ADDRESSES

18. Define
Empathy
Ideate Prototype
Launch
Test
 G00 Point-to-point positioning, rapid traverse
 G01 Line interpolation
 G02 Circular interpolation, clockwise (WC)
 G03 Circular interpolation, anti-clockwise (CCW)
 G04 Dwell
 G13-G16 Axis designation
 G17 XY plane designation
 G18 ZX plane designation
 G19 YZ plane designation
 G33 Thread cutting, constant lead
 G34 Thread cutting, linearly increasing lead
 G35 Thread cutting, linearly decreasing lead
 G40 Cutter compensation-cancels to zero
G CODES OR PREPARATORY FUNCTIONS
G CODES OR PREPARATORY FUNCTIONS

19. Define
Empathy
Ideate Prototype
Launch
Test
 G41 Cutter radius compensation-offset left
 G42 Cutter radius compensation-offset right
 G43 Cutter compensation-positive
 G44 Cutter compensation-negative
 G53 Deletion of zero offset
 G54-G59 Datum point/zero shift
 G63 Tapping cycle
 G64 Change in feed rate or speed
 G70 Dimensioning in inch units
 G71 Dimensioning in metric units
G CODES OR PREPARATORY FUNCTIONS
G CODES OR PREPARATORY FUNCTIONS

20. Define
Empathy
Ideate Prototype
Launch
Test
 G80 Canned cycle cancelled
 G81-G89 Canned drilling and boring cycles
 G90 Specifies absolute input dimensions
 G91 Specifies incremental input dimensions
 G92 Programmed reference point shift
 G94 Feed rate/min (inch units when combined with G70)
 G95 Feed rate/rev (metric units when combined with G71)
 G96 Spindle feed rate for constant surface feed
 G97 Spindle speed in revolutions per minute
G CODES OR PREPARATORY FUNCTIONS
G CODES OR PREPARATORY FUNCTIONS

21. Define
Empathy
Ideate Prototype
Launch
Test
 M00 Program stop, spindle and coolant off
 M01 Optional programmable stop
 M02 End of program-often interchangeable with M30
 M03 Spindle on, CW
 M04 Spindle on, CCW
 M05 Spindle stop
 M06 Tool change
 M07 Coolant supply No. 1 on
MISCELLANEOUS FUNCTIONS, M
MISCELLANEOUS FUNCTIONS, M

22. Define
Empathy
Ideate Prototype
Launch
Test
 M08 Coolant supply No. 2 on
 M09 Coolant off
 M13 Spindle on, CW + coolant on
 M14 Spindle on, CCW + coolant on
 M19 Spindle stop at specified angular position
 M30 Program stop at end tape + tape rewind
MISCELLANEOUS FUNCTIONS, M
MISCELLANEOUS FUNCTIONS, M

23. Define
Empathy
Ideate Prototype
Launch
Test
A Manufacturing Planning and Control (MPC) system is
concerned with planning and controlling all aspects
of manufacturing,
 Materials,
 Scheduling machines and people
 Coordinating suppliers and customers.
An effective MPC system is critical to the success of any
Business.
MANUFACTURING PLANNING & CONTROL
MANUFACTURING PLANNING & CONTROL

24. Define
Empathy
Ideate Prototype
Launch
Test
 Manufacturing planning and control are administrative
processes that are inextricably linked.
 Without planning and control, a business can run into
challenges turning raw materials into actual products.
 Production planning and control coordinates different
processes, departments and people to ensure they are all
making efficient and cost-effective use of time.
 Production planning is the process through which a
business determines its production needs and plans for
how to meet those needs.
MANUFACTURING PLANNING & CONTROL
MANUFACTURING PLANNING & CONTROL

25. Define
Empathy
Ideate Prototype
Launch
Test
 Such planning is an ongoing process that begins before
production starts and encompasses every aspect of
production.
 It includes planning the purchase and maintenance of tools
and materials for production, ranging from metal and wires to
large machines.
 It includes planning for sufficient personnel to complete and
oversee each step of the process.
 It includes knowledge of how much demand there is for a
specific product, how much people will pay for it and how
much it costs to make.
MANUFACTURING PLANNING & CONTROL
MANUFACTURING PLANNING & CONTROL

26. Define
Empathy
Ideate Prototype
Launch
Test
 Costs, both internal and external.
 Quantities.
 Needed materials and machinery.
 Schedules, including the manufacturing sequence and
production timetable.
 Start and completion dates.
 Job assignments.
 Processes.
SIGNIFICANCE
SIGNIFICANCE

27. Define
Empathy
Ideate Prototype
Launch
Test
 Acquiring materials
 Continuous production
 Effective use of resources
 Meeting deadlines
 Improved communication
 Keeping costs down
 Quality control
 Inventory control
 Morale boost
OBJECTIVES
OBJECTIVES

28. Define
Empathy
Ideate Prototype
Launch
Test
 Strategic Business Plan ( SBP)
 Sales & Operations Plan ( S& OP)
 Master Production Schedule ( MPS)
 Material Requirements Planning ( MRP)
 Purchasing & Production Activity Control (PAC)
EXECUTION
EXECUTION

29. Define
Empathy
Ideate Prototype
Launch
Test
 Strategic planning is an organization's process of defining
its strategy, or direction, and making decisions on allocating its
resources to pursue this strategy.
 It may also extend to control mechanisms for guiding the
implementation of the strategy.
 Also outlines an organization's overall direction, philosophy,
and purpose,
 It examines its current status in terms of its strengths,
weakness, opportunities, and threats (see SWOT Analysis),
 It sets long-term objectives, and formulates short-term tactics
to reach them.
STRATEGIC BUSINESS PLAN
STRATEGIC BUSINESS PLAN

30. Define
Empathy
Ideate Prototype
Launch
Test
STRATEGIC BUSINESS PLAN
STRATEGIC BUSINESS PLAN

31. Define
Empathy
Ideate Prototype
Launch
Test
 Sales and operations planning (S&OP) is an integrated
business management process through which the
executive/leadership team continually achieves focus,
alignment and synchronization among all functions of the
organization.
 Companies that have an effective sales and operations
planning process are improving their visibility across their
enterprise.
 The Sales and Operations Planning process is about turning
strategy into revenue and is critical to the success of any supply
chain.
SALES & OPERATIONS PLAN
SALES & OPERATIONS PLAN

32. Define
Empathy
Ideate Prototype
Launch
Test
SALES & OPERATIONS PLAN
SALES & OPERATIONS PLAN

33. Define
Empathy
Ideate Prototype
Launch
Test
 MPS is the process that helps manufacturers plan which
products and related quantities to produce during certain
periods.
 It actually drives the production process in terms of what
is manufactured and what materials are procured.
 It serves a bridge to sales as it informs them about what is
available to promise to customers and when deliveries
can be made.
MASTER PRODUCTION SCHEDULE
MASTER PRODUCTION SCHEDULE

34. Define
Empathy
Ideate Prototype
Launch
Test
 Material requirements planning (MRP) is a system for
calculating the materials and components needed to
manufacture a product.
 It consists of three primary steps:
 taking inventory of the materials and components on
hand,
 identifying which additional ones are needed and
 scheduling their production or purchase.
MATERIAL REQUIREMENTS PLANNING
MATERIAL REQUIREMENTS PLANNING

35. Define
Empathy
Ideate Prototype
Launch
Test
Production activity control (PAC) is responsible for
executing the master production schedule and the material
requirements plan.
At the same time, it must make good use of labor and
machines, minimize work-in-process inventory, and maintain
customer service.
PRODUCTION ACTIVITY CONTROL
PRODUCTION ACTIVITY CONTROL

36. Define
Empathy
Ideate Prototype
Launch
Test
It is responsible for executing the master production schedule and
the material requirements plan.
At the same time, it must make good use of labour and machines,
minimize work-in-process inventory, and maintain customer
service.
The material requirements plan authorizes PAC:
• To release work orders to the shop for manufacturing.
• To take control of work orders and make sure they are completed on
time.
• To be responsible for the immediate detailed planning of the flow of
orders through manufacturing, carrying out the plan, and controlling
the work as it progresses to completion.
• To manage day-to-day activity and provide the necessary support
PRODUCTION ACTIVITY CONTROL
PRODUCTION ACTIVITY CONTROL

37. Define
Empathy
Ideate Prototype
Launch
Test
The use of computer application to mimic performance in
order to improve product designs or assist in the resolution of
engineering problems for a wide range of industries.
simulation, validation and optimization of products, processes, and manufacturing tools.
INTRODUCTION TO CAE
INTRODUCTION TO CAE

38. Define
Empathy
Ideate Prototype
Launch
Test
Preprocessing - the engineers model the geometry (or a system
representation) and the physical properties of the design, as well
as the environment in the form of applied loads or constraints.
Solving - the model is solved using an appropriate mathematical
formulation of the underlying physics.
Postprocessing - the results are presented to the engineer for
review.
PHASES OF CAE
PHASES OF CAE

39. Define
Empathy
Ideate Prototype
Launch
Test
• Stress and dynamics analysis on components and
assemblies using finite element analysis (FEA)
• Thermal and fluid analysis using computational fluid
dynamics (CFD)
• Kinematics and dynamic analysis of mechanisms
(multibody dynamics)
• Acoustics analysis using FEA or a boundary element
method (BEM)
• 1D CAE, or mechatronic system simulation, for multi-
domain mechatronics system design
APPLICATION
APPLICATION

40. Define
Empathy
Ideate Prototype
Launch
Test
• Mechanical event simulation (MES)
• Control systems analysis
• Simulation of manufacturing processes like casting,
molding and die press forming
• Optimization of the product or process
APPLICATION
APPLICATION

41. Define
Empathy
Ideate Prototype
Launch
Test
 Design decisions can be made based on their impact on
performance.
 Designs can be evaluated and refined using computer
simulations rather than physical prototype testing, saving
money and time.
 CAE can provide performance insights earlier in the
development process, when design changes are less
expensive to make.
 CAE helps engineering teams manage risk and understand
the performance implications of their designs.
BENEFITS
BENEFITS

42. Define
Empathy
Ideate Prototype
Launch
Test
 Integrated CAE data and process management extends
the ability to effectively leverage performance insights
and improve designs to a broader community.
 Warranty exposure is reduced by identifying and
eliminating potential problems.
 When properly integrated into product and
manufacturing development, CAE can enable earlier
problem resolution.
 It has dramatically reduce the costs associated with the
product lifecycle.
BENEFITS
BENEFITS

43. MEE3501
PRODUCT DEVELOPMENT AND
MANAGEMENT
L T P J C
2 0 2 4 4
Module CAD/CAM/CAE
Lecture
Hours
1
Review of : Product cycle- Design process-
sequential and concurrent engineering- Computer
aided design CAD system architecture-
Computer graphics Introduction to CAM-
NC/CNC Machines, Manufacturing Planning,
Manufacturing control, Manufacturing methods,
Introduction to CAE.
7