3. PROCESS PLANNING
DEFINITION:
Also know as Operation Planning is defined as
the act of preparing a detailed processing
documentation for the manufacture of a piece part or
assembly
4. INTRODUCTION TO PROCESS PLANNING
Process planning is also called: manufacturing planning,
process planning, material processing, process
engineering, and machine routing.
• Which machining processes and parameters are to be
• Which machining processes and parameters are to be
used (as well as those machines capable of performing
these processes) to convert (machine) a piece part from
its initial form to a final form predetermined (usually by a
design engineer) from an engineering drawing.
• The act of preparing detailed work instructions to produce
a part.
6. PROCESS PLANNING
• Objective of process planning
• Scope of process planning
• Approaches to process planning
• Process planning activities
» Volume of production
» Selection of tools, jigs and fixtures
» Selection of material equipment
» Allocation of operator
» Calculation of machining cost , time.
• Finished part requirements
• Operating sequences
7. PROCESS PLANNING
• Machine selection
» Make or buy decisions
» Break even analysis
• Material selection parameters
• Set of documents for process planning
• Set of documents for process planning
» Operation and route sheet
» Process Planning sheet
• Developing manufacturing logic and knowledge
» Manual Process Planning
» Computer Aided Process Planning
• Production time calculation
• Selection of cost optimal processes
9. FACTORS AFFECTING PROCESS
PLAN SELECTION
• Shape
• Tolerance
• Surface finish
• Size
• Size
• Material type
• Quantity
• Value of the product
• Urgency
• Manufacturing system itself
• etc.
10. PROCESS PLANNING CLASSIFICATION
1. MANUAL
2. COMPUTER-AIDED PROCESS PLANNING
(a) VARIANT
- GT based
- Computer aids for editing
- Parameters selection
(b) GENERATIVE
- Some kind of decision logic
- Decision tree/table
- Artificial Intelligence
- Objective-Oriented
- Still experience based
3. AUTOMATIC
Design understanding
Geometric reasoning capability
11. REQUIREMENTS IN
MANUAL PROCESS PLANNING
• Ability to interpret an engineering drawing.
• Familiar with manufacturing processes and practice.
• Familiar with tooling and fixtures.
• Know what resources are available in the shop.
• Know how to use reference books, such as machinability
data handbook.
• Able to do computations on machining time and cost.
• Familiar with the raw materials.
• Know the relative costs of processes, tooling, and raw
materials.
12. DRAWBACKS OF MANUAL
PROCESS PLANNING
• Traditional Approach
• Done by the Expert Engineers depending on the
past knowledge and experience
• Product may not be qualitative
19. TYPES OF COST ESTIMATION
1. Estimation of Material cost
2. Estimation of Labour cost
3. Estimation of Over heads
3. Estimation of Over heads
4. Allocation of overheads
a) Allocation based on man hour rate
b) Allocation of machine hour rate
20. STEPS INVOLVED IN COST
ESTIMATION
• Calculation of Material cost
• Calculation of Labour cost
• Calculation of Expenses
• Calculation of Prime cost
• Calculation of Factory cost
• Calculation of Total cost
• Calculation of Selling price
21. COST ESTIMATION
• Types of estimates
• Realistic and unrealistic estimate
• Methods of estimates
• Methods of estimates
• Data requirements and sources
• Collection of cost
• Allowances in estimation
