Computer-aided Process Planning
Process planning is concerned with determining the sequence of individual manufacturing operations needed to produce a given part or product. The resulting operation sequence is documented on a form typically referred to as a route sheet containing a listing of the production operations and associated machine tools for a workpart or assembly. Process planning in manufacturing also refers to the planning of use of blanks, spare parts, packaging material, user instructions (manuals) etc.
The term "Computer-Aided Production Planning" is used in different context on different parts of the production process; to some extent CAPP overlaps with the term "PIC" (Production and Inventory Control).
Process planning translates design information into the process steps and instructions to efficiently and effectively manufacture products. As the design process is supported by many computer-aided tools, computer-aided process planning (CAPP) has evolved to simplify and improve process planning and achieve more effective use of manufacturing resources. process planning is of two types as- 1. generative type computer aided process planning. 2. variant type process planning.
Process planning encompasses the activities and functions to prepare a detailed set of plans and instructions to produce a part. The planning begins with engineering drawings, specifications, parts or material lists and a forecast of demand. The results of the planning are:
- Routings which specify operations, operation sequences, work centers, standards, tooling and fixtures. This routing becomes a major input to the manufacturing resource planning system to define operations for production activity control purposes and define required resources for capacity requirements planning purposes.
- Process plans which typically provide more detailed, step-by-step work instructions including dimensions related to individual operations, machining parameters, set-up instructions, and quality assurance checkpoints.
- Fabrication and assembly drawings to support manufacture (as opposed to engineering drawings to define the part).
Keneth Crow stated that "Manual process planning is based on a manufacturing engineer's experience and knowledge of production facilities, equipment, their capabilities, processes, and tooling. Process planning is very time-consuming and the results vary based on the person doing the planning".
According to Engelke, the need for CAPP is greater with an increased number of different types of parts being manufactured, and with a more complex manufacturing process.
Computer-aided process planning initially evolved as a means to electronically store a process plan once it was created, retrieve it, modify it for a new part and print the plan. Other capabilities were table-driven cost and standard estimating systems, for sales representatives to create customer quotations and estimate delivery time.
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