COMPUTERIZED
MANUFACTURING PLANNING
Module 4
TRADITIONAL PROCESS PLANNING
• What is process planning?
• Process planning is concerned with the
preparation of route sheet that list the
sequence of operations and workcenters
required to produce the products and its
components.
Limitations of traditional process planning
• Tied to personal experience
• Knowledge of planer of production facilities,
equipment, their capabilities, process and
tooling. This results in inconsistent planning.
• Manual process planning is time consuming
and slow.
• Slow in responding to product design and
production.
Computer Aided Process Planning(CAPP)
Automating the task of process planning using
computer aided process planning
Computer Aided Process Planning(CAPP)
• Benefits of CAPP
• Process rationalization and standardization
• Increased productivity of process planner
• Reduced lead time for process planning
• Improved legibility
• Incorporation of other application programs
Benefits of CAPP
• Process rationalization and standardization:-
• Standard plans leads to lower
manufacturing cost and higher
production quality.
Benefits of CAPP
• Increased productivity of process planner
• Availability of standard process plans in the
data files permit more work to be done by the
process planner.
Benefits of CAPP
• Reduced lead time for process planning
• Process planer can provide route sheet in a
shorter lead time compare to manual
preparation.
Benefits of CAPP
• Improved legibility
• Computer – prepared route sheets are neater
and easier to read than manually prepared
route sheets.
Benefits of CAPP
• Incorporation of other application programs
• The CAPP program can be interfaced with
other application programs such as cost
estimation and work standards.
Approaches of CAPP
• Retrievals – type CAPP system (variant system)
• Generative CAPP system
• Combination of above two processes semi –
generative CAPP
Retrieval CAPP system
• Retrieval CAPP system is also called as variant
CAPP system, is based on the principle of
group technology (GT) and parts classification
and coding.
What is group technology?
• Group technology is a manufacturing
philosophy in which similar parts are identified
and grouped together to take advantage of
their similarities in design and production.
What is parts classification and coding?
• In parts classification and coding similarities among
parts are identified and these similarities are related
in a coding system.
• Two categories of part similarities can be
distinguished.
• Design attribute: geometry, size, and material.
• Manufacturing attributes: process steps required to
make a part.
Retrieval CAPP system
Derive GT code
for part
Search part family file for Part family Select coding system and
GT code number file form part families
Retrieve standard process Standard process Prepare standard process
plan plan file plans for part families
Edit existing plan
or write new plan
Process plan Other application
formatter programs
Process plan
(route sheet)
Generative type of CAPP
• Creation of Knowledge Base.
• Computer Compatible part description-CAD
model.
• Inference engine.
Production planning and control (PPC)
• Production planning and control (PPC) is concerned
with the logistics problems that are encountered in
manufacturing.
• That is managing the details of what and how many
products to produce and when.
• And obtaining the raw materials, parts and resources
to produce those parts.
Production planning
It consists of
• Deciding which products to make in what
quantities and when they should be
completed.
• Scheduling the delivery/production.
• Planning the manpower and equipment
resources.
Aggregate production planning
Aggregate planning is a high – level corporate
planning activity.
The aggregate production plan indicates
production output levels for the major
product lines of the company.
Aggregate production plan
Master production schedule(MPS)
• The production quantities of the major
product lines listed in the aggregate plan must
be converted into a very specific schedule of
individual products, known as the master
production schedule (MPS).
Master production schedule(MPS)
Material requirement planning(MRP)
• Material requirement planning (MRP) is a
computational technique that converts the
master schedule for end products into a detail
schedule for the raw material & components
used in the end product.
Independent and dependent demand
INDEPENDENT DEMAND
• Demand for a product is unrelated to demand
for other items. Example final products
DEPENDENT DEMAND
• Demand for a product is directly related to
demand for other items. Example component
parts, raw materials and sub assemblies.
Inputs to the MRP system
• Master production schedule
• The bill of materials file and other
engineering and manufacturing data
• Inventory record file
Inputs to the MRP system
Continued….
How MRP works?
MRP operates on
• Master production schedule(MPS)
• Bill Of Material(BOM)
• Inventory record
MRP output and benefits
• Planned order release :-this provides authority
to place order that have been planned by MRP
system.
• Report of planned order release in future
• Rescheduling notices, indicating changes in
due dates for open orders.
MRP output and benefits
• Cancellation notices, indicating that certain
open orders have been cancelled because in
the MPS.
• Reports on inventory status.
Benefits of MRP
• Reduction in inventory
• Quicker response to change in demand
• Reduced setup and product changeover cost
• Better machine utilization
• Improved capacity to respond to changes in
the master schedule
• Aide in developing the master schedule
Capacity planning
Capacity adjustments
• Long term adjustments
• Short term adjustments
Short term adjustments
• Employment levels
• Number of temporary workers
• Number of work shifts
• Number of labor hours
• Inventory stockpiling
• Order backlogs
• Workload through subcontracting
Long term adjustments
• Investing in new equipment
• Constructing new plant
• Purchasing existing plants from other
companies
• Acquiring existing companies
• Closing plants