Thapathali Campus, Institute of Engineering

Manufacturing
Engineering
lecture - 3
Process Planning

Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Introduction to process planning

For an organization to manufacture a product, it should meet following
criteria
Design specification.
The manufacture of each component part of the product must be
thoroughly planned.
Quality Assurance.
The manufacture of the product must be cost-effective, i.e. maximize
the added value.
Meet the agreed deadlines.
Therefore, through process planning the manufacturing engineer is
responsible
To ensure the product is manufactured to the correct specification, at
the lowest possible cost and completed on time.

Department of Mechanical Engineering

 Thapathali Campus, Institute of Engineering

Design & manufacture cycle

marketing :
promotion of existing products in order
to gain sales.
carry out market research and identify
possible gaps in the market for the
products.

Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Product Design
Specification
PDS

Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

PDS in Design Process

Recognition
of Need

Becoming
Informed
Market analysis
Background study

Problem
Definition

Product Design
Specifications

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Thapathali Campus, Institute of Engineering

PDS
It is NOT the final specifications/achievements
It is a control document of what designers try to achieve
It acts like a design checklist and applicable to all design
applications
It is dynamic rather than static can be improved, changed
to suit design requirements
It defines the constraints/boundary of the design.

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Thapathali Campus, Institute of Engineering

Elements of PDS

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Thapathali Campus, Institute of Engineering

Elements of PDS Contd.

Performance target, attainable values
Environment effects on product during manufacture use, effects on
environment
Life in service 7 days/week, 24hrs/day, @ X years
Maintenance maintenance philosophy, need for special tools, ease of
maintenance
Targeted production cost
Competition data from benchmarking, IP, info search
Shipping delivery method, lifting capability
Packing cost & method of packing
Quantity will affect other costs such as tooling, processes
Manufacturing facility in-house or vendor, support system, machinery

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Thapathali Campus, Institute of Engineering

Elements of PDS Contd.

Size affects user, cost, shipping & handling
Weight - affects user, cost, shipping & handling
Aesthetics user perception or acceptance
Materials
Product Life Span life in production line
Ergonomics people's efficiency in their working environment.
Standard and Regulations government, BS/ISO/DIN
Customer target customer
Quality & Reliability subjected to standards (BS, ISO, DIN)
Shelf Life storage risks and problems
Processes processes involved, in-house facility/vendor
Time-scales period to complete the design

9 Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Elements of PDS Contd.

Testing methods, facility, requirements/standards
Safety safety requirements
Company Constraints house, facility, cost
Market Constraints local conditions, full market knowledge
Patents, literature & Product data clash & IP laws
Political & Social Implications social unrest, rejection
Legal product liability legislation (product defects, defects of
manufacture, defects of design,)
Installation assembly consideration (stand alone, subsystem)
Documentation manual, user instructions
Disposal environment.

10 Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Format of PDS
11 Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering

Writing PDS Document

It is a control document
Should be clearly written
Use sharp and definitive statements, NOT in essay form
Try to quantify parameters or estimate a figure
Date and put your issue number
Clearly document revisions

12 Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Assignment 3
Carry out your information analysis of the Hydraulic car jack
design based on your information analysis plan.
Develop your PDS based on your information analysis.
( include at least Ten elements of PDS)
Submission Date: 19th Jestha 2017/2nd June 2017, Friday
Note: Individual assignment

13 Department of Mechanical Engineering

 Thapathali Campus, Institute of Engineering

Design & manufacture cycle

Design concept stage:

No of possible solutions are generated.
evaluate to finalize the best option.
detail design stage:
all the necessary information required
to manufacture the product will be
generated
i.e. drawings, parts lists/bills of materials,
material specifications and so on.
cost analysis is carried out on the design
to determine if it is cost-effective or
not.
If the results of this analysis are
unsatisfactory, then modifications may
be made to the design.

Department of Mechanical Engineering

 Thapathali Campus, Institute of Engineering

Design & manufacture cycle

A prototype of the product is constructed
in order to evaluate both
The function of the product.
Identify any manufacturing problems.

Trial batch being manufactured as part

of the pilot and test run stage.

The production plans are developed to

meet the right quantities at the right
time
Sales 3 major role
To generate customer orders.
Forecast orders and service and repair
requirements
Continuous feedback for improvement
of the product
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering

What is Process Planning ?

Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

PROCESS PLANNING

Design Machine
Tool

Process
Planning

Scheduling and Production Control

Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Process Planning
the selection and sequencing of processes and operations to
transform a chosen raw material into a finished component.
Includes detailed work instructions to produce a
component.
Include the selection of manufacturing processes and
operations, production equipment, tooling and jigs and
fixtures.
Include determining manufacturing parameters and
specifying criteria for the selection of quality assurance (QA)
methods to ensure product quality.

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Thapathali Campus, Institute of Engineering

What methods are used?

Machining methods
Press working
Welding/fabrication
Casting
Powder materials
Layered deposition
Others

Department of Mechanical Engineering

 Thapathali Campus, Institute of Engineering

Welding/fabrication :
Additive techniques

Final Product
Weld Weld
Initial Add-on Add-on
Stock

Department of Mechanical Engineering

 Thapathali Campus, Institute of Engineering

Machining Methods:
Subtractive techniques

Final Product
Initial Slotting Drilling
Stock

Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Casting:
Form Methods

Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Process planning activities

In order to be effective in the role of a process planner, the
manufacturing engineer must possess a variety of skills and knowledge.

an ability to interpret engineering drawings.

knowledge of materials and manufacturing processes. Material
evaluation and process selection
knowledge of jigs and fixtures.
an ability to use reference material, for example: machining data,
tooling data, Selection of machines and tooling
knowledge of the relative costs of materials, processes and tooling
an ability to calculate manufacturing parameters and costs.
knowledge of inspection/QA procedures and specifications.

23 Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

Process planning activities Contd.

Preparing the process planning documentation.
There are two documents involved in the preparation of the
process plans.
I. Routing sheets.
specifies the route from which the raw material follows
through the manufacturing environment.
lists the production equipment and tooling to be used
II. operations list.
the detailed plan for every operation

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Thapathali Campus, Institute of Engineering

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Thapathali Campus, Institute of Engineering

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Thapathali Campus, Institute of Engineering

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Thapathali Campus, Institute of Engineering

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Thapathali Campus, Institute of Engineering

29 Department of Mechanical Engineering

 Thapathali Campus, Institute of Engineering

Process planning methods

Department of Mechanical Engineering

Thapathali Campus, Institute of Engineering

VARIANT PROCESS PLANNING

part part standard Standard
coding family plan process
formation preparation plans &
individual
process
plans
part part process
coding family plan
search retrieval

finished process
process plan
plan editing

GROUP TECHNOLOGY BASED RETRIEVAL SYSTEM

Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering

PROBLEMS ASSOCIATED WITH

THE VARIANT APPROACH
The components to be planned are limited to
similar components previously planned.
Experienced process planners are still required
to modify the standard plan for the specific
component.
Details of the plan cannot be generated.
Variant planning cannot be used in an entirely
automated manufacturing system, without
additional process planning.

Department of Mechanical Engineering

 Thapathali Campus, Institute of Engineering

ADVANTAGES OF THE VARIANT APPROACH

Once a standard plan has been written, a variety of
components can be planned.
Comparatively simple programming and
installation (compared with generative systems) is
required to implement a planning system.
The system is understandable, and the planner has
control of the final plan.
It is easy to learn, and easy to use.

Department of Mechanical Engineering

 Thapathali Campus, Institute of Engineering

GENERATIVE APPROACH
A system which automatically synthesizes/creates a
process plan for a new component.
No human intervention in theory.
Main components of a generative system
A part description that defines the geometry including geometric and
dimensional tolerances and surface finish specifications.
Manufacturing data based on reference data and process analysis
Manufacturing plans are produced by the computer by means of
decision making logic, formulae, algorithms and geometric analysis.
a database of information on the production equipment available;
a report generator to produce the process plan.
Department of Mechanical Engineering
 Thapathali Campus, Institute of Engineering

COMPUTER-AIDED PROCESS PLANNING

ADVANTAGES
It can reduce the skill required of a planner.
It can reduce the process planning time.
It can reduce both process planning and
manufacturing cost.
It can create more consistent plans.
It can produce more accurate plans.
It can increase productivity.

Department of Mechanical Engineering