Computer Aided Process

Planning

What is CAPP

Design approaches of CAPP systems

Retrieval CAPP systems/ Variant CAPP
Generative CAPP systems

Variant (Retrieval) CAPP Methodology

Variant CAPP

Variant CAPP

Variant CAPP

Generative CAPP Methodology

CAPP Model
CAD system

Preprocessor

Knowledge

Input

CAPP

Output

Planning rules
CAPP Model
Postprocessor
Production planning and
Scheduling

Advantages of Generative Process Plan :

1.

They rely less on group technology code numbers since the process, usually uses
decision tree to categorize parts into families.

2.

Maintenance and updating of stored process plans are largely unnecessary. Since,
any plan may be quickly regenerated by processing through the tree.

Variant or Generative?
A variant system is better for manufacturing setting where similar parts are
manufactured repetitively. Because parts are similar, Group Technology can easily be
implemented and shows quick and significant return on investment (ROI). Because
similar parts are produced repetitively, process plan can be retrieved, slightly modified
and used, without going through too much trouble.
A Generative process planning is better suited for a manufacturing environment in
which part does not exhibit too much similarity and new part are introduced on a
regular basis. In this case, benefits cannot be gained from Group Technology due to
dissimilarity of parts. Because, new parts are regularly introduced, historical data does
not have too much value to the process planner.

Benefits derived from CAPP :

Process rationalizationand standardization
Increased productivity of process planners
Reduced lead time for process planning
Improved legibility
Incorporation of other application programs

Recent trends in CAPP systems include :

1. Automated translation of the design dimensions.
2. Tolerances into manufacturing dimensions.

3. Tolerances considering process capabilities.

4. Dimensional chains.
5. And to make CAPP system affordable for small and medium scale
manufacturing industries.

Shop Floor Control

Definition: Shop Floor Control (SFC) is the process by which
decisions directly affecting the flow of material through the factory
are made.
WIP
Tracking

Throughput
Tracking

Functions:
Status
Monitoring

Material Flow
Control

Capacity
Feedback

Work
Forecasting

Quality
Control
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The Shop Floor Control System

The three steps or modules are:
1. Order release
2. Order scheduling
3. Order progress

Order Release:
The purpose of the order release module is to provide the necessary document
that accompanies an order as it is processed through the shop. These are referred
to collectively as the shop packet
1.Route sheet-listing the operation sequence and tools needed
2. Material requisitions-to draw the necessary raw material from stock
3. Job Cards-enough job cards to report the labor for each operation on the route sheet
4. Move tickets-to move the parts between work centers
5. Parts list-for assembly jobs

Order Scheduling:
The purpose of order scheduling is to make assignments of the orders to the
various machines in the factory.
Inputs to this module consist of the order release and priority control.
The basic document prepared by the order scheduling module is the dispatch list.
It reports the jobs that should be done at each work center and certain details
about the routing of the part.

Order Progress:
The order scheduling module satisfies the first function of shop floor control. The
purpose of the order release module is to accomplish the remaining three
functions of SFC.
The order progress module maintains a file of the transactions reported on each of
the uncompleted jobs. This file is called the open order file, and it contains the
latest status of each job order in the factory. The types of reports that can be
generated from the open order file include the following:
1. Work order status report
2. Exception Report

Automatic data identification methods

Used to collect data in material handling and manufacturing applications
-

In material handling, the applications include shipping and receiving,

storage, sortation, order picking.

In manufacturing, the applications include monitoring the status of order

processing,
work-in-process, machine utilization, worker attendance.

The principal components of automatic data identification technologies:

1) Encoded data
2) Machine reader or scanner
3) Decoder

Bar codes
The symbol consists of bars and spaces of varying width. The pattern of
bars and spaces is coded to represent numeric or alphanumeric charecters.

- The light reflections are sensed by a photoconductor, which converts the spaces into
an electrical signal and the bars into absence of an electrical signal.
- The width of the bars and spaces is indicated by the duration of the corresponding
signals
- The decoder analyzes the pulse train to validate and interpret the corresponding data

 Radio frequency identification

Magnetic stripes
Optical character recognition
Machine vision system