Chapter 2 Lecture 4 Computer Aided Process Planning (CAPP)

8.1 Introduction
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 operation sheet. The operation sheet is a listing of
the production operations and associated machine tools for a work part or assembly. Process
planning is an important stage of product development since production tooling like jigs, fixtures,
special tools etc. can be designed only after the process is finalized.
Role of process planning
1. Interpretation of product design data
2. Selection of machining processes.
3. Selection of machine tools.
4. Determination of fixtures and datum surfaces.
5. Sequencing the operations.
6. Selection of inspection devices.
7. Determination of production tolerances.
8. Determination of the proper cutting conditions.
9. Calculation of the overall times.
10. Generation of process sheets including NC data.

Approaches to Process planning

1. Manual approach
2. Variant or retrieval type CAPP system
3. Generative CAPP system

All the information determined by the process planning function is recorded on a sheet
called process plan. The process plan is frequently called an operation sheet, route sheet or
operation planning sheet. This provides the instructions for the production of the part. It contains
the operation sequence, processes, process parameters and machine tools used. Fig 8.1 shows
a typical process planning sheet.
In conventional production system, a process plan is created by a process planner. It
requires a significant amount of time and expertise to determine an optimal routing for each new
part design. However, individual engineers will have their own opinions about what constitutes
the best routing. Accordingly, there are differences among the operation sequences developed
by various planners. Efficient process planning requires the service of experienced process
planners.
Because of the problems encountered with manual process planning, attempts have been
made in recent years to capture the logic, judgment and experience required for this important
function and incorporates them into computer programmes. Based on the features of a given part,
the program automatically generates the sequence of manufacturing operations. The process
planning software provides the opportunity to generate production routings which are rational,
consistent and perhaps even optimal.
It has the following advantages:
i. Reduces the skill required of a planner.
ii. Reduces the process planning time.
iii. Reduces the process planning and manufacturing cost.
iv. Creates more consistent plans.
v. Produces more accurate plans.
vi. Increases productivity.
The current approaches for computer aided process planning can be classified into two groups:
i. Variant
ii. Generative

Structure of a Process Planning Software

Fig.8.1 represents the structure of a computer aided process planning system. In Fig. 8.1,
the modules are not necessarily arranged in the proper sequence but can be based on importance
or decision sequence. Each module may require execution several times in order to obtain the
optimum process plan. The input to the system will most probably be a solid model from a CAD
data base or a 2-D model. The process plan after generation and validation can then be routed
directly to the production planning system and production control system.
 Fig. 8.1 Structure of a Computer Aided Process Planning System

Information required for Process Planning

The geometric model of the part is the input for the process planning system. The system
outputs the process plan (Fig.8.2). The input to the process planning system may be engineering
drawing or CAD model. The other prerequisites for process planning are given below:
- Parts list
- Annual demand/batch size
- Accuracy and surface finish requirement (CAD Database)
- Equipment details (Work centre Database)
- Data on cutting fluids, tools, jigs & fixtures, gauges
- Standard stock sizes
- Machining data, data on handling and setup
 Fig. 8.2 Activities in Process Planning

In a computerized process planning system, a formal structure and a knowledge database

are required in order to transform the engineering design information into the process definition.
A brief description of the operation of a computer aided process planning software is given in the
following section.

Methods of Computer Aided Process Planning

The ultimate goal of a system is to integrate design and production data into a system
that generates useable process plans. As already mentioned there are two approaches:
i. Variant process planning
ii. Generative process planning

Variant Process Planning

A variant process planning system uses the similarity among components to retrieve the
existing process plans. A process plan that can be used by a family of components is called a
standard plan. A standard plan is stored permanently with a family number as its key. A family is
represented by a family matrix which includes all possible members. The variant process planning
system has two operational stages:
• A preparatory stage and
• A production stage.
During the preparatory stage, existing components are coded, classified, and
subsequently grouped into families. The process begins by summarizing process plans already
prepared for components in the family. Standard plans are then stored in a data base and indexed
by family matrices (Fig. 8.3).
 Fig. 8.3 Process Family Matrix

The operation stage occurs when the system is ready for production. An incoming part is
first coded. The code is then input to a part family search routine to find the family to which the
component belongs. The family number is then used to retrieve a standard plan. Some
other functions, such as parameter selection and standard time
calculations, can also be added to make the system more complete (Fig. 8.4). This system is
used in a machine shop that produces a variety of small components.

Fig.8.4 Part Search and Retrieval

Design of Variant Process Planning System

The following are the sequences in the design of a variant process planning system:
i. Family formation
ii. Data base structure design
 iii. Search algorithm development and implementation
iv. Plan editing
v. Process parameter selection/updating

Family Formation

Part family classification and coding were discussed earlier. This is based on the
manufacturing features of a part. Components requiring similar processes are grouped into the
same family. A general rule for part family formation is that all parts must be related. Then, a
standard process plan can be shared by the entire family. Minimum modification on the standard
plan will be required for such family members.
Data Base Structure Design
The data base contains all the necessary information for an application, and can be
accessed by several programs for specific application. There are three approaches to construct
a data base: hierarchical, network, and relational.
Search Procedure
The principle of a variant system is to retrieve process plans for similar components. The
search for a process plan is based on the search of a part family to which the component belongs.
When, the part family is found, the associated standard plan can then be retrieved. A family matrix
search can be seen as the matching of the family with a given code. Family matrices can be
considered as masks. Whenever, a code can pass through a mask successfully, the family is
identified.
Plan Editing and Parameter Selection
Before a process plan can be issued to the shop, some modification of the standard plan
may be necessary, and process parameters must be added to the plan. There are two types of
plan editing: One is the editing of the standard plan itself in the data base, and the other is editing
of the plan for the component. For editing a standard plan, the structure of the data base must be
flexible enough for expansion, additions, and deletions of the data records.
 A complete process plan includes not only operations but also process parameters. The
data in the process parameter files are linked so that we can go through the tree to find the speed
and feed for an operation. The parameter file can be integrated into variant planning to select
process parameters automatically.

Generative Process Planning

Generative process planning is a system that synthesizes process information in order to
create a process plan for a new component automatically. In a generative planning system,
process plans are created from information available in manufacturing data base without human
intervention. Upon receiving the design model, the system can generate the required operations
and operation sequences for the component. Knowledge of manufacturing must be captured and
encoded into efficient software. By applying decision logic, a process planner’s decision making
can be imitated. Other planning functions, such as machine selection, tool selection, process
optimization, and so on, can also be automated using generative planning techniques. The
generative planning has the following advantages:
i. It can generate consistent process plans rapidly.
ii. New process plans can be created as easily as retrieving the plans of existing
components.
iii. It can be interfaced with an automated manufacturing facility to provide detailed and
up-to-date control information.

Generative CAPP
Process plans are generated by means of decision logics, formulas, algorithms, and geometry
based data that are built or fed as input to the system.
Format of input
– Text input (interactive)
– Graphical input (from CAD models)
First key: to develop decision rules appropriate for the part to be processed. These rules are
specified using decision trees, logical statements, such as if-then-else, or artificial intelligence approaches
with object oriented programming.
Second key: Finding out the data related to part to drive the planning. Simple forms of generative
CAPP systems may be driven by GT codes.
 A pure generative system can produce a complete process plan from part classification
and other design data which does not require any further modification or manual interaction.
• In generating such plans, initial state of the part (stock) must be defined in order to
reach the final state i.e., finished part.
• Forward or backward planning can be done.
• Forward and backward planning apparently appear to be similar but they effect
programming significantly. The requirement and the results in of a setup in forward
planning are the results and requirements, respectively, of the set up in backward
planning.
• Forward planning suffers from conditioning problems; the results of a setup affect the
next set up.
• In backward planning, conditioning problems are eliminated because setups are
selected to satisfy the initial requirements only.
• The generative CAPP has all the advantages of variant CAPP however it has an
additional advantage that it is fully automatic and a up-to-date process plan is generated
at each time.
• It requires major revisions if a new equipment or processing capabilities became
available.
• The development of the system in the beginning is a difficult

Decision Tables
A table of rows and columns, separated into four quadrants
• Conditions
• Condition alternatives
• Actions to be taken
• Rules for executing the actions
 The standard format used for presenting a decision table

Developing Decision Tables

• Determine conditions that affect the decision
• Determine possible actions that can be taken
• Determine condition alternatives for each condition
• Calculate the maximum number of columns in the decision table
• Fill in the condition alternatives
• Complete table by inserting an X where rules suggest actions
• Combine rules where it is apparent
• Check for impossible situations
• Rearrange to make more understandable

Constructing a decision table for deciding which catalog to send to customers who order
only from selected catalogs
Checking for Completeness and Accuracy Four main problems
• Incompleteness
• Impossible situations
• Contradictions
• Redundancy
Checking the decision table for inadvertent contradictions and redundancy is important
Fig.8.5 Type of Decision Table
 Fig. 8.6 Modular structure of a generative CAPP system.

The generative part consists of:

• Component representation module
• Feature extraction module
• Feature process correlation module
• Operation selection and sequencing module
• Machine tool selection module
• Standard time / cost computation module
• Report generation module
In order to generate a more universal process planning system, variables such as process
limitations, and capabilities, process costs and so on, must be defined at the planning stage.
Several of methods have been proposed for creating generative process plans. A few methods
that have been implemented successfully are:
 i. Forward and backward planning
ii. Input Format
iii. CAPP based on CAD models
iv. CAPP based on decision logic either using decision trees or decision tables
v. CAPP based on artificial intelligence

Forward and Backward Planning

In generative process planning, when process plans are generated, the system must
define an initial state in order to reach the final state (goal). The path taken represents the
sequence of processes. For example, the initial state is the raw material and the final state is the
component design. Then a planner works in modifying the raw workpiece until it takes on the final
design qualities. This is called forward planning.
Backward planning uses a reverse procedure. Assuming that we have a finished
component, the goal is to go back to the un-machined workpiece. Each machining process is
considered a filling process. Forward and backward planning may seem similar. However they
influence the programming of the system significantly. Planning each process can be
characterized by a precondition of the surface to be machined and a post condition of the
machining (the end result). For forward planning, we must know the successor surface before we
select a process, because the post condition of the first process becomes the precondition for
second process. Backward planning eliminates this problem since it begins with the final surfaces
from and processes are selected to satisfy the initial requirements. In forward planning, the steps
to obtain the final surface with the desirable attributes must be carefully planned to guarantee the
result. On the other hand, backward planning starts with the final requirements and searches for
the initial condition.
Process Planning Systems
The majority of existing process planning systems is based on variant process planning
approach. Some of them are: CAPP, MIPLAN, MITURN, MIAPP, UNIVATION, CINTURN,
COMCAPPV, etc. However, there are some generative system, such as METCAPP, CPPP,
AUTAP, and APPAS. Some of the planning systems are discussed in the following paragraph.
These are systems continuously evolving in many cases. The descriptions are therefore only
approximate.
CAM-I CAPP
The CAM-I (Computer Aided Manufacturing-International) system (CAPP) is perhaps the
most widely used of all process planning systems. CAPP is a database management
system written in ANSI standard FORTRAN. It provides a structure for a data base,
retrieval logic, and interactive editing capability. The coding scheme for part classification
and the output format are added by the user. PI-CAPP, an extension of CAPP, has its
own (built-in) coding and classification system. This eliminates the requirement of a user
developed coding scheme. A typical CAPP system is shown in Fig. 8.6.

Fig. 8.6 CAPP System

MIPLAN and MULTICAPP

Both MIPLAN and MULTICAPP were developed in conjunction with OIR (Organization
for Industrial Research). They are both variant systems that use the MICLASS coding
system for part description. They are data retrieval systems which retrieve process plans
based on part code, part number, family matrix, and code range. By inputting apart
code, parts with a similar code are retrieved. The process plan for each part is then
displayed and edited by the user. A typical MULTICAPP system is shown in Fig. 8.7.
 Fig. 8.7 MULTICAPP System

APPAS and CADCAM

APPAS is a generative system for detailed process selection. CADCAM is an example of
APPAS. CADCAM operates using a CAD “front end” to interface with APPAS. APPAS describes
the detailed technological information of each machined surface by means of a special code.
CADCAM provides an interactive graphics interface to APPAS. Components can be modeled
graphically and edited interactively.
AUTOPLAN and RPO
AUTOPLAN is generative only in the detailing of the part. The process selection and
process sequencing level do not differ significantly from CAPP or MIPLAN. The four major
modules of the system are:
i. Group technology retrieval-process plan retrieval.
ii. Graphical planning aides- tooling layout, verification and work instruction and reparation.
iii. Generative process planning.
iv. Process optimization.
AUTAP System
The AUTAP system is one of the most complete planning systems in use today. AUTAP
uses primitives to construct a part similar to a constructive solid geometry (CSG). AUTAP is a
system designed especially to interface with a CAD system. It can be installed as part of an
integrated CAD/CAM system.

CPPP
CPPP (computerized production process planning) was designed for planning cylindrical
parts. CPPP is capable of generating a summary of operations and the detailed operation sheets
required for production. The principle behind CPPP is a composite component concept. A
composite component can be thought of as an imaginary component which contains all the
features of components in one part family. CPPP incorporates a special language, COPPL, to
describe the process model. CPPP allows an interactive mode whereby the planner can interact
with the system at several fixed interaction points.

GARI
GARI is an experimental problem solver which uses artificial intelligence (AI) techniques.
The unique feature of the GARI is the representation of planning knowledge. GARI employs a
production rule knowledge base to store process capabilities.

TIPPS
Although the process planning steps have been discussed, an integrated approach to
generative process planning has yet to be presented. TIPPS is acronym for Totally Integrated
Process planning. TIPPS is generative process planning system that has evolved from the
APPAS and CAD/CAM systems. In TIPPS, the logical divisions of process planning are broken
into functional modules. TIPPS has the following features:
• It has a modular structure
• It can interact with a CAD system
• It allows for interactive surface identification
• It contains a process/knowledge description language
Fig. 8.8 TIPPS