ME 714: Computer-integrated Manufacturing (CIM)

Lecture 9: Computer-aided Process Planning

Soham Mujumdar
Email: sohammujumdar@[Link]
Webpage: [Link]

Ref: Some of the course material has been adopted from ME 451 at the University of Illinois at Urbana-Champaign taught by Prof. S. G. Kapoor.

ME 714 CIM (1), Lecture 9 1

Process Planning

Surfaces to be machined

ME 714 CIM (1), Lecture 9 2

What do we need to know?
• Ability to interpret an engineering drawing.
• Familiar with manufacturing processes and practice.
• Familiar with tooling and fixtures.
• Know what resources are available in the shop.
• Familiar with the raw materials.
• Know how to use reference books, such as machinability data
handbook (to set process parameters)
• Know the relative costs of processes, tooling, and raw materials.
• Able to do computations on machining time and cost (is the
process productive and economical?)

ME 714 CIM (1), Lecture 9 3

Manufacturing Processes

Manufacturing and engineering technology, Kalpakjian, 1992

ME 714 CIM (1), Lecture 9 4

Example: Identify features
Surfaces to be machined • Since the part is a rotational component, a lathe most likely
to be used.

• Let’s assume a pre-cut bar stock is used as raw material

• From the drawing, the following features are identified:

 S1: end surface

 S2: 2.752 in. cylindrical surface

 S3: flat surface

 S4: large diameter, 5.25 in. diameter with chamfer of 0.25 in. R

 S5: threaded cylinder with 0.25 in. x 0.25 in. neck

 S6: flat surface

 S7: 1.627 in. diameter bore

 S8: four counterbore holes.

ME 714 CIM (1), Lecture 9 5

Example: Setup and Operations
• Setups:
 Since bar stock is used, a minimum of two setups is required.

 Since the threaded area cannot be chucked, faces S1, S2, S3 and
S4 should be cut in the first setup and S5 & S6 in a second
setup.

 S7 can be drilled in either setup

 S8 cannot be drilled on a lathe, a drill press will be needed, thus

another setup will be needed

• Operations:
 S1, S3, and S6 require facing operations

 S2 and S4 require turning

 S5 requires turning followed by threading and an undercut

 Drilling operations are needed for S7 and S8.

ME 714 CIM (1), Lecture 9 6
Example: Process Plan
Setup 1 [Lathe Machine]
1. Chuck the workpiece
2. Turn S4 to a 5.25 in. diameter
3. Turn S2 to a 2.751 in. diameter
4. Face S1 and the S3
5. Core drill and drill S7

Setup 2 [Lathe Machine] Setup 3 [Drill Press]

1. Chuck the workpiece on S4 1. Locate the workpiece using S3 and S7
2. Turn S5 to 2.75-in. diameter 2. Mark and center drill four holes, S8
3. Thread S5 3. Bore four holes, S8
4. Undercut the neck
5. Face S6
6. Remove the part and move it to a drill press
ME 714 CIM (1), Lecture 9 7
Computer-aided Process Planning (CAPP)
Motivation: Problems with experience-based (manual) process planning
• Experience requires a significant period of time to accumulate.
• Experience represents only approximate, not exact knowledge.
• Experience is not directly applicable to new processes or new systems.
Can we automate this? -> CAPP

The objectives of a Computer-Aided Process Planning system are to:

• Provide the opportunity to generate production routings that are rational,
consistent and perhaps even optimal
• Offer the potential for reducing the routine clerical work of manufacturing
engineers
 It can reduce the skill required of a planner.
 It can reduce the process planning time.
 It can increase productivity.
ME 714 CIM (1), Lecture 9 8
CAPP System
• Design inputs
• Material selection
• Process selection
• Process sequencing
• Machine and tool selection
• Fixture selection
• Machining parameter selection
• Cost/time estimation

ME 714 CIM (1), Lecture 9 9

Approaches to CAPP
Variant Systems Generative Systems
• Process similar to manual method • Make new plan for each part
• Find a similar part with known • Capture the logic behind developing a
process plan and modify it to suit process plan and implement it in a
the new part software
• Has two stages • Process logic in the form of decision
1. Preparatory Stage: Code the parts,
tables, decision trees, rule or
Form families (Group Technology), constraint-based
Make standard process plans for each • Check part design and conditional
family and store them in a database requirements and select the process
2. Production Stage: Identify code and • Lot of detailed information must be
family for new part, Retrieve the present in the system
standard process plan, Make • Fully-automated
modifications
[Link]

ME 714 CIM (1), Lecture 9 10

Existing CAPP Systems

[Link]

ME 714 CIM (1), Lecture 9 11

Variant CAPP System

Part Family

ME 714 CIM (1), Lecture 9 12

Group Technology
• An approach to manufacturing in which similar parts are
identified and grouped together in order to take advantage of
their similarities in design and production
• Similarities among parts permit them to be classified into part
families
• Part family: A group of parts that possess similarities in
geometric shape and size, or in the processing steps used in their
manufacture
• In each part family, processing steps are similar
• The improvement is typically achieved by organizing the
production facilities into manufacturing cells that specialize in
production of certain part families -> ’Cellular Manufacturing’

[Link]

ME 714 CIM (1), Lecture 9 13

How to form Part Families?
• Parts classification and coding: Identifying similarities and
differences among parts and relating them by means of a coding
scheme
• What could be the basis for classification?

Design Attributes: Manufacturing Attributes:

Major dimensions Major process
Basic external shape Operation sequence
Basic internal shape Batch size
Length/diameter ratio Annual production
Material type Machine tools
Part function Cutting tools
Tolerances Material type
Surface finish

ME 714 CIM (1), Lecture 9 14

Opitz Coding System

ME 714 CIM (1), Lecture 9 15

Example
• Step 1: The total length of the part is 1.75,
overall diameter 1.25, L/D = 1.4 (code 1)
• Step 2: External shape: a rotational part that
is stepped on both with one thread (code 5)
• Step 3: Internal shape: through hole (code 1)
• Step 4: By examining the drawing of the part
(code 0)
• Step 5: No auxiliary holes and gear teeth
(code 0)

Code: 15100

ME 714 CIM (1), Lecture 9 16

Cellular Manufacturing
• In Cellular manufacturing all or a portion of a firm’s manufacturing system has
been converted into cells.
• A manufacturing cell is a cluster of machines or processes located in close
proximity and dedicated to the manufacture of a family of parts.
• The parts are similar in their processing requirements, such as operations,
tolerances, and machine tool capacities

ME 714 CIM (1), Lecture 9 17

Functional vs. Cellular Layouts

Functional Cellular

ME 714 CIM (1), Lecture 9 18

Cell Design
• Design of a cellular manufacturing system is a complex exercise
with broad implications for an organization
Objectives:
• Reduce setup times (by using part family tooling and sequencing)
• Reduce flow times (by reducing move times, wait time for moves,
and using smaller batch sizes)
• Reduce inventories
• Improve market response times

The cell design process involves issues related to both system

structure and system operation

ME 714 CIM (1), Lecture 9 19

System Structural Issues
• Selection of part families and grouping of parts into families
• Selection of machine and process populations and grouping of
these into cells
• Selection of tools, fixtures, and pallets
• Selection of material-handling equipment
• Choice of equipment layout

ME 714 CIM (1), Lecture 9 20

System Operation Issues
• Detailed design of jobs
• Organization of supervisory and support personnel around the
cellular structure
• Formulation of maintenance and inspection policies
• Design of procedures for production planning, scheduling,
control, and acquisition of related software and hardware
• Modification of cost control and reward systems
• Outline of procedures for interfacing with the remaining
manufacturing system (in terms of work flow and information,
whether computer-controlled or not)

ME 714 CIM (1), Lecture 9 21

Evaluation of Cell Designs
• Equipment and tooling investment (low)
• Equipment relocation cost (low)
• Material-handling costs (low)
• Floor space requirements (low)
• Extent to which parts are completed in a cell (high)
• Flexibility (high)

• Equipment utilization (high)

• Work-in-process inventory (low)
Operational
• Queue lengths at each workstation (short) Performance
• Job throughput time (short)
• Job delays (low)
ME 714 CIM (1), Lecture 9 22
Example 1
• Consider a problem of 4 machines and 6 parts
• How to group them in cells?
Components/Parts
Machines 1 2 3 4 5 6
M1 1 1 1
M2 1 1 1
M3 1 1 1
M4 1 1 1

Machines 2 4 6 1 3 5
M1 1 1 1

M2 1 1 1

M3 1 1 1

M4 1 1 1

ME 714 CIM (1), Lecture 9 23

Example 2
Components/Parts
Machines 1 2 3 4 5 6 7 8 9 10
M1 1 1 1 1 1 1 1 1 1
M2 1 1 1 1 1
M3 1 1 1 1
M4 1 1 1 1 1 1
M5 1 1 1 1 1 1 1 1

Need a better method ! -> Cell Formation Algorithms

• Rank Order Clustering (Machine-Component Group Type)
• Single Linkage Cluster Analysis (Similarity Coefficient-based)

ME 714 CIM (1), Lecture 9 24

Rank Order Clustering
It is based on sorting rows and columns of the machine-part incidence matrix and
involves four steps:
Step 1: Assign binary weight and calculate a decimal weight for each row and
column using the following formulas:
m
Decimal weight for row i= b
p=1
ip 2m-p

n
Decimal weight for column j =  bpj 2n  p
p=1

where m = total # of columns, n = total # of rows, bij = 1 or 0

Step 2: Rank the rows in order of decreasing decimal weight values
Step 3: Repeat steps 1 and 2 for each column
Step 4: Continue preceding steps until there is no change in the position of each
element in the row and the column
ME 714 CIM (1), Lecture 9 25
Example: Step 1

Binary weight
29 28 27 26 25 2 4 23 2 2 21 20

Components
Machines 1 2 3 4 5 6 7 8 9 10 Decimal
equivalent

M1 1 1 1 1 1 1 1 1 1 1007
M2 1 1 1 1 1 451
M3 1 1 1 1 568
M4 1 1 1 1 1 1 455
M5 1 1 1 1 1 1 1 1 1020

ME 714 CIM (1), Lecture 9 26

Example: Step 2

Components
Binary Machines 1 2 3 4 5 6 7 8 9 10
weight
24 M5 1 1 1 1 1 1 1 1
23 M1 1 1 1 1 1 1 1 1 1
22 M3 1 1 1 1
21 M4 1 1 1 1 1 1
20 M2 1 1 1 1 1
Decimal
equivalent
28 27 27 27 28 20 28 26 11 11

ME 714 CIM (1), Lecture 9 27

Example

Binary weight
29 28 27 26 25 24 23 22 21 20

Components
Binary Machines 1 5 7 2 3 4 8 6 9 10 Decimal
weight equivalent

24 M5 1 1 1 1 1 1 1 1 1020
23 M1 1 1 1 1 1 1 1 1 1 1019
22 M3 1 1 1 1 900
21 M4 1 1 1 1 1 1 123
20 M2 1 1 1 1 1 115
Decimal
equivalent
28 28 28 27 27 27 26 20 11 11

ME 714 CIM (1), Lecture 9 28

Single Linkage Cluster Analysis (SLCA)
• It is a hierarchical machine grouping method that uses similarity coefficients
between machines and construct a tree called a dendrogram.
• The similarity coefficient between two machines is defined as the ratio of the
number of parts visiting both machines and the number of parts visiting one
of the two machines:

X
N

ijk
k=1
Sij =
(Y
N

ik + Z jk - Xijk )
k 1

where: N = Total no. of parts

Xijk = operation on part k performed both on machines i and j,
Yik = operation on part k performed on machine i,
Zjk = operation on part k performed on machine j.

ME 714 CIM (1), Lecture 9 29

SLCA Algorithm
• Step 1: Compute similarity coefficients for all possible pairs of
machines
• Step 2: Select the two most similar machines to form the first
machine cell
• Step 3: Lower the similarity level (threshold) and form new
machine cell by including all the machines with similarity
coefficients not less than the threshold value
• Step 4: Continue step 3 until all machines are grouped into a
single cell

ME 714 CIM (1), Lecture 9 30

Example
Components/Parts
Machines 1 2 3 4 5 6 7 8 9 10
M1 1 1 1 1 1 1 1 1 1
M2 1 1 1 1 1
M3 1 1 1 1
M4 1 1 1 1 1 1
M5 1 1 1 1 1 1 1 1

Machine M1 M1 M1 M1 M2 M2 M2 M3 M3 M4
pairs M2 M3 M4 M5 M3 M4 M5 M4 M5 M5
SC 0.55 0.30 0.67 0.70 0.00 0.83 0.30 0.00 0.50 0.40

ME 714 CIM (1), Lecture 9 31

Dendogram
Machine M1 M1 M1 M1 M2 M2 M2 M3 M3 M4
pairs M2 M3 M4 M5 M3 M4 M5 M4 M5 M5
SC 0.55 0.30 0.67 0.70 0.00 0.83 0.30 0.00 0.50 0.40

M 4 M 2 M 5 M 1 M 3

0 . 8 3

0 . 7 0
0 . 6 7

0 . 5 0

0 . 0 0
D e n d r o g r a m

ME 714 CIM (1), Lecture 9 32

Cell Configurations
M 4 M 2 M 5 M 1 M 3

0 . 8 3

0 . 7 0
0 . 6 7

0 . 5 0

0 . 0 0
D e n d r o g r a m

Similarity Coeff. Number of Cell configuration

Threshold cells formed
1.00 5 (M1), (M2), (M3), (M4), (M5)
0.83 4 (M2, M4), (M5), (M1), (M3)
0.70 3 (M2, M4), (M1, M5), (M3)
0.67 2 (M1, M2, M4, M5), (M3)
0.50 1 (M1, M2, M3, M4, M5)
So many configuration choices. Which one is the best one?
ME 714 CIM (1), Lecture 9 33
Evaluation of Cell Design
• The criteria is to minimize the distance that the parts should
travel during the processes

How do we accomplish this?

• Minimize the material handling costs of intercell (between cells)
and intracell (within cell) movements of the parts.

What are the factors that influence these costs?

• The layout of machines in a group
• The layout of machine groups
• The sequences of parts through machines and machine groups

ME 714 CIM (1), Lecture 9 34

Cost for the Part Movement

𝑇𝑜𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝐶𝑜 𝑁𝑜 + 𝐶𝑖 ෍ 𝒅𝑁𝑗

𝑗
Where,
No is the number of total intercell movements, and
Co is the cost per intercell movement
Nj is the number of total intracell movements between two
machines by all the parts in cell j, and
Co is the cost per distance in the intracell movement
d is the expected distance moved between two machines in an
intracell layout

ME 714 CIM (1), Lecture 9 35

Cost for Part Movements
Expected distance ‘d’ between two machines

𝑁+1
• When N machines are arranged in a straight line, 3

2 𝑁
• When N machines are arranged in a square layout 3

Assumptions:
1. In the absence of real data, it is assumed that the machines are
laid out in a random manner.
2. There is one unit distance between each machine in a group of
N machines.
3. A part has to visit two machines in a group of N machines.

ME 714 CIM (1), Lecture 9 36

Example: 3 Cell Configuration

Cell Design: (M1, M5) M3 (M2, M4)

Components
Machines 1 5 7 2 3 4 8 6 9 10

M5 1 1 1 1 1 1 1 1
M1 1 1 1 1 1 1 1 1 1
M3 1 1 1 1
M4 1 1 1 1 1 1
M2 1 1 1 1 1

ME 714 CIM (1), Lecture 9 37

Movements
Number of moves passing through two machines by all the parts,
• In cell (M1, M5) = 7
• In cell (M2, M4) = 5
• In cell (M3) = 0

Expected distances for each cell

Components

d for (M1, M5) = (2+1)/3 = 1 Machin 1 5 7 2 3 4 8 6 9 1

es
0
d for (M2, M4) = (2+1)/3 = 1
M5 1 1 1 1 1 1 1 1
M1 1 1 1 1 1 1 1 1 1
Number of Intercell movements M3 1 1 1 1
= 10
M4 1 1 1 1 1 1
M2 1 1 1 1 1
ME 714 CIM (1), Lecture 9 38
Cost of 3 Cell Configuration
Assume,

Ci = ₹ 1 (Cost of intracell movement per unit distance)

Co = ₹ 2 (Cost of intercell movement per movement)

Total cost = 2*10 + 1*(1*7+1*5+0) = ₹ 32

ME 714 CIM (1), Lecture 9 39

Cell Configurations
M 4 M 2 M 5 M 1 M 3

0 . 8 3

0 . 7 0
0 . 6 7

0 . 5 0

0 . 0 0
D e n d r o g r a m

Similarity Coeff. Number of Cell configuration

Threshold cells formed
1.00 5 (M1), (M2), (M3), (M4), (M5)
0.83 4 (M2, M4), (M5), (M1), (M3)
0.70 3 (M2, M4), (M1, M5), (M3)
0.67 2 (M1, M2, M4, M5), (M3)
0.50 1 (M1, M2, M3, M4, M5)
So many configuration choices. Which one is the best one?
ME 714 CIM (1), Lecture 9 40
Cost Comparison

Number of Total distance

Cell
intercell of intracell Total cost
Configuration
moves moves
[(M1), (M2), (M3),
5-cells 22 0 2 x 22 + 1 x 0 = 44
(M4), (M5)]
[(M2, M4), (M5),
4-cells 17 5 2 x 17 + 1 x 5 = 39
(M1), (M3)]
[(M2, M4), (M1,
3-cells 10 12 2 x 10 + 1 x 12 = 32
M5), (M3)]
[(M1, M2, M4,
2-cells 4 30 2 x 4 + 1 x 30 = 38
M5), (M3)]
[(M1. M2, M3, M4,
1-cells 0 44 2 x 0 + 1x 44 = 44
M5)]

ME 714 CIM (1), Lecture 9 41