Computer-Aided Process Planning (CAPP)

Product design is the plan for the product. To convert the design into a physical entity, a manufacturing plan is needed. Developing such a plan is called process planning a link b/n product design and manufacturing. Process planning Process planning involves determining the most appropriate manufacturing and assembly processes and the sequence to produce according to specifications in the product design. The scope and variety of processes are limited by the available equipment and technological capabilities. The choice of processes is also limited by the details of the product design.

 Process planning is usually accomplished by manufacturing engineers; (Other titles include industrial engineer, production engineer, and process engineer) who must be familiar with available manufacturing processes in the factory and be able to interpret engineering drawings.
The steps are developed in the most logical sequence. Decisions and details included within process planning are: Interpretation of design drawings. Analyses of materials, dimensions, tolerances, surface finishes, etc. Processes and sequence. Selecting required processes and their sequence (brief description).

 Equipment selections - utilize existing equipment or purchase the, or invest in new equipment. Tools, dies, molds, fixtures, and gages for each processing step. Design, fabrication and contract of these tools is delegated to a tool design / room department and tool Methods analysis. Workplace layout, small tools, material handling and motions must be specified. Work standards. Time standards for each operation. Cutting tools and cutting conditions. for machining operations, with reference to standard recommendations.

Computer-aided Process Planning There is much interest by mnfg firms in automating the task of process planning using computer-aided process planning (CAPP) systems. An alternative way to replace shop-trained people who are retiring to do process planning is needed, and CAPP systems are providing this alternative. CAPP is considered to be part of computer-aided manufacturing (CAM). In fact, a synergy results when CAM is combined with CAD to create a CAD/CAM system. In such a system, CAPP becomes the direct connection between design and manufacturing. The benefits of CAPP include: Process rationalization and standardization. more logical and consistent process plans than manual Increased productivity of process planners. The systematic approach and standard process plans in the data files permit more work. Reduced lead time for process planning. provide route sheets in a shorter lead time.

The benefits of CAPP include: Process rationalization and standardization. more logical and consistent process plans than manual Increased productivity of process planners. The systematic approach and standard process plans in the data files permit more work. Reduced lead time for process planning. provide route sheets in a shorter lead time. Improved legibility. neater and easier to read route sheets. Incorporation of other application programs. interfacing with cost estimating and work standards.

Computer-aided process planning systems are designed around two approaches. These approaches are called: (1) Retrieval CAPP systems and (2) Generative CAPP systems. Retrieval CAPP Systems A retrieval or variant CAPP system is based on GT principles of parts classification and coding. A standard process plan (route sheet) is stored in computer files for each part code number based on current part routings in use or on an ideal process plan prepared for each family.

Steps in CAPP preparatory phase consists of the following steps: (1) Selecting an appropriate classification and coding scheme (2) Forming part families and (3) Preparing standard process plans for the part families. Steps (2) and (3) continue as new parts are designed and added to the company's design data base.

After the preparatory phase the system is ready for use. For a new component which need process plan Derive the GT code number. With this code number, a search is made of the part family file to determine if a standard route sheet exists. If the file contains a process plan, it is retrieved and displayed for the user.

 The plan is examined for any modifications. The user edits the standard plan accordingly. If the file does not contain a standard process plan for code number, the user may search the file for a similar existing code number. Either by editing an existing plan, or by starting from scratch, the route sheet is prepared for the new part. The process planning session concludes with the process plan formatter, which prints out the route sheet in the proper format. It may call other application programs into use; for example, To determine machining conditions for operations in the sequence, To calculate standard times for the operations (e.g., for direct labor incentives), or To compute cost estimates for the operations.

The computer is programmed to apply the appropriate labor and overhead rates to the sequence of planned operations for new products. The program then sums the individual component costs from the engineering bill of materials to determine the overall product cost.

Generative CAPP Systems represent an alternative approach to automated process planning. Instead of retrieving and editing an existing plan, a generative system creates the process plan based on logical procedures similar to the procedures a human planner would use. In a fully generative CAPP system, the process sequence is planned without human assistance and without a set of predefined standard plan The generative CAPP system is considered part of expert systems, a branch of artificial intelligence. An expert system is a computer program that is capable of solving complex problems that normally require a human with years of education and experience. Process planning fits within the scope of this definition.

Ingredients required First, the technical knowledge of manufacturing and the logic used by successful process planners must be captured and coded into a computer program (knowledge base). The system then uses that knowledge base to solve process planning problems (i.e., create route sheets). second, a computer-compatible description of the part containing all of the pertinent data and information needed to plan the process sequence. The possible ways of providing this description are: (1) The geometric model of the part that is developed on a CAD system during product design and (2) a GT code number of the part that defines the part features in significant detail. Third, is the capability to apply the process knowledge and planning logic contained in the knowledge base to a given part description to solve a specific problem. This problemsolving procedure is referred to as "inference engine". By using its knowledge base and inference engine, the CAPP system synthesizes a new process plan from scratch

Computer Aided Quality Control

Automated Inspection Automation of inspection procedure reduces inspection time per piece with out fatigue and mental errors. Automated inspection can be defined as the automation of step/s involved in the inspection procedure. Alternative ways in which automated inspection can be: 1. Automated presentation with an operator performing the examination and decision with possible errors. 2. Automated examination and decision by an automatic machine, with manual loading. 3. Completely automated inspection system Automated inspection can be statistical sampling or 100%. With either inspection, automated systems can commit inspection errors, just as human inspectors. The full potential of automated inspection is achieved when it is integrated in the mnfg process, inspection is 100% and when the results lead to some positive action.

The positive actions can take either or both of two possible forms, (a) Feedback process control. Data are fed back to the preceding manufacturing process responsible for the quality characteristics to allow compensating adjustments, to reduce variability and improve quality. If the automated inspection indicate drift in output of the process, corrections can be made in the input parameters to bring the output back to the nominal value.

(b) Parts sortation. Parts are sorted according to quality level: acceptable versus unacceptable quality. There may be more than two levels (e.g., acceptable, reworkable, and scrap). Sortation and inspection may be accomplished to both inspect and sort at the same station to locate one or more inspections along the processing line, with a single sortation station near the end of the line. Inspection data are analyzed and instructions are forwarded to the sortation station indicating what action is required for each part.

Coordinate measuring machines (CMM)

Coordinate metrology is concerned with the measurement of the actual shape and dimensions of an object and comparing it with desired shape and dimensions, as might be specified on a part drawing. coordinate metrology consists of the evaluation of the location, orientation, dimensions, and geometry of the part.

Coordinate measuring machines (CMM) Coordinate measuring machine (CMM) is an electromechanical system designed to perform coordinate metrology. A CMM consists of a contact probe that can be positioned in threedimensional (3-D) space relative to the surface of work; and the x, y, and z coordinates of the probe can be accurately recorded to obtain dimensional data concerning the part geometry.

CMM Applications and Benefits

The most common applications of CMM are off-line inspection and on-line/post-process inspection. One common application is to check the first part machined on a numerically controlled machine tool; if it passes inspection, then the remaining parts in the batch are assumed to be identical to the first. Even though sampling techniques areused, CMMs are sometimes used for 100% inspection if the inspection cycle is compatible with the production cycle (it often takes less time to produce a part than it does to inspect it) and the CMM can be dedicated to the process. Other CMM applications include audit inspection (incoming parts from a vendor) and calibration of gages and fixtures.

CMMs are most appropriate for applications possessing the following characteristics: Many inspectors performing repetitive manual inspection operations to reduce labor cost and increase throughput. Post-process inspection. inspection performed after the manufacturing process. Measurement of geometric features requiring multiple contact points. Multiple inspection setups are required if parts are manually inspected Complex part geometry. High variety of parts to be inspected. Repeat orders; once the part program has been prepared, subsequent parts from repeat orders can be inspected using the same program.

the advantages of using CMMs over manual methods are: Reduced inspection cycle time- inspection procedures are speeded and labor productivity is improved. Flexibility to inspect a variety of part configurations with minimal changeover time. Reduced operator errors in measurements and setups. Greater inherent accuracy and precision than the manual surface plate methods. Avoidance of multiple setups all measurements can be made in a single setup.

Machine vision Machine vision can be defined as the acquisition of image data, followed by the processing and interpretation of these data by computer for some useful application. Vision systems are either 2-D (quite adequate for most industrial applications) or 3-D. Functions machine vision system:

Functions machine vision system:

1. Image acquisition and digitization-is accomplished using a video camera and digitizing system to store data for subsequent analysis. The image obtained is divided into pixels. The pixel value (light intensity) is converted in to digital value by analogue-to-digital converter.

Image processing and analysis - this is done by one of the two segmentation technique.
Thresholding conversion of pixel intensity level in to binary value, white or black. Edge detection determines location of boundaries of between an object and its surroundings an image. feature extraction characterizes the object by its features such as area length, diameter, perimeter, center of gravity and is designed to determine these features based on the area and boundary of the object (using thresholding, edge detection, or other technique.

Interpretation is object recognition based on extracted features. The image is compared with predefined models or standard values either by template matching (compare an image with the corresponding model or template stored in a computer memory) or featuring interpretation techniques (assigning a weight to each feature according to its relative importance in identifying the object). The score is compared with score of the ideal object residing in computer memory

Machine Vision Applications Are divide into three categories: (1) Inspection constitutes about 80% of machine vision applications either on-line/in-process or on-line/postprocess. The applications are almost always in mass production. Typical industrial inspection tasks include: Dimensional measurement - determining the size of certain dimensional features of parts usually moving at relatively high speeds on a moving conveyor. Dimensional gauging - gauging function rather than measurement. Verification of the presence of components in an assembled product. Verification of hole location and number of holes in a part. Detection of surface flaws and defects - revealing Flaws and defects on the surface as a change in reflected light. Detection of flaws in a printed label. a poorly located label or poorly printed text, numbering, or graphics on the label.

Other Machine Vision Applications. 2 Part identification applications to recognize and perhaps distinguish parts so that some action can be taken; such as part sorting, counting different types of parts and inventory monitoring. Reading of 2-D bar codes and character recognition represent additional identification applications. 3 Visual guidance and control - a vision system is teamed with a robot to control the movement of the machine. Examples include seam tracking in continuous arc welding, part positioning and/or reorientation, bin picking, collision avoidance, machining operations, and assembly tasks.

Assignment 2
Discuss the Application of Computers in the Following Production Functions:
Sales forecasting Marketing Accounting Distribution Work measurement Management Education Plant design and Layout