UNIVERSITI TEKNOLOGI MARA

FACULTY OF MECHANICAL ENGINEERING

Computer Integrated Manufacturing:

Computerized Manufacturing Planning
Systems

CHAPTER 2:
2.1 Computer Aided Processes Planning (CAPP)
2.2 Computer Integrated Production Planning Systems
2.3 Material Requirements Planning (MRP)
2.4 Capacity Planning System

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Process Planning

Determining the most appropriate manufacturing

processes and the sequence in which they should be
performed to produce a given part or product
specified by design engineering.
Limitations imposed by available processing
equipment and productive capacity of the factory
must be considered.
Parts or subassemblies that cannot be made internally
must be purchased from external suppliers.

Details in Process Planning

Processes and sequence - process plan should briefly

describe all processing steps used on the work unit
in the order they are performed.
Equipment selection - try to develop process plans
that utilize existing plant equipment.
Otherwise, the part must be purchased, or new
equipment must be installed in the plant.
Tools, dies, molds, fixtures, and gages - design is
usually delegated to the tool design group, and
fabrication is accomplished by the tool room.

More Details in Process Planning

Methods - hand and body motions, workplace layout,

small tools, hoists for lifting heavy parts.
Methods must be specified for manual operations
(e.g., assembly) and manual portions of machine
cycles (e.g., loading and unloading a production
machine).
Production costs - often accomplished by cost estimators
with help from the process planner.
Cutting tools and cutting conditions for machining
operations.

The Route Sheet

The document that specifies the details of the

process plan.
The route sheet is to the process planner what the
engineering drawing is to the product designer.
Route sheet should include all manufacturing
operations to be performed on the workpart, listed
in the order in which they are to be performed.

Route Sheet

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Computer-Aided Process
Planning (CAPP)

During the last several decades, there has been

considerable interest in automating the process
planning function by computer systems.
Shop people knowledgeable in manufacturing
processes are gradually retiring.
Tradition process planning is very time
consuming and not efficient.

Computer-Aided Process
Planning

An alternative approach to process planning is

needed, and computer-aided process planning
(CAPP) systems provide this alternative.
Requires extensive software and good
coordination with CAD/CAM & other aspects.
Efficient tool for planning & scheduling
manufacturing operations.
CAPP is especially good for small volume, high
variety parts production.
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CAPP Systems
Computer-aided process planning systems are designed
around either of two approaches:
1. Retrieval systems (variant/derivative system)
2. Generative systems

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Retrieval CAPP Systems

Also known as variant CAPP systems.

Based on GT and parts classification and coding.
A standard process plan is stored in computer files for each part code
number .

The standard plans are based on current part routings in use in

the factory, or on an ideal plan prepared for each family .

For each new part, the standard plan is edited if modifications

are needed.

Retrieval CAPP Systems - continued

If the file does not contain a standard process plan

for the given code number, the user may search
the file for a similar code number.
By editing an existing process plan, or
starting from scratch, the user develops a new
process plan that becomes the standard plan
for the new part code.
Final step is the process plan formatter.
Formatter may call other application
programs: determining cutting conditions,
calculating standard times, or computing cost
estimates.

Generative CAPP Systems

Rather than retrieving and editing an existing plan from a

data base, the process plan is created using systematic
procedures that might be applied by a human planner.
In a fully generative CAPP system, the process sequence
is planned without human assistance and without
predefined standard plans.
Designing a generative CAPP system is a problem in
expert systems - computer programs capable of solving
complex problems that normally require a human with
years of education and experience.

Cost Savings of CAPP

Reduction in process planning effort

Saving in direct labor
Saving in material
Saving in scrap
Saving in tooling
Reduction in work-in-process

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Benefits of CAPP

Process standardization CAPP leads to more

logical and consistent process plans than
traditional process planning, more complete and
detailed process plans.
Increased productivity of process planners.
Reduced lead time to prepare process plans.
Improved legibility over manually written route
sheets.
CAPP programs can be interfaced with other
application programs, such as cost estimating,
work standards, and others.
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Material Requirements Planning

System (MRP)

A computer-based system for managing inventories & delivery

schedules of raw materials & tools.
Converts the master production schedule for end products into
a detailed schedule for the raw materials and components used
in the end products.
The detailed schedule indicates:
Quantities of each item to be ordered.
When the order must be placed.
When the order must be delivered to achieve the master
schedule .

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MRP Operational Model

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MRP Inputs

Starts process with the MPS (master production schedule) which provides the
quantity of each model or product required in future periods. This required
production quantity becomes the driver of plans for all material items and
subassemblies that make up the product.
Two additional inputs, BOM and current inventory, provide critical
information for an effective MRP system. Inputs must be accurate and timely.
Eg. Parts from vendors arrive daily and when they arrive the inventory
control system has to be updated to provide timely information for planners.
BOM provides with the part number and quantity of all parts required to
build and assemble the product.
Inventory control system supplies the projected on-hand balance of all parts
and materials listed on the BOM. (how much on hand, where it is stored and
the status of material)

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MRP Inputs

The system can either be manual or computer aided

driven by data supplied to it.
The critical data needed by the MRP system include
manufacturing order information that incorporates the
critical information in the master schedule: the specific
quantities of products to be made and when they are due,
item number, description, planning lead times, costs, etc.
Purchased order data provide information on what
material is currently on order and the status of open
purchase orders.
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MRP Outputs

The results or outputs can be generalized into 2 information

streams:
The primary output is the system-generated plan for
future purchase orders for the material needed to
produce the quantities of products shown in the master
schedule (production order schedule for finished
products).
The order will become the plan that drives the
production on the shop floor. Capacity Requirements
Planning (CRP) is a computer-based extension of the
MRP process to calculate planned workloads.
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MRP Outputs

Manufacturing planners can evaluate the

projected workload and assess the capability of
manufacturing to complete the planned work. The
results of the CRP process are used to determine
short-term capacity needs for equipment and
labor skills.

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MRP Output Reports

Order releases - authorize placement of orders planned by

MRP system
Planned order releases in future periods
Rescheduling notices, indicating changes in due dates for
open orders
Cancellation notices - indicate that certain orders are
canceled due to changes in the master schedule
Inventory status reports
Exception reports, showing deviations from schedule,
overdue orders, scrap, etc.
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Material Requirements Planning

Benefits:

Improved customer service

Reduction in past-due orders

Better understanding of capacity constraints

Significant increases in productivity

Reduction in lead time

Reduction in the inventory for finished goods, raw materials, component

parts and safety stock

Reduction in WIP

Elimination of annual inventory

Significant drops in annual accounting adjustments for inventory

problems

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Manufacturing Resource
Planning (MRP-II)

Controls all aspects of manufacturing

planning through feedback.
System is complex, able to produce final
production scheduling of monitoring actual
results in terms of performance and output,
& comparing results against the master
production schedule.
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Enterprise Resource Planning

(ERP)

An extension of MRP-II. An effective method for

planning & control of all the resources needed in
a business enterprise to take orders for products,
produce them, ship them to the customer and
service them. It coordinates, optimizes, and
integrates all information sources & widely
diverse technical and financial activities in a
manufacturing organization.

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Capacity Requirements Planning

System (CRP)

Capacity Planning: the process of determining the

amount of capacity required to produce in the
future.
The function of establishing, measuring and
adjusting limits or levels of capacity. Detail
amount of labour and machine resources required
to accomplish the tasks of production. May show
insufficient capacity during specific time periods.

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Just-In-Time Production /
Manufacturing

Definition: Elimination of all waste and on continuous

improvement (Kaizen) of productivity. It encompasses the
successful execution of all manufacturing activities
required to produce a final product, from design
engineering to delivery, and includes all stages of
conversion from raw material onward.
Primary elements are: only required inventory when
needed; to improve quality to zero defects; to reduce lead
times by reducing set-up times, queue lengths and lot
sizes; revise the operations incrementally; and minimize
activity costs.
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Just-In-Time Manufacturing

First Implemented in Japan.

Eliminate sources of manufacturing waste.
Receive supplies Just-In-Time.
Produce parts Just-In-Time.
Produce subassemblies Just-In-Time.
Produce and deliver finished products Just-In-Time to be
sold.
Pull system parts are produced to order and the
production is matched with demand for the final assembly
of products.
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Advantages of JIT

Low inventory carrying costs.

Fast detection of defects in the production
or the delivery of supplies and, hence, low
scrap loss.
Reduced inspection and reworking of parts.
High quality parts produced at low cost.

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Kanban

The implementation of JIT involved kanban visible

records. Two types of cards:
Production card authorizes the production of one
container or cart of identical, specified parts at a
workstation.
Conveyance or move card authorizes the type or
one container or cart of parts from that particular
workstation to the workstation where the parts will
be used.

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Group Technology

First developed in Europe in early 1900s.

Definition: GT is manufacturing philosophy that justifies
small and medium-size batch production by capitalizing
on design and/or manufacturing similarities among
component parts.
Parts can be grouped and produced by classifying into
families based on geometry (external & internal shapes,
surface finish, dimensional tolerances, etc) and production
/ manufacturing characteristics (primary processes,
secondary and finishing processes, etc.). GT coding given
on all parts and components.
The production equipment is organized into machine cells
and specializes in the production of a part family called
cellular manufacturing.
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Group Technology

Two tasks to carry out:

Identifying the part families. Review all part drawings and

grouping the parts into families.
Rearranging production machines into machine cells.

Benefits:

Promotes standardization of tooling, fixturing and set-ups.

Reduces material handing because the distances within a
machine cell are much shorter than within the entire factory.
Shorter lead and set-up times.
Reduces work-in-process and finished-goods inventories.
Simplifies production planning and control.

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Part Families

Ten parts are different in

size, shape, and material,
but quite similar in terms of
manufacturing.
All parts are machined
from cylindrical stock by
turning; some parts require
drilling and/or milling.

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Traditional Process Layout

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Cellular Layout Based on GT

Each cell
specializes in
producing one
or a limited
number of
part families.

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Database in CIM

The enterprise must have the automation systems and

computers in all department areas linked to a Product
Development Management system through an information and
data network. PDM system is designed to organize and support
the shared database.
It controls the BOM (information on individual parts, subassembly and materials) in a hierarchical system called a
product structure. The technique used is called a relational
database since part data are linked to numerous files related to
the part, assembly and product. The links could be to CAD
models, CAD drawings, vendor specifications or analyses
results.
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Data Interfaces

It addresses the sharing of CAD and other product and

engineering data across the enterprise. The process includes (1)
creating the product with CAD, (2) converting the CAD part
geometry and attributes file to the format required by other
departments, and (3) saving the different versions of the
drawing files in the product structure.
The part geometry and specifications created in CAD are used
by production machines in manufacturing, manufacturing
resource planning (MRPII) software systems in production
planning and control, and text and graphics documentation
software systems in marketing and other front office
departments.
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Enterprise Network

Linking to a common data storage is done through LAN.

The structure and operation of LAN covers the topology,
protocols and media.
Topology refers to the shape of the network and is either
physical (the way it is wired) or logical (the way it is
made to work) bus, ring, star, tree topology.
Protocols refers to the rules and encoding specifications
for sending data and whether the network uses a peer-topeer or a client-server architecture Ethernet (LAN
architecture using either a bus or star topology, supports
10 megabits per second, IEEE 802.3), Token ring
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Enterprise Network

(Used with ring topology , IEEE 802.5)

Media indicates how devices are interconnected

(twisted-pair wire, coaxial cable, etc)

Learn more in Chapter 3.

Electronic data communications must extend

beyond internal divisions. Frequently used
technology for external networks is electronic
data interchange (EDI).

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Computer Simulation of
Manufacturing Processes & Systems

Simulation takes 2 forms:

A model of a specific operation intended to
determine the viability of a process or to optimize or
improve its performance.
Models multiple processes and their interactions to
help process planners and plant designers in the
layout of machinery and facilities.
Examples: process viability formability of sheetmetal in dies, process optimization to identify hot
spots, minimize defects, etc.
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Inventory

Types of inventory encountered in

manufacturing:

Raw materials

Purchased components

In-process inventory (work-in-process)

Finished products

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