Computer Aided Process Planning System for Generating Alternative Process Plans

114 Pages·2017·3.59 MB·English

by  Rao T. Gali

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Master's Theses Graduate College
8-1991
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Rao T. Gali
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Gali, Rao T., "Computer Aided Process Planning System for Generating Alternative Process Plans" (1991).
Master's Theses. 967.
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COMPUTER AIDED PROCESS PLANNING SYSTEM FOR
GENERATING ALTERNATIVE PROCESS PLANS
by
Rao T. Gali
A Thesis
Submitted to the
Faculty of The Graduate College
in partial fulfillment of the
requirements for the
Degree of Master of Science
Department of Industrial Engineering
Western Michigan University
Kalamazoo, Michigan
August 1991
Reproduced with permission of the copyright owner. Further reproduction prohibited without permission.
COMPUTER AIDED PROCESS PLANNING SYSTEM FOR
GENERATING ALTERNATIVE PROCESS PLANS
Rao T. Gali, M.S.
Western Michigan University, 1991
Computer Aided Process Planning (CAPP) has a key role
in Computer Integrated Manufacturing (CIM) as an interface
between design and manufacturing. Current CAPP systems
treat process planning as a static function, and always
generate the same machine and process combinations. Thus,
these CAPP systems are inadequate for advanced manufac­
turing facilities such as Flexible Manufacturing Systems
(FMS). This thesis presents research conducted for the
design and development of a CAPP system called Alternative
Computer Aided Process Planning (A-CAPP) which generates
alternative process plans by interacting with production
planning and machine loading functions to satisfy system
capacity constraints.
A-CAPP is a variant approach based process planning
system and it uses 21-digit KK-3 code as its input. Two
salient features of the A-CAPP system are: (1) it inter­
acts with production planning functions and (2) it gener­
ates alternative process plans. This A-CAPP system exem­
plifies the feasibility of the proposed system.
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ACKNOWLEDGEMENTS
I wish to express a special acknowledgement and
sincere appreciation to my advisor and committee chair
person, Dr. Tarun Gupta, for his encouragement, assistance,
direction, and support throughout my course of study. I
sincerely thank Dr. Gupta once again for his invaluable
suggestions during this research.
My sincere thanks are due to my committee members,
Dr. Richard E. Munsterman and Dr. Frederick Chen, for their
advice, guidance, and assistance.
I thank the employees of CAE Center, Kalamazoo, MI,
for their assistance during this research. Last, but not
least, I thank all those who have helped me directly or
indirectly in completing this research.
Rao T. Gali
ii
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Order Number 1345526
Computer aided process planning system for generating
alternative process plans
Gali, Rao T., M.S.
Western Michigan University, 1991
U M I
300 N. Zeeb Rd.
Ann Arbor, MI 48106
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Reproduced with permission of the copyright owner. Further reproduction prohibited without permission.
TABLE OF CONTENTS
ACKNOWLEDGEMENTS.......... ii
LIST OF TABLES....................................... vii
LIST OF FIGURES...................................... viii
CHAPTER
I. INTRODUCTION................................... 1
Manufacturing Trends........................ 1
Process Planning............................ 2
Importance of Process Planning.............. 6
Need for Automating Process Planning...... 7
Lack of Qualified Process Planners..... 7
Complexity of the Task.................. 6
Inconsistency in Manually Generated
Process Plans............................ 8
Reduced Product Life Cycles............. 8
Link Between CAD and CAM................ 9
Need for the Incorporation of
Knowledge of Continually New
Processes................................ 9
Computer Aided Process Planning............ 9
. Benefits of CAPP............................ 11
Flexible Manufacturing System.............. 12
Problem Identification..................... 13
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Table of Contents— Continued
CHAPTER
II. LITERATURE SURVEY............................. 15
Traditional Manual Approach................ 15
Computer Assisted Variant Approach........ 16
Variant Process Planning System: An
Example..................................... 18
Family Formation......................... 18
Data Base Structure..................... 21
Search Procedure......................... 22
Plan Editing and Parameter Selection.... 23
Computerized Generative Approach........... 25
Artificial Intelligence Based Approach 27
Factors Affecting the Selection of a
Particular Approach........................ 31
Manufacturing System Components........ 31
Production Volume/Batch Size............ 33
Number of Different Production
Families................................. 34
Group Technology............................ 35
GT Part Family and Code Structures........ 36
III. CAPP AND ITS RELEVANCE TO FMS................ 38
CAPP-CIM Link............................... 38
iv
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