Computer Assisted

Manufacturing Management
System
Dr Atul Sidola

Topics to be covered
CAPP
Computer Integrated Production Management

System
Inventory Management, MRP, MRP-II
Shop Floor Control, Computer Aided Process
Monitoring
Computer Aided Quality Control and Inspection

Dr Atul Sidola

 CAPP
Computer Integrated Production Management

System
Inventory Management, MRP, MRP-II
Shop Floor Control, Computer Aided Process
Monitoring
Computer Aided Quality Control and Inspection

Dr Atul Sidola

Process Planning
Process planning is concerned with determining the

sequence of individual manufacturing operations

needed to produce a given part or product.
In the process geometrical features, dimensional sizes,
tolerances, materials, and surface finishes are analyzed
and evaluated to determine an appropriate sequence
of processing operations

Dr Atul Sidola

General inputs to process

planning
Design data,
Raw material data,
Facilities data (machining

data, tooling data, fixture

data, etc.),
Quality
requirements
data, and
Production type data.

Output of process planning is

the process plan
The process plan is often

documented into a specific

format and called :

Process plan sheet,

Process sheet,
Operation sheet,
Planning sheet,
Route sheet,
Route plan, or
Part program

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Traditional process planning

The process planning process is very much dependent on

experience and judgment of planners.

It is the responsibility of manufacturing engineer or
industrial engineer to write the process plan.
Many people participate in planning process, such as
manufacturing engineer, planners, part programmers etc.
However, individual engineers each have their own opinion
about what constitute the best routing. It create the
problem in planning.

Dr Atul Sidola

Automated Process Planning

or
Computer Aided Process Planning
On the basis of characteristic of given part, the

program automatically generates the process plan.

Two approaches of CAPP:
Retrieval type CAPP system or variant system
2. Generative CAPP
1.

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Retrieval type CAPP

The retrieval approach, which is also called variant

approach, uses a group technology (GT) code to select

a generic process plan from the existing master process
plans developed for each part family and then edits to
suit the requirement of the part.
Variant approach is commonly implemented with GT
coding system. Here, the parts are segmented into
groups based on similarity and each group has a
master plan.

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Advantage of retrieval CAPP

Once a standard plan has been written, a variety of

components can be planned.

Programming and installation are comparatively
simple.
The system is understandable, and the planner has
control of the final plan.
It is easy to learn and easy to use.

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Disadvantage of retrieval CAPP

The components to be planned are limited to

previously planned similar components.

Experienced process planners are still required to
modify the standard plan for the specific component.
Details of the plan cannot be generated.
Variant planning cannot be used in an entirely
automated manufacturing system, without additional
process planning.

Dr Atul Sidola

Generative CAPP
In a generative approach, a process plan for each

component is created from scratch without human

intervention. These systems are designed to
automatically synthesize process information to
develop a process plan for a part
Generative CAPP systems contain the logic to use
manufacturing data bases, knowledge bases and
suitable part description schemes to generate a process
plan for a particular part.

Dr Atul Sidola

Advantages of generative CAPP

Consistent process plans can be generated rapidly.
New components can be planned as easily as existing

components.
It has potential for integrating with an automated
manufacturing facility to provide detailed control
information.

Dr Atul Sidola

Main steps to CAPP

Identification of part specifications.
Selection of blanks or stock.
Selection of machining operations.
Selection of machine tools.
Selection of cutting tools.
Calculation of cutting parameters.

Generation of setup plans.

Selection of work holding devices (fixtures).
Calculation of times and costs.
Generation of process plans

Dr Atul Sidola

Benefits of CAPP
Reduction in process planning time.
Reduction in the required skill of the process planner.

Reduction in costs due to efficient use of resources.

Increased productivity.
Production of accurate and consistent plans.

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Traditional production planning &

control
Production planning and control : Production (or

manufacturing) planning and control (PPC or MPC)

system is concerned with planning and controlling all
aspects of manufacturing including materials,
scheduling of machines and people, and coordinating
suppliers and customers.
Traditional PPC functions are given in coming slides .

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Dr Atul Sidola

Forecasting: This is concerned with projecting or

predicting the future sales activity.
2. Production planning: It establishes the production levels
for product groups over the next coming years. It is based
on the sales forecast and used to maintain the desired
inventories levels.
3. Process planning : Process planning involves determining
the sequence of manufacturing operations required to
produce a certain product and\ or its components.
1.

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4. Estimating : It is a process of determining prices,

predicting costs, preparing schedules & estimation of

manufacturing lead time etc.
5. Master scheduling : The production plan must be
translated into a master schedule which specifies how
many units of each product are to be delivered and when.
6. Requirements planning: Based on the master schedule,
the individual components and subassemblies that make
up each product must be planned. Raw material and
purchased parts are ordered on the basis of it.

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Purchasing : After requirement planning, the make- or

buy decision is carried out. For made in house, raw
material have to be acquired, and other components are
purchased.
8. Machine Loading and scheduling: On the basis of
requirement planning production scheduling is done.
9. Dispatching : The dispatching function is concerned with
issuing the individual orders to the machine operators.
7.

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10. Expediting: In expediting actual progress is compared with

production schedule. The expediter recommends corrective

action.
11. Quality control: The quality control department is responsible
for assuring that the quality of the product and its components
meets the standards specified by the designer .
12. Shipping and inventory control: This is final steps in the
production control cycle involves shipping the product directly
to the customer or stocking the item in inventory. The purpose
of inventory control is to ensure that enough products of each
type available to satisfy customer demand.

Dr Atul Sidola

Problems with traditional

production planning & control

Plant capacity problems

Suboptimal production scheduling
Long manufacturing lead times
Inefficient inventory control
Low work center utilization
Process planning not followed
Errors in engineering and manufacturing records
Quality problem

Dr Atul Sidola

 CAPP
Computer Integrated Production Management

System
Inventory Management, MRP, MRP-II
Shop Floor Control, Computer Aided Process
Monitoring
Computer Aided Quality Control and Inspection

Dr Atul Sidola

Dr Atul Sidola

Engineering database: The database comprises all the

information needed to fabricate the components and
assemble the products. It includes the BOM, part design
data, process route data sheets etc.
2. Material
requirement planning:
MRP involves
determining when to order
raw materials and
components for assembled products.
3. Capacity planning: It is concerned with determining the
labor and equipment resources needed to meet the
production schedule.
1.

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4. Inventory management : It is efficient utilization of

inventory and closely related with MRP.

5. Shop floor control: It refers to a system for monitoring
the status of production activity in the plant and
reporting the status t0 management so that effective
control can be exercised.
6. Cost planning and control: The cost planning and control
system consists of the data base to determine expected
costs to manufacture each of the firms products.

Dr Atul Sidola

 CAPP
Computer Integrated Production Management

System
Inventory Management, MRP, MRP-II
Shop Floor Control, Computer Aided Process
Monitoring
Computer Aided Quality Control and Inspection

Dr Atul Sidola

Inventory management
It deals with flow as well as storage of inventory so that

optimum balance between cost of inventory and

serviceability could be maintained.

Dr Atul Sidola

Types of inventory in manufacturing

Raw material inventory:
2. Work- in-process inventory
3. Finished product inventory
4. Maintenance, repair and tooling inventories: These
include cutting tool, fixtures and repair parts needed
to fix the problem.
1.

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Inventory control procedures

There are two strategy to control the inventory
1. Order point system: In this system items are restocked
when the inventory levels becomes low.
2. Material requirement planning(MRP)
MRP is suitable control procedure for raw material
and work in process inventory (type 1 and type 2).
Order pint system is suitable for finished goods and
maintenance, repair, tooling inventories ( type 3 and
type 4).

Dr Atul Sidola

Material requirement planning

Material requirements planning is a computational

technique that converts the master schedule for end

products into a detailed schedule for the raw materials
and components used in the end products.
The detailed schedule identifies the quantities of each
raw material and component item.

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Basic MRP components

Independent versus dependent demand
Independent demand indicates that demand for a
product which is unrelated to the demand items.(such
as end products and spare parts).
Dependent demands indicates the demand for the item
which is related directly to the demand for some other
product.

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 Lumpy demand : Demand is sudden or in large

quantity/increments so as to make a certain batch of final

product.

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 Lead time: Lead time is the time from start to finish of

the job. Two kinds of lead time:

Ordering lead time: The time required from initiation of

the purchase requisition to receipt of the item from the

vendor.
Manufacturing lead time: The time required to process
the part through the sequence of machine specified on
the route sheet . It includes not only the operation times
but also the nonproductive time.

Common use items

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Input to MRP
Master production schedule(MPS): It is a list of what

end products are to be produced how many of each

product is to be produced.
Boll of material(BOM): It lists component parts &
subassemblies that make of each product.
Inventory record file: This file keep record of inventory
status. Lead time for the raw material, components
and assemblies must be established in the inventory.

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MRP system structure

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MPS Sheet
Week no.

Product 1
Product 2

35
30

70

45
30

60

10
25

35

Product 3

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BOM
p1

Level 0

s1

Level 1
Level 2

T1

T2

s2
T3

T4

T5

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Inventory record file

period

Item no. C1
Gross
requirement
Scheduled
receipts
On hand

40
40

80

Ne t
requirement
Planed order
release

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Benefits of MRP
Reduction in inventory
Improved customer service
Quicker response to changes in demand and in the

master schedule
Greater productivity
Reduced setup and product changeover costs
Better machine utilization
Increased sales and reductions in sales price

Dr Atul Sidola

MRP II
MRP systems that deal with resource capacities are

known as MRP II.

MRP II system consists of the basic MRP modules plus
the Capacity Planning, SFC (Shop Floor Control) and
financial system modules.

Dr Atul Sidola

 CAPP
Computer Integrated Production Management

System
Inventory Management, MRP, MRP-II
Shop Floor Control, Computer Aided Process
Monitoring
Computer Aided Quality Control and Inspection

Dr Atul Sidola

Function of shop floor control

Priority control and assignment of shop orders
Maintain information on work in process for MRP

Monitor shop order status information

Provide production output data for capacity control

purposes

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Steps to shop floor control systems

Order release
Order scheduling

Order progress

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1. Order release
The objective of order release module is to provide the necessary

documentation that accompanies an order as it is processed

through the shop.
The documents are collectively called shop packet.
Shop packet consists of

Route sheet(listing of operation sequence)

Material requisitions (to draw the raw material from stock)
Job cards (to report the labor for each operation on route sheet)
Move tickets ( to move the parts between work centers)
Parts list(for assembly)

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2. Order scheduling
The objective of order scheduling is to make

assignments the various machines in the factory.

Order scheduling is done on the basis of priorities of
the orders.

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Priority rules in order scheduling

Priority to orders may be given as per following rules
First come first serve
Earlier due date first
Shortest processing time first
Least slack first

Time remaining until due date processing time

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3. Order progress
The objective of order progress is to provide data

relative to work in process, shop order status , and

capacity control.

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Computer process monitoring

It is a data collection system in which the computer is

connected directly to the workstation and associated

equipment for the purpose of observing the operation.
Three computer process monitoring systems are:
Data logging systems

Data acquisition systems

Multilevel scanning

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1.Data logging systems

Data logger is used for this purpose.
It is a device that automatically collects and stores the

data for off line analysis.

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2.Data acquisition system

It

is a system that collects data

communication to a central computer.
It is on-line system.

for

direct

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3. Multilevel scanning
If the total number of monitored variable are quite large

then multi level scanning is done.

Two level of scanning:
High level
Low level

High level scan uses key variable and status data for

monitoring.
In low level scan more complete data logging and analysis
is done to ascertain the source of the malfunction .

Dr Atul Sidola

 CAPP
Computer Integrated Production Management

System
Inventory Management, MRP, MRP-II
Shop Floor Control, Computer Aided Process
Monitoring
Computer Aided Quality Control and Inspection

Dr Atul Sidola

Quality
What customer requires is quality.
The quality of something can be determined by comparing
a set of inherent characteristics with a set of requirements.
If those inherent characteristics meet all requirements, high
or excellent quality is achieved. If those characteristics do not
meet all requirements, a low or poor level of quality is
achieved.
The product should not only conform to specification but

also provide a reliable performance, besides meeting the

cost and delivery requirements.

Dr Atul Sidola

Quality assurance
It is carried before the manufacturing of the product

for maximizing the probability that the component

would be manufactured according to the given
specifications.
It cover proper selection of work material, equipments,
tooling and manufacturing process.

Dr Atul Sidola

Quality control
Quality control is carried out after QA and it enables

detection of poor quality, suggests corrective action to

be taken, the inspection procedures to be followed and
specifications of gauges and instruments to be used.
Quality control is a set of activities intended to
ensure that quality requirements are actually
being met.

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So.
When these activities are computerized, the procedure becomes

automatic and output documentation is carried out in a

systematic manner.
This is an island of automation and it becomes necessary to
integrate it to
manufacturing system to save time and
movements.
It leads towards use of non contact sensors.
It is helpful in elimination of contact with component, stopping

and need of repositioning of the component.

The arrangement also provides feedback, hence leading to near
perfect manufacture of the components.

Dr Atul Sidola

Effects of CAQC
The inspection and testing will be accomplished on a

100% basis rather than sampling methods.

Inspection during production will be integrated into
the manufacturing process rather than requiring that
the parts be taken to some inspection area.
The use of non contact devices help in reducing the
inspection time.
Manual activity is reduced.

Dr Atul Sidola

Types of inspection technology

Contact inspection

Non contact inspection

Coordinate measuring

Optical techniques

machine(CMM)
Mechanical probes

Machine vision
Scanning beam devices
Photogrammetry

Non optical techniques

Electrical field techniques
Reluctance
Capacitance
Inductance
Radiation technique
Ultrasonic

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Coordinate measuring machine

It consists of a table and movable head which holds a

sensing probe.
The probe can move in 3 directions corresponding to 3
coordinates.
The probe comes in to contact with part surface and
provide the information about coordinate positions.

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Machine vision
The machine vision system consists of TV camera, a

digital computer .
The system digitize the picture and analyzes the image
by comparing it with data stored in memory.
The data are often in the form of models of the object.

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Scanning laser beam devices

Laser beam is used for measurement purpose.
It measures the time rather than light.
A beam of light is made to sweep across the component to

be measured.
As the object is scanned the duration of time for which the
lights interrupted is measured.
With the help of logic circuitry and program, this is
converted into part dimension and also interfaced to the
sorting unit and the handling device.

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Photogrammetry
It involves the extraction of three dimensional data

from a pair of photographs taken at different angles.

The twp photograph are read by a device called a
monocomparator to establish coordinates and
positions of objects.
The data are then computer analyzed to get the desired
information.

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Reluctance technique
Reluctance transducer are used as proximity

transducer.
It indicates the presence and distance from the probe
of a ferromagnetic substance.
The limitation is that object must be electromagnetic.

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Capacitance technique
In this technique capacitance is used to measure the

distance of an object from the face of a probe.

The capacitance is inversely proportion to the
distance between the probe face and part thus the
distance can be calculated.
The material should electrical conductor.

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Inductance technique
The inductance system operate by subjecting the object to

an alternative magnetic field by means of an

electromagnetic coil.
It results generation of eddy current in the object.
These eddy currents , in turn , create their magnetic field ,
which interacts with the primary field.
The interaction affects the impedance of the coil, which
can be measured and analyzed to determine certain
characteristic of the object.

Dr Atul Sidola

Computer Aided Testing

Computer aided testing is simply the application of the

computer in the testing procedure.

This is used at two levels:
At the lowest level , the computer is used to monitor
test and analyze the result.
2. Automation at series of testing stations interconnected
by material handling system. This is used where
product is complicated such as : automobile engines,
aircraft engines, electronic integrated circuit.
1.

Dr Atul Sidola