1. Automation (21-541) Sharif University of Technology Session # 13
Advanced Manufacturing Laboratory
Department of Industrial Engineering
Sharif University of Technology
Session # 13

2. Automation (21541), Session # 13
Session Schedule
Computer-Aided Process Planning (CAPP)
CAPP integration with CAD
Computer-Aided Process Planning based on CAD software solutions
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 2

3. Computer-Aided Process planning (CAPP)
Process planning primitives
Process planning is concerned with determining the sequence of individual manufacturing operations needed to produce a given part or product.
The resulting operation sequence is documented on a form typically referred to as operation sheet.
The operation sheet is a listing of the production operations and associated machine tools for a work part or assembly.
Process planning is an important stage of product development since production tooling like jigs, fixtures, special tools etc. can be designed only after the process plan is finalized.
Process planning is concerned with determining the sequence of individual manufacturing
operations needed to produce a given part or product. The resulting operation sequence is
documented on a form typically referred to as operation sheet. The operation sheet is a
listing of the production operations and associated machine tools for a work part or
assembly. Process planning is an important stage of product development since production
tooling like jigs, fixtures, special tools etc. can be designed only after the process is finalized.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 3

4. Computer-Aided Process planning (CAPP)
Process planning primitives
The current approaches for computer aided process planning can be classified into two groups:
Variant
Generative
The current approaches for computer aided process planning can be classified into
two groups:
i. Variant
ii. Generative
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 4

5. Computer-Aided Process planning (CAPP)
Variant Process planning- Group Technology
A part family is a collection of parts which are similar either because of geometry and size or because similar processing steps are required in their manufacture.
The parts within a family are different, but their similarities are close enough to merit their identification as members of the part family.
There are three general methods for solving this problem.
Visual inspection
Production flow analysis
Parts classification and coding system
A part family is a collection of parts which are similar either because of geometry and size
or because similar processing steps are required in their manufacture. The parts within a
family are different, but their similarities are close enough to merit their identification as
members of the part family. The major obstacle in changing over to group technology
from a traditional production shop is the problem of grouping parts into families. There
are three general methods for solving this problem.
i. Visual inspection
ii. Production flow analysis
iii. Parts classification and coding system
What is desirable in a computer integrated manufacturing environment is a software
which will analyze the geometric model of the part and come out with a set of alphabetic/
numeric characters which can broadly embed similarities.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 5

6. Computer-Aided Process planning (CAPP)
Variant Process planning- Group Technology
Part Design Attributes
Basic (External/Internal) shape Axisymmetric/Prismatic/sheet metal
Length/diameter ratio Material
Major dimensions Minor dimensions
Tolerances Surface finish
Part Manufacturing Attributes
Major process of manufacture Surface treatments/coatings
Machine tool/processing equipment Cutting tools
Operation sequence Production time
Batch quantity Production rate
Fixtures needed
Part Design Attributes
Basic (External/Internal) shape
Axisymmetric/Prismatic/sheet metal
Length/diameter ratio
Material
Major dimensions
Minor dimensions
Tolerances
Surface finish
Part Manufacturing Attributes
Major process of manufacture
Surface treatments/coatings
Machine tool/processing equipment
Cutting tools
Operation sequence
Production time
Batch quantity
Production rate
Fixtures needed
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 6

7. Computer-Aided Process planning (CAPP)
Variant Process planning- Coding structures
A part coding scheme consists of symbols that identify the
part’s design and/or manufacturing attributes.
The symbols in the code can be all numeric, all alphabetic, or a combination of both types.
There are three basic code structures used in group technology applications:
Hierarchical structure
Chain type structure
Hybrid structure which is a combination of the above two
A part coding scheme consists of symbols that identify the part’s design and/or
manufacturing attributes. The symbols in the code can be all numeric, all alphabetic, or
a combination of both types. There are three basic code structures used in group
technology applications:
i. Hierarchical structure
ii. Chain type structure
iii. Hybrid structure which is a combination of the above two
With the hierarchical structure, the interpretation of each succeeding symbol depends
on the value of the preceding symbols. In the chain type structure, the interpretation of
each symbol in the sequence is fixed and does not depend on the value of preceding digits.
Most of the commercial parts coding systems are used in industry are a combination of the
two pure structures.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 7

8. Computer-Aided Process planning (CAPP)
Variant Process planning- Coding structures
Coding systems that have been successfully implemented in process planning:
OPITZ system
The CODE system
The KK-3 system
The MICLASS system
DCLASS system
COFORM (coding for machining)
Some of the coding systems that have been successfully implemented in process
planning are given below:
i. OPITZ system
ii. The CODE system
iii. The KK-3 system
iv. The MICLASS system
v. DCLASS system
vi. COFORM (coding for machining)
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 8

9. Computer-Aided Process planning (CAPP)
Variant Process planning- Coding structures
OPITZ classification system:
The OPITZ coding system digit sequence: ABCD
The first nine digits are intended to convey both design and manufacturing data.
The first five digits, 12345, are called the “form code” and describe the primary design attributes of the part.
The next four digits, 6789, constitute the “supplementary code”. It indicates some of the attributes that would be of use to manufacturing (work material, raw work piece shape, and accuracy).
The extra four digits, “ABCD”, are referred to as the “secondary code” and are intended to identify the production operation type and sequence.
The Opitz coding system uses the following digit sequence:
ABCD
The basic code consists of nine digits, which can be extended by adding four more
digits. The first nine digits are intended to convey both design and manufacturing data.
The general interpretation of the nine digits is indicated in Fig 9.5. The first five digits,
12345, are called the “form code” and describe the primary design attributes of the part.
The next four digits, 6789, constitute the “supplementary code”. It indicates some of the
attributes that would be of use to manufacturing (work material, raw work piece shape,
and accuracy). The extra four digits, “ABCD”, are referred to as the “secondary code” and
are intended to identify the production operation type and sequence. The secondary code
can be designed by the firm to serve its own particular needs.
In the form code, the first digit identifies whether the part is a rotational or a nonrotational
part. It also describes the general shape and proportions of the part. Fig 9.5
shows the specification scheme. For the rotational work pieces, the coding of the first five
digits is given in Fig. 9.6.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 9

10. Computer-Aided Process planning (CAPP)
Variant Process planning- Coding structures
OPTIZ classification system:
The OPTIZ coding system digit sequence: ABCD
The Opitz coding system uses the following digit sequence:
ABCD
The basic code consists of nine digits, which can be extended by adding four more
digits. The first nine digits are intended to convey both design and manufacturing data.
The general interpretation of the nine digits is indicated in Fig 9.5. The first five digits,
12345, are called the “form code” and describe the primary design attributes of the part.
The next four digits, 6789, constitute the “supplementary code”. It indicates some of the
attributes that would be of use to manufacturing (work material, raw work piece shape,
and accuracy). The extra four digits, “ABCD”, are referred to as the “secondary code” and
are intended to identify the production operation type and sequence. The secondary code
can be designed by the firm to serve its own particular needs.
In the form code, the first digit identifies whether the part is a rotational or a nonrotational
part. It also describes the general shape and proportions of the part. Fig 9.5
shows the specification scheme. For the rotational work pieces, the coding of the first five
digits is given in Fig. 9.6.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 10

11. Computer-Aided Process planning (CAPP)
Variant Process planning- Coding structures
OPTIZ classification system:
The OPTIZ coding system digit sequence: ABCD
The Opitz coding system uses the following digit sequence:
ABCD
The basic code consists of nine digits, which can be extended by adding four more
digits. The first nine digits are intended to convey both design and manufacturing data.
The general interpretation of the nine digits is indicated in Fig 9.5. The first five digits,
12345, are called the “form code” and describe the primary design attributes of the part.
The next four digits, 6789, constitute the “supplementary code”. It indicates some of the
attributes that would be of use to manufacturing (work material, raw work piece shape,
and accuracy). The extra four digits, “ABCD”, are referred to as the “secondary code” and
are intended to identify the production operation type and sequence. The secondary code
can be designed by the firm to serve its own particular needs.
In the form code, the first digit identifies whether the part is a rotational or a nonrotational
part. It also describes the general shape and proportions of the part. Fig 9.5
shows the specification scheme. For the rotational work pieces, the coding of the first five
digits is given in Fig. 9.6.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 11

12. Computer-Aided Process planning (CAPP)
Variant Process planning- Coding structures
OPITZ classification system:
The OPITZ coding system digit sequence: ABCD
The overall length/diameter ratio, L/D = 1.6,
so the first code = 1.
The part is stepped on both ends with a screw thread on one end,
so the second digit code would be 5
The third digit code is 1 because of the through hole.
The fourth and fifth digits are both 0, since no surface machining is required and there are no auxiliary holes or gear teeth on the part.
The complete form code in the OPITZ system is “15100”.
To add the supplementary code, we would have to properly code the sixth through ninth digits with data on dimensions, material, starting work piece shape, and accuracy
The Opitz coding system uses the following digit sequence:
ABCD
The basic code consists of nine digits, which can be extended by adding four more
digits. The first nine digits are intended to convey both design and manufacturing data.
The general interpretation of the nine digits is indicated in Fig 9.5. The first five digits,
12345, are called the “form code” and describe the primary design attributes of the part.
The next four digits, 6789, constitute the “supplementary code”. It indicates some of the
attributes that would be of use to manufacturing (work material, raw work piece shape,
and accuracy). The extra four digits, “ABCD”, are referred to as the “secondary code” and
are intended to identify the production operation type and sequence. The secondary code
can be designed by the firm to serve its own particular needs.
In the form code, the first digit identifies whether the part is a rotational or a nonrotational
part. It also describes the general shape and proportions of the part. Fig 9.5
shows the specification scheme. For the rotational work pieces, the coding of the first five
digits is given in Fig. 9.6.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 12

13. Computer-Aided Process planning (CAPP)
Variant Process planning
The following are the sequences in the design of a variant process planning system:
Family formation
Data base structure design
Search algorithm development and implementation
Plan editing
Process parameter selection/updating
The following are the sequences in the design of a variant process planning system:
i. Family formation
ii. Data base structure design
iii. Search algorithm development and implementation
iv. Plan editing
v. Process parameter selection/updating
Family Formation
Part family classification and coding were discussed earlier. This is based on the
manufacturing features of a part. Components requiring similar processes are grouped
into the same family. A general rule for part family formation is that all parts must be
related. Then, a standard process plan can be shared by the entire family. Minimum
modification on the standard plan will be required for such family members.
DATA BASE STRUCTURE DESIGN
The data base contains all the necessary information for an application, and can be accessed
by several programs for specific application. There are three approaches to construct a
data base: hierarchical, network, and relational.
SEARCH PROCEDURE
The principle of a variant system is to retrieve process plans for similar components. The
search for a process plan is based on the search of a part family to which the component
belongs. When, the part family is found, the associated standard plan can then be retrieved.
A family matrix search can be seen as the matching of the family with a given code. Family
matrices can be considered as masks. Whenever, a code can pass through a mask
successfully, the family is identified.
PLAN EDITING AND PARAMETER SELECTION
Before a process plan can be issued to the shop, some modification of the standard plan
may be necessary, and process parameters must be added to the plan. There are two
types of plan editing: One is the editing of the standard plan itself in the data base, and
the other is editing of the plan for the component. For editing a standard plan, the
structure of the data base must be flexible enough for expansion, additions, and deletions
of the data records.
A complete process plan includes not only operations but also process parameters.
The data in the process parameter files are linked so that we can go through the tree to find
the speed and feed for an operation. The parameter file can be integrated into variant
planning to select process parameters automatically.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 13

14. Computer-Aided Process planning (CAPP)
Generative Process planning
Generative process planning is a system that synthesizes process information in order to create a process plan for a new component automatically.
Knowledge of manufacturing must be captured and encoded into efficient software. By applying decision logic, a process planner’s decision making can be imitated.
The generative planning has the following advantages:
It can generate consistent process plans rapidly.
New process plans can be created as easily as retrieving the plans of existing components.
It can be interfaced with an automated manufacturing facility to provide detailed and up-to-date control information.
Generative process planning is a system that synthesizes process information in order
to create a process plan for a new component automatically. In a generative planning
system, process plans are created from information available in manufacturing data base
without human intervention. Upon receiving the design model, the system can generate
the required operations and operation sequences for the component. Knowledge of
manufacturing must be captured and encoded into efficient software. By applying
decision logic, a process planner’s decision making can be imitated. Other planning
functions, such as machine selection, tool selection, process optimization, and so on, can
also be automated using generative planning techniques. The generative planning has
the following advantages:
i. It can generate consistent process plans rapidly.
ii. New process plans can be created as easily as retrieving the plans of existing
components.
iii. It can be interfaced with an automated manufacturing facility to provide detailed
and up-to-date control information.
Fig shows the modular structure of a generative CAPP system.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 14

15. Computer-Aided Process planning (CAPP)
Generative Process planning
In generative process planning, when process plans are
generated, the system must define an initial state in order to
reach the final state (goal).
In forward planning, the initial state is the raw material
and the final state is the component design. A planner works in
modifying the raw work piece until it takes on the final design
qualities.
Backward planning uses a reverse procedure. Assuming that we
have a finished component, the goal is to go back to the un-machined
Work piece. Each machining process is considered a filling process
In generative process planning, when process plans are generated, the system must define
an initial state in order to reach the final state (goal). The path taken represents the sequence
of processes. For example, the initial state is the raw material and the final state is the
component design. Then a planner works in modifying the raw workpiece until it takes
on the final design qualities. This is called forward planning.
Backward planning uses a reverse procedure. Assuming that we have a finished
component, the goal is to go back to the un-machined workpiece. Each machining process
is considered a filling process.
Forward and backward planning may seem similar. However they influence the
programming of the system significantly. Planning each process can be characterized by a
precondition of the surface to be machined and a post condition of the machining (the end
result). For forward planning, we must know the successor surface before we select a
process, because the post condition of the first process becomes the precondition for second
process. Backward planning eliminates this problem since it begins with the final surfaces
from and processes are selected to satisfy the initial requirements.
In forward planning, the steps to obtain the final surface with the desirable attributes
must be carefully planned to guarantee the result. On the other hand, backward planning
starts with the final requirements and searches for the initial condition.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 15

16. Computer-Aided Process planning (CAPP)
Generative Process planning
Decision logic
The decision logic determines how a process or processes are selected. The major function of the decision logic is to match the process capabilities with the design specification.
The different techniques in decision logic are: Decision trees; Decision tables
Artificial Intelligence (AI)
There are two types of knowledge involved in process planning systems: Component knowledge, and process knowledge. The component knowledge defines the current state of the problem to be solved (declarative knowledge). On the other hand, the knowledge of processes defines how the component can be changed by processes (procedural knowledge).
CAPP BASED ON DECISION LOGIC
The decision logic determines how a process or processes are selected. The major function
of the decision logic is to match the process capabilities with the design specification. The
different techniques in decision logic are:
i. Decision trees
ii. Decision tables
These two techniques are methods of describing or specifying the various actions
associated with the combination of input conditions.
CAPP BASED ON ARTIFICIAL INTELLIGENCE (AI)
AI can be defined as the ability of a device to perform functions that are normally associated
with the human intelligence. These functions include reasoning, planning, and problem
solving. Applications for AI have been in natural language processing, intelligent data
base retrieval, expert consulting systems, theorem proving, robotics, scheduling, and
perception problems. Process planning applications have been considered as part of an
expert consulting system.
There are two types of knowledge involved in process planning systems: Component
knowledge, and process knowledge. The component knowledge defines the current state
of the problem to be solved (declarative knowledge). On the other hand, the knowledge of
processes defines how the component can be changed by processes (procedural knowledge).
There are several methods to represent declarative knowledge:
i. First order predicate calculus
ii. Frames and semantic networks
Procedural knowledge can be represented by IF (condition), THEN (action) statements
which are similar to decision trees or decision tables. In AI such rules can be called
production rules.
Even after the descriptive and procedural knowledge have been represented,
conclusions cannot be deduced, because we do not have mechanism to apply the
appropriate rules to the problem. Control knowledge is similar to human knowledge in
reasoning, which deduces certain facts from the knowledge base concerning problem. This
can be a difficult task to program on a computer.
Computer Aided Process Planning has been an active area of research work in AI for
many years. Feature recognition, feature process correlation, process sequencing, blank
selection, cutting parameter selection, tool selection etc. are the segments of CAPP where
AI can contribute to improve the quality of process plans.s
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 16

17. Computer-Aided Process planning (CAPP)
Implementation consideration
The process planning function is manufacturing system dependent. This implies that no
one single process planning system can satisfy all of the different manufacturing systems
needs. There are several factors that must be considered when one attempts to implement
a process planning system. These include:
i. Manufacturing system components
ii. Production volume/batch size
iii. Number of different production families
For a moderate number of component families and many similar components in each
family, a variant process planning system is usually the most economic automated planning
alternative. Fig Illustrates the economic regions for the different planning alternatives.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 13 17