Steps for Process Planning for a Product from Raw Material to Finished Product: Specific activities involved in planning a process for a product from raw material to finished product in an industry are described below;
[1] Analysis of the finished part requirements as specified in the engineering design: In this stage, component drawing should be analyzed to identify its features, dimensions, and tolerance specifications. Part’s requirement defined by its features, dimensions, and tolerance specifications will determine corresponding processing requirements [2] Determining the sequence of operation required: Basic aim is to determine the type of processing operation that has the capability to generate various types of features, given the tolerance requirements [3] Selecting the proper equipment to accomplish the required operations: Machine selection requires determining how the part would be processed on each of the alternative machines so that best machine can be selected. At this stage, organization has to decide whether to make or buy the component part. Break even analysis is most convenient method for selecting optimum method of manufacture or machine amongst the competing ones. [4] Selecting the proper material for the components/parts: The factors considered while selecting the materials are Function, Appearance, Reliability, Service life, Environment, Compatibility, Productivity and Cost. [5] Calculating the specific operation setup times and cycle times on each machine : Determination of set-up times requires knowledge of available tooling and sequence of steps necessary to prepare the machine for processing given work piece. For establishing accurate set-up times, detailed knowledge of equipment capacity, tooling, and shop practice also required. [6] Documenting the established process plans: Process plan is documented as job routing or operation sheet. Operation sheet also called “route sheet”, “instruction sheet”, “traveler”, “planner”. Information provided by route sheet is, Part identification, Description of processing steps in each operation, Operation sequence and machines, Standard set-up and cycle times, Tooling requirements for each operation and Production control information showing the planning lead time at each operation. [7] Communicating the manufacturing knowledge to the shop floor: Communication is essential to ensure that part will be processed according to most economical way. Process documentation and communication provide basis for improved part consistency and quality in manufacturing. [8] Combining the operations to reduce production cycle: In this many operations can be combined to put them in the best sequence to reduce the production time. This operation described in detail, in later section of this chapter. [9] Inspection of tooling, gauges for proper working: Inspection involves, determining the stages of inspection, the tools and gauges required for inspection. This operation described in detail, in later section of this chapter.