CAPPC Presentation 12-5-05

Computer-Aided Manufacturing
Yien-Sheng Ao
Scott Currie
Joe Butner
Taylor Grisham
Manufacturing
Efficiency
Cost
Integration
High quality/low cost can be

achieved by:
Computer-Aided
Manufacturing
Computer-Aided Design
Computer-Aided
Engineering
Computer-Aided Process
Planning
Simulator of Process and
System
Manufacturing System
Flexible system to
accommodate changes
Global events/economy
affects manufacturing
Predictions
Computer-Integrated Manufacturing
(CIM)
Computerized
integration
Instantaneous
communication of
subsystems
Can be expansive
(CIM)
(CIM)
Benefits:
Better process control
Product quality
Efficiency
Total control
Computer-Aided Design and
Engineering
Drawing Exchange
Format (DFX) are
softwares that convert
data between different
CAD vendors. Ex. Pro-
E and Solidworks
Autodesk can do just
that
Design Analysis and Optimization
To analyze stresses,
strains, deflections, and
other physical or
temperature tolerances
Able to determine
product effectiveness
Computer-Aided Manufacturing
(CAM)
Involves the use of

computers in all phases of
manufacturing. A process
known as knowledge based
machining.
Computer-Aided Design (CAD) and
Computer-Aided Manufacturing (CAM)
Some typical applications of CAD/CAM

Process planning and scheduling.
Programming for numerical control and industrial
robots.
Design of dies and molds for casting.
Die for metal working operations.
Design of tooling and fixtures and EDM electrodes.
Quality control and inspection.
Plant layout.
Computer-Aided Process Planning
(CAPP)
Computer-Aided Process Planning is concerned with

the preparation of a route sheet for the engineering
drawing of the work part which must be interpreted in
terms of manufacturing process to be used. The
route sheet is a listing of the sequence of operations.
Closely related to process planning are the functions
of determining appropriate cutting conditions for the
machining operations and setting the time standards
for the operations which are aided by computers.
CAPP Systems
Two types of CAPP systems

Variant - Contain a standard process plan.
Generative
Creates a new plan.

Material-requirements planning and
manufacturing resource planning
(MRP)
MRP keep complete records of inventories of
Materials,
Supplies,
parts in various stages of production,
Orders,
Purchasing, and
Scheduling.
Computer simulation of Manufacturing
Processes and Systems
Simulation takes two forms:

It is a model of a specific operation intended
to determine the viability of a process or to
optimize or improve its performance.
It models multiple processes and their
interactions to help process planners and
plant designers in the layout of machinery
and facilities.
Group Technology (GT)
Group technology takes

advantage of the design
and processing
similarities among parts
to be produced. By
grouping these parts into
families related to one
another by code and
classification.
Classification and coding of parts
Is a critical and complex process and is done

according to two attributes:
Design - this attribute is related in the
similarities in geometric features of the part.
Manufacturing -this attribute is related by the
similarities in manufacturing processes
performed on the part.
Coding
The coding of parts can be company owned or

purchased commercially.
The three basic codes vary in degree of
complexity:
Hierarchical coding
Polycodes
Decision-tree coding
Summary
The computer age has provided for

improvements in all manufacturing
processes.
Product Design and Process Selection
As engineers, we must
design products that are
cost effective to
manufacture
Designing cheap parts that
still maintain high-quality
requires an understanding
of all parts of the
manufacturing process
Factors For Competitive Design
Product design
Product quality and life
expectancy
Life-cycle assessment and
engineering
Material selection/ substitutions
Manufacturer process
capabilities
Manufacturing cost and cost
reduction
Product Design
DFMA-design for manufacture and

assembly
Reduce number of components
Use commercially available parts
such as fasteners
Use fewer, stronger fasteners
Consider surface finishing
processes and how they will affect
dimensional tolerances
Quantity of Materials in Design
As production rates go up, costs of

materials used and wasted can
make a substantial difference in cost
This can be achieved by using
different materials or manufacturing
techniques
Reducing the materials used too
much can lead to difficulty in
manufacture or product failure
Product Quality and Life Expectancy
Quality and life expectancy affect

cost
We must limit how much is spent on
quality improvements; eventually this
is not cost effective
Product life must meet customers
expectations
Product must function properly over
its lifetime
Must be able to be manufactured at
a rate to meet customer demand
Life Cycle Assessment and
Engineering
This is also known as Sustainable Manufacturing, where

long-term resource availability and conservation are
considered
Life Cycle Assessment modeling is done to assess
every step in manufacturing a product
Engineers must design products that are
environmentally friendly to make
Waste products from manufacture
can often be recycled or reused
Material Selection for Products
We must consider mechanical, chemical, and

physical properties
Some materials can be replaced by lighter or
less expensive ones
Materials must meet minimum design
specifications and requirements
Must have reliable and readily available
supply of raw materials
Shapes of Commercially Available
Materials
Raw metals come in one of

several standard shapes, such
as rods, ingots, plate or sheet,
foil, wire, tubing, and some
structural shapes such as I-
beam
We must select the raw material
that requires the least additional
processing to form the final part
Additional Material Selection Factors
Manufacturing characteristics of
materials-can our stock
withstand the stress of
manufacture without adverse
affects?
Reliability of material supply
Recycling considerations
Material and processing cost
Material Substitution
Substituting materials can

allow products to be made
lighter and more cheaply
Materials can be used that
provide resistance to wear,
corrosion, and fatigue
Common materials can be
substituted for scarce ones
Materials Substitution cont.
Adjustments can be made

based on market
availability of materials
Potentially dangerous
materials (such as lead)
substituted for safe ones
These practices are used
extensively in the
automotive and aerospace
industries
Manufacturing Process
Capabilities
Dimensional tolerances and surface finish

Production Quantity
Production Rate
Lead Time
Process Selection
Characteristicsof the workpiece material

Geometric Features
of the part
Production rate
and quantity
Process selection
considerations
Important Questions
Is the tooling required available in the plant?

Can the part be produced to final dimensions
without requiring additional processing?
Are the processing parameters optimized?
Is scrap minimized?
Have all alternative manufacturing processes
been investigated?
Methods of Making a Simple Part
Manufacturing Costs and Cost
Reduction
Material cost
Tooling cost
Fixed cost
Capital costs
Direct/indirect labor costs
Manufacturing costs and production quantity
Cost reduction
Tooling Costs
Boring mill M-H

Deep Drawing M-H
Extrusion Press M-H
Gear Shaping L
Milling L-M
Roll Forming L-M
Sand Casting L-M
L: low; M: medium; H: high; VH: very high
Fixed Costs
Electric power
Fuel
Taxes on real estate
Rent
Insurance
Capital
** Not sensitive to production volume!

Capital Costs
Investment in buildings
Land
Machinery
Tooling
Equipment
Direct and Indirect Labor Costs
Direct Labor Cost

* Includes all labor from the time the raw
materials are first handled to the time when
the product is finished.
Indirect Labor Cost
* Includes the servicing of the total

manufacturing operation.
Cost Reduction
Design 5%
Material 50%
Direct Labor 15%
Overhead 30%
ELECTRIC MOTOR
Value Analysis
A really cool system that evaluates each step

in design, materials, processes, and
operations in order to manufacture a product
that performs all of its intended functions at
the lowest cost!!
Value= (Product function and performance)

Product Cost
Value Analysis Phases
1. Information Phase
2. Analysis Phase
3. Creative Phase
4. Evaluation Phase
5. Implementation Phase
6. Review Phase
Work-Cited
http://www.optima-design.co.uk/graphics/images/computer_aided
_verification.jpg
http://www.nd.edu/~manufact/figures.html
http://www.wwtc.edu/machine_tool/Computer_FeatureCAM.jpg
http://www.edu-c.pref.okayama.jp/jugyosien/chu/Koumin/seisa
n/Dougu.htm
http://engineershandbook.com/Software/cadcam.htm
http://www.delcam.com/
http://www.nd.edu/~manufact/pdfs/

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CAPPC Presentation 12-5-05

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Computer-Aided Manufacturing

High quality/low cost can be

Involves the use of

Some typical applications of CAD/CAM

Computer-Aided Process Planning is concerned with

Two types of CAPP systems

Creates a new plan.

Simulation takes two forms:

Group technology takes

Is a critical and complex process and is done

The coding of parts can be company owned or

The computer age has provided for

DFMA-design for manufacture and

As production rates go up, costs of

Quality and life expectancy affect

This is also known as Sustainable Manufacturing, where

We must consider mechanical, chemical, and

Raw metals come in one of

Substituting materials can

Adjustments can be made

Dimensional tolerances and surface finish

Characteristicsof the workpiece material

Is the tooling required available in the plant?

Boring mill M-H

** Not sensitive to production volume!

Direct Labor Cost

* Includes the servicing of the total

A really cool system that evaluates each step

Value= (Product function and performance)

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