PROCESS PLANNING

Process Planning Process planning is concerned with planning the conversion or transformation process needed to convert the materials into finished products. A production process is a series of manufacturing operations performed at work stations to achieve the design specifications of the planned output. A vast number of different operations and various kinds of equipments and machines may be required to produce a complex product

Process planning consists of two parts namely (i) Process design and (ii) Operations design.

Process planning is the basis for the design of buildings, layout of facilities and selection of production equipment and machinery. Process planning also affects quality control, human resource requirements, job design and capacity of the plant. Process design determines the details of how products/service will be produced.

Process planning and process design describe the specific steps in the production process and the linkages among the steps that will enable the production system to produce products /services of the desired quality in the required quantity, at the tome customers want them and at the budgeted cost.

PROCESS DESIGN

1. What are the characteristics of the product or service being supplied or offered to customers?
2. What is the expected volume of output?
3. What kinds of equipment or machinery by custom built?
4. What is the cost of equipment and machinery needed?
5. What types of labour skills are available, in what quantities and at what wages rates?
6. What types of labour skills are available, in what quantities and at what wage rates?
7. How much money can be spent on the manufacturing process?
8. Should the process be capital intensive on labour intensive?
9. Should the components or parts be made of purchased? (Make or buy decisions)
10. How best to handle materials?

PROCESS PLANNING PROCEDURE

a. Selection of Process based on:
For converting raw material to finished goods.

Select the most economical process

This selection depends on:
· Current Production Commitment
· Delivery date
· Quantity to be produced
· Quality standards

b. Selection of Material
· Correct shape and size of the material for reducing the scrap
· Right quality, chemical composition as per the given material specification.

b. Selection of Jigs, Fixtures and Special attachments

Support devices for higher production rate.
· To reduce unit cost of production

c. Selection of Cutting tools and Inspection gauges
· To reduced the production time
· Separate tools for initial course machining and for fine finishing
· Accurate inspection at a faster rate.
· Find setup time and standard time for each operation

TYPE OF PROCESS DESIGNS
The basic type of production system and the finished goods inventory policy to be used must be decided at the earliest stages of process planning. The common type of production system are:
(i) Product-focused production system
(ii) Process-focused production system
(iii) Group-technology/cellular manufacturing system