MODULE 2 : Manufacturing support System (KMBN OM 05.

2)

1. Process Planning (Manufacturing Engineering & Technology, Fundamentals of Modern

 Definition:

o Process planning is the systematic determination of the methods by which a product is to

o It involves translating design specifications into manufacturing instructions.

 Key Activities:

o Part Print Analysis: Understanding the geometry, tolerances, surface finish, and material
of the part.

o Process Selection: Choosing the appropriate manufacturing processes (e.g., machining,

o Operation Sequencing: Determining the optimal order of manufacturing operations.

o Machine and Tool Selection: Selecting the required machines, tools, fixtures, and cutting
parameters.

o Process Parameter Determination: Specifying cutting speeds, feed rates, depths of cut,
and other process variables.

o Time and Cost Estimation: Estimating the manufacturing time and cost for each
operation.

o Documentation: Creating detailed process sheets, route sheets, and work instructions.

 Types of Process Planning:

o Manual Process Planning: Based on the experience and knowledge of process planners.

o Variant Process Planning: Retrieving and modifying existing process plans for similar
parts.

o Generative Process Planning: Automatically generating process plans using computer

 Considerations:

o Material properties

o Production volume

o Equipment availability

o Cost constraints

o Quality requirements

o Safety requirements
2. Computer-Aided Process Planning (CAPP) (Manufacturing Engineering & Technology, Fundamentals
of Modern Manufacturing)

 Definition:

o CAPP is the use of computer systems to automate process planning tasks.

 Benefits:

o Increased efficiency and productivity.

o Reduced planning time and cost.

o Improved consistency and accuracy of process plans.

o Enhanced integration with CAD/CAM systems.

o Standardization of process planning.

 Types of CAPP Systems:

o Variant CAPP Systems: Based on group technology and part classification.

 Parts are classified into families based on their geometric and manufacturing
similarities.

 Standard process plans are created for each part family.

 New parts are planned by retrieving and modifying existing plans.

o Generative CAPP Systems: Based on decision logic and algorithms.

 Process plans are generated automatically from part geometry and

 Requires a comprehensive knowledge base of manufacturing rules and data.

 Key Components:

o Part classification and coding system.

o Process knowledge base.

o Decision logic and algorithms.

o User interface.

o Output generation.
3. Production Planning and Control (PPC) Systems (Production and Operations Management,
Fundamentals of Modern Manufacturing)

 Definition:

o PPC is the planning and control of all activities involved in the manufacturing process,
from raw material procurement to finished product delivery.

 Objectives:

o Meet customer demand.

o Minimize inventory costs.

o Maximize resource utilization.

o Maintain product quality.

o Minimize production delays.

 Key Functions:

o Demand forecasting

o Aggregate planning

o Master production scheduling (MPS)

o Material requirements planning (MRP)

o Capacity planning

o Shop floor control

o Inventory control.

Demand Forecasting

According to Production and Operations Management by K. Aswathappa & K. Shridhara Bhat, demand
forecasting is a crucial process in production planning, helping businesses predict future demand based
on historical data, market trends, and statistical techniques. It ensures that companies produce the right
quantity of products at the right time, reducing stock outs and excess inventory. Techniques like moving
averages, exponential smoothing, and regression analysis are commonly used to improve forecasting
accuracy.

Inventory Control

As explained in Manufacturing Engineering & Technology, inventory control focuses on maintaining the
optimal stock levels required to meet production and customer demands without excessive holding costs.
Techniques like Just-in-Time (JIT), Economic Order Quantity (EOQ), and ABC analysis help balance
inventory costs while ensuring smooth supply chain operations. Proper inventory management minimizes
waste, prevents shortages, and improves overall manufacturing efficiency.
4. Aggregate Planning and Master Production Schedule (MPS) (Production and Operations
Management, Fundamentals of Modern Manufacturing)

 Aggregate Planning:

Aggregate planning is a medium-term planning process that helps balance supply and demand by
adjusting production rates, workforce levels, and inventory. It aims to optimize resource utilization
while minimizing costs associated with underproduction or overproduction. This process is critical
in industries where demand fluctuates, and production adjustments must be made efficiently.

o Developing a high-level production plan for a medium-term horizon (e.g., 6-18 months).

o Focuses on aggregate product families rather than individual products.

o Balances supply and demand by adjusting production rates, inventory levels, and
workforce levels.

o Strategies include: level production, chase demand, and hybrid strategies.

 Master Production Schedule (MPS):

MPS serves as a detailed production plan that breaks down aggregate planning into specific
schedules for individual products. It determines what to produce, in what quantity, and when,
ensuring alignment with demand forecasts and material availability. MPS helps manufacturers
avoid bottlenecks, improve production efficiency, and meet customer delivery schedules
effectively.

o A detailed plan that specifies the quantity and timing of end products to be produced.

o Disaggregates the aggregate plan into specific product items.

o Forms the basis for material requirements planning (MRP).

o Drives the production system.

5. Material Requirements Planning (MRP) (Production and Operations Management, Fundamentals of

As per Manufacturing Processes for Engineering Materials by Kalpakjian & Schmid, MRP is a structured
approach used to determine material requirements for production based on the MPS. It considers
inventory levels, lead times, and bill of materials (BOM) to ensure that the right materials are available at
the right time, reducing waste and avoiding production delays. MRP plays a key role in modern
manufacturing systems by improving efficiency and cost control.

 Definition:

o A computer-based inventory control and production planning system.

o Determines the timing and quantity of material orders.

 Key Inputs:

o Master production schedule (MPS)

o Bill of materials (BOM)

o Inventory status records

 Key Outputs:

o Planned order releases

o Planned order receipts

o Changes to planned orders

o Exception reports

6. Capacity Planning (Production and Operations Management, Fundamentals of Modern

Capacity planning, as detailed in Production and Operations Management, involves assessing the
production capacity needed to meet future demand. It ensures that resources like machines, labor, and
facilities are efficiently allocated to prevent underutilization or overload. There are three levels of capacity
planning: long-term (strategic), medium-term (tactical), and short-term (operational). Effective capacity
planning helps maintain smooth production flow and reduces unnecessary costs.

 Definition:

o Determining the capacity required to meet the production plan.

o Ensuring that sufficient resources (e.g., machines, labor) are available.

 Types of Capacity Planning:

o Rough-cut capacity planning (RCCP): Checking the feasibility of the MPS.

o Capacity requirements planning (CRP): Determining the detailed capacity requirements

 Key Considerations:

o Available capacity

o Required capacity

o Capacity constraints

o Lead times.
7. Introduction to Shop Floor Control (Production and Operations Management, Fundamentals of
Modern Manufacturing)

According to Fundamentals of Modern Manufacturing by Groover, shop floor control involves tracking,
scheduling, and managing work-in-progress (WIP) on the production floor. It ensures that operations run
smoothly by monitoring job progress, resource utilization, and adherence to schedules. Technologies like
Manufacturing Execution Systems (MES) and automation help improve shop floor efficiency, reduce
errors, and enhance productivity.

 Definition:

o Monitoring and controlling the progress of work on the shop floor.

 Objectives:

o Ensure that production schedules are met.

o Minimize work-in-process (WIP) inventory.

o Maximize machine utilization.

o Provide real-time information on production status.

 Key Functions:

o Dispatching

o Progress reporting

o Priority control

o Input/output control.

8. Overview of Automatic Identification and Data Capture (AIDC) (Manufacturing Engineering &
Technology, Fundamentals of Modern Manufacturing)

 Definition:

o Technologies that automatically identify and collect data without manual intervention.

 Benefits:

o Improved data accuracy.

o Increased efficiency.

o Reduced labor costs.

o Enhanced inventory control.

o Improved tracking and tracing.

 Technologies:

o Bar code technology

o Magnetic stripe cards

o Optical character recognition (OCR)

o Voice recognition

o Biometrics.

9. Bar Code Technology and Radio Frequency Identification (RFID) (Manufacturing Engineering &
Technology, Fundamentals of Modern Manufacturing)

 Bar Code Technology:

o Uses optical scanners to read encoded information in the form of parallel lines.

o Widely used for inventory control, product identification, and data entry.

o Low cost, and easy to implement.

 Radio Frequency Identification (RFID):

o Uses radio waves to automatically identify and track tags attached to objects.

o Can read data without line-of-sight.

o Offers greater data capacity and security than bar codes.

o Used in supply chain management, asset tracking, and access control.