Planning in Tool Design Engineering

Planning in Tool Design Engineering

Planning is an essential activity in an organization and an important tool. Planning basically gives an idea of the following: what should be done, how should be done how should it to be done, who should do it, where it should be done. Thus process planning gives detailed planning of operations necessary to convert the raw material in to finished products. The work to be carried out at each stage is specified along with details of the equipment, tooling methods and procedures and number of personnel required for the operation. The operations are arranged in a sequence which is logical, economical and practical.

The operation sheet serves as medium of communication among the members of production team. Thus the process planning establishes an efficient sequence of operations, selection of proper equipment tools and specifies their operation in such a manner that the product will meet all requirement stipulated in the specification. At the same time the process will be performed at minimum cost and maximum productivity.

Before starting the actual production process planning is done. It gives the idea of sequence of operations, selection of machine, cost and time required, at the same time process will be performed with high percentage of material utilization. Planning is a primary function of human and material resources in an enterprise to realize maximum profits.

Process planning represents the link between engineering design and shop floor manufacturing. Since process planning determines how a part will be manufactured, it is the major determinant of manufacturing costs and profitability.

PLANNING CONSISTS OF FOLLOWING WORKS

1. Tool and high tech component: it involves job planning with effective utilization of machines available & using right tool for right operation.

2. Preparing process sheet: process sheet in forms the operations and machining conditions such as diameter of component, feed, speed, material setting g etc.

3. Job follows up: to follow up the progress of job in the shop floor.

4. Pre tooling: pre machining of the job in conventional machines to save the time of high tech machines.

5. Route card: route card is prepared to mention operations in sequence.

Principles of Process Planning

• Establish Reference Datum Surfaces at Early Stage. For cubicle parts, first operation is generally machining the resting face, which can be used as datum for the subsequent operations. In cylindrical work pieces, the first operation is generally turning. The turned portion can be used as datum for subsequent operations.
  
• Choose Economical Machining Process like turning which is cheaper than grinding.
• Unimportant faces can be machined cheaply on shaping machines. It might be necessary to use milling for better finish and flatness. For perfect parallelism and high degree of surface finish it is necessary to use a costlier surface grinding operation. The size of the machine should also be commensurate with size of the work piece. It would be uneconomical to machine a small piece on a large machine.
  

Customer’s materials receive and issue procedure:

• Check and ensure that a details like respective drawings, materials (if supplied by the customer). Special instructions, if any been received along with order confirmation copy for the work orders received from marketing department.
• Check and ensure that materials received from the store are as per specification. Check and ensure that the correct material is issued to shop as per the specification and the color code.
• Check and ensure that the test piece is included in with machined parts whiie carrying out the heat treatment operation.

Process planning - route card and job card preparation:

• Check and ensure that the planning department will receive the approved for fabrication, Drawings including special instruction if any and all the required details.
• Check and ensure that the process planning (consisting of process sheets, job cards and route cards) carried out for the parts which are to be processed in manufacturing.