There are many computer-aided process planning (CAPP) systems available on the market today that enable automated process planning from product data that is in a digital format, notably DXF (AutoCAD) or IGES. A few CAPP product vendors today are also advertising an AP203 STEP input capability. However, each of these data formats was developed primarily to assist product designers to more quickly and efficiently exchange geometry-related information between heterogeneous CAD systems. None of them was ever intended to provide for the exchange of the disparate types of information that are needed to rapidly and accurately manufacture products.

That’s where AP224 comes in. Officially the Mechanical Product Definition for Process Planning Using Machining Features, this AP is ‘owned’ by Team SCRA (as its lead developer and international advocate). It provides not only the geometry of the part, but also the part’s features, dimensions and tolerances, material requirements, and notational information. In other words, everything a manufacturer needs to know to efficiently produce the right part the first time. As far as we know, STEPPlan is the only AP224 STEP-driven process planning system available today that’s been proven within an operational production environment.

The figure below depicts Team SCRA’s proven approach to accomplishing generative process planning for machined parts from AP224-compliant STEP data, as well as from AP203 STEP, IGES, and raster data. Even from paper if that’s all you’ve got. We call our system STEPPlan. As shown, the system’s primary function is the creation of what’s called macro process plans—shop floor routings, bills of materials, tooling and fixturing requirements, and time estimates—from a digital input that is ideally in AP224 STEP compliant format.

STEPPlan uses feature-based CAPP technology to quickly generate process plans within a unique data fusion environment. Unambiguous product data, shop resource information, and specific knowledge about a manufacturing operation’s processes and practices are combined to quickly generate, from scratch, consistent process plans for a wide variety of machined parts.

STEPPlan features a distinctive plan editing interface which balances automation with user control. In the system’s generative environment, the operator is a valuable source of planning knowledge. STEPPlan’s flexible interface lets the user override the system at any point. Automated, assisted, and manual functions can be used in any combination to satisfactorily complete the plan.

STEPPlan has been designed and developed to greatly alleviate the many problems commonly associated with the process planning function within a machined part manufacturing facility. The ultimate objective of the system is to enable its user to rapidly prepare accurate process plans that will, in turn, optimize the utilization of shop floor resources. It also enables the more timely delivery of raw materials when they are needed. We know that when those objectives can be achieved, the individuals out on the floor who are ultimately responsible for the physical manufacture of your products should be more efficient. And that saves them time and your organization money.

An experienced STEPPlan operator, starting with an AP224-compliant STEP file input, can typically complete a macro process plan for a reasonably complex mechanical part in no more than 3 hours. And, of course, another benefit of the system is that, once a process plan has been completed and verified through the actual manufacture of the part, that plan can be archived and used over and over again by the various functional elements within the organization.

How quickly an organization’s investment in STEPPlan is returned will be greatly dependent on the extent to which the process plans that are created by the system are re-used in the future. Meaning the system provides the greatest payback when utilized within a manufacturing environment that is characterized by small lot production of a variety of different mechanical products. SCRA can assist you in determining your specific return, based on your business environment, product lines, and workload.