International Journal of Research in Advanced Engineering and Technology

International Journal of Research in Advanced Engineering and Technology


International Journal of Research in Advanced Engineering and Technology
International Journal of Research in Advanced Engineering and Technology
Vol. 4, Issue 3 (2018)

Process plan optimization: A case of plastic manufacturing company


Charles Chikwendu Okpala, Austin Kelechi Okonkwo, Ezeanyim Okechukwu Chiedu

Achieving manufacturing excellence through the reduction of production metrics such as lead time and cost is one of the objectives of having an efficient process planning system. Computer Aided Process Planning (CAPP), a very robust and efficient process planning system that involves the application and use of computer technology to aid in process planning can help manufacturers come close to achieving this manufacturing excellence. The systematic and empirical approach used throughout the paper studied and identified performance areas of improvement in a plastic products manufacturing facility, with emphasis on its process planning. The existing manual process planning was actually replaced with MIPLAN, a retrieval CAPP system. Though CAPP thrives in a production facility that produces a wide variety of products, just as was the case with the case study facility, the MIPLAN CAPP was applied in planning production of two of their products, as a pilot test. The results obtained were emphatic; 13.4%, 22.2%, 92.1%, 36.2% and 62.5% improvements were observed for raw materials cost savings, direct labor, scrap volume, production lead time and delivery lead time respectively for the manufacture of a given quantity of plastic chair. Also the CAPP program was applied in the manufacture of 25 Liters jerry can with the following improvements observed; 6.5 %, 22.2%, 95.1%, 36.4% and 48.5% respectively for the same configuration of performance metrics. These very significant improvements observed when manual process planning is replaced with CAPP at the case study facility are in agreement with postulates of theoretical framework that process planning can be optimized with CAPP.
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How to cite this article:
Charles Chikwendu Okpala, Austin Kelechi Okonkwo, Ezeanyim Okechukwu Chiedu. Process plan optimization: A case of plastic manufacturing company. International Journal of Research in Advanced Engineering and Technology, Volume 4, Issue 3, 2018, Pages 07-12
International Journal of Research in Advanced Engineering and Technology International Journal of Research in Advanced Engineering and Technology