UNIT - IV - Group Technology in CADCAM.pptx

Group Technology in CADCAM

1. NALLA MALLA REDDY ENGINEERING COLLEGE DEPARTMENT OF MECHANICAL ENGINEERING 1 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM

2. 2 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM

3. 3 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM

4. 4 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Definition : It is a manufacturing philosophy in which similar parts are identified and grouped together to take advantage of their similarities in manufacturing and design. Similar parts are arranged into part families. For e.g , a plant producing 10,000 different part numbers may be able to group the vast majority of parts into 50 or 60 distinct families. Each family would possess similar design and manufacturing characteristics. Hence, the processing of each member of a given family would be similar, and this results in manufacturing efficiencies. Group technology was introduced by Frederick Taylor in 1919 as a way to improve productivity. One of long term benefits of group technology - it helps to implement a manufacturing strategy aimed at greater automation.

5. 5 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

6. 6 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY A Part family is a collection of parts which are similar either because of geometric shape and size or because similar processing steps are required in their manufacture . The parts within a family are different, but their similarities are close enough to merit their identification as members of the part family.

7. 7 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Parts Classification and Coding Part - Design attributes Basic external shape Basic internal shape Length/diameter ratio Material type Part function Major dimensions Minor dimensions Tolerances Surface finish Part - Manufacturing attributes Major process Minor operations Major dimension Length/diameter ratio Surface finish Machine tool Operation sequence Production time Batch size Annual production Fixtures needed Cutting tools

8. 8 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

9. 9 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

10. 10 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Examples of part families that can be grouped by geometry or processing methods.

11. 11 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Thirteen parts with similar manufacturing Process requirements but different design attributes

12. 12 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Layout of machines with process grouping in a conventional job shop, T - Turning, M - Milling, D - Drilling, CG - Cylindrical grinding and SG - Surface grinding

13. 13 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

14. 14 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY GROUP LAYOUT

15. 15 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Composite part and its variants possible.

16. 16 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

17. 17 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

18. 18 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY One of the main advantages of using the Group Technology is that the machine tools can be reorganised into cells to follow the operation sequence closely. Data collection, Sorting of Process Routing, PFA Chart, Analysis

19. 19 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

20. 20 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

21. 21 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Economic Order Quantity Model Total Inventory cost TIC (Annual) where C h = inventory carrying cost, Q = batch quantity, C su = set-up or ordering cost, and D a = annual demand From the total inventory cost equation can be derived the batch size that minimizes the sum of inventory carrying costs and setup costs

22. 22 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Advantages of Group Technology [GT] Group technology allows similar designs can be easily modified from the existing designs from the database instead of starting from scratch. Standard process plans can be developed for the groups. Greater efforts can be applied in optimising the process plans. Tooling and setups - standard tooling can be developed for a part family, and then standard setup procedures can be used. The use of GT allows faster production, therefore less inventory, and Work in Process (WIP). The throughput time gets reduced. Material handling and movement is reduced.

23. 23 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

24. 24 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

25. 25 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

26. 26 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

27. 27 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

28. 28 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

29. 29 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Implementation Process Step 1: Part Analysis Examine all existing parts and identify their characteristics - dimensions, features, materials, tolerances, manufacturing processes. Step 2: Classification Assign codes to parts based on chosen coding system. Parts with similar codes form families. Step 3: CAD Database Organization Structure CAD libraries by part families. When a designer needs a bracket, they browse the "bracket family" rather than thousands of random parts. Step 4: Design Retrieval System Implement search functionality where designers input requirements and the system suggests similar existing designs. Step 5: Cellular Manufacturing Organize production floor into cells dedicated to specific part families, with machines grouped accordingly.

30. 30 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Types of Group Technology Group Technology can be classified into different types based on various criteria. Here are the main classifications: 1. Based on Classification Approach A. Design Attributes-Based GT Focuses on geometric and design similarities: Shape similarity : Rotational vs. non-rotational, prismatic, etc. Size and dimensions : Length, diameter, volume ranges Design features : Holes, threads, grooves, chamfers Material specifications : Steel, aluminum, plastic, composites Tolerance requirements : Precision levels needed B. Manufacturing Attributes -Based GT Focuses on production process similarities: Machine requirements : Lathe, mill, drill, grinder Operation sequences : Turn→drill→grind Tooling requirements : Similar cutting tools, fixtures, jigs Setup time : Similar machine configurations Production volume : High volume vs. low volume parts C. Hybrid GT Combines both design and manufacturing attributes for comprehensive classification.

31. 31 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 2. Based on Coding Systems A. Hierarchical ( Monocode ) Structure Each digit depends on the previous digit's value. Example : Opitz system Tree-like structure where each level narrows down characteristics More detailed but complex to use B. Chain ( Polycode ) Structure Each digit is independent of others. Example : MICLASS system Each position represents a specific attribute Easier to use but may be less detailed Better for computer processing C. Mixed Structure Combines hierarchical and chain coding. Example : KK-3 system (Japan) Flexible and comprehensive Used in complex manufacturing environments

32. 32 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 3. Based on Part Families A. Rotational Parts Family Shafts, spindles, pins, bushings Cylindrical or conical shapes Primarily turned on lathes Examples : Engine shafts, axles, rollers B. Non-Rotational (Prismatic) Parts Family Blocks, plates, brackets Rectangular or cubic shapes Milled, drilled, or ground Examples : Engine blocks, mounting brackets, housings C. Sheet Metal Parts Family Flat or formed sheet components Stamped, bent, or welded Examples : Body panels, covers, enclosures D. Complex/Special Parts Family Irregular geometries Multiple manufacturing processes Examples : Impellers, turbine blades, custom castings

33. 33 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 4. Based on Application Level A. Component Level GT Individual parts grouped into families Focus on single manufactured items Part-by-part classification B. Assembly Level GT Grouping similar assemblies or subassemblies Product families with similar assembly processes Example : Different engine models sharing assembly procedures C. Product Level GT Entire products grouped by similarity Product families serving similar markets Example : Family of sedan models vs. SUV family

34. 34 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 5. Based on Implementation Scope A. Manual GT Visual inspection and manual classification Used in small shops with limited parts Expert knowledge-based grouping Lower cost but time-consuming B. Computer-Aided GT (CAGT) Automated classification using software CAD integration for feature recognition Database-driven part retrieval Faster and more consistent C. Artificial Intelligence-Based GT Machine learning algorithms for classification Neural networks for pattern recognition Automatic feature extraction from CAD models Most advanced, still emerging

35. 35 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 6. Based on Organizational Structure A. Functional GT Parts grouped but processed in functional departments Traditional job shop with GT awareness Limited rearrangement of machines B. Cellular Manufacturing GT Complete reorganization into manufacturing cells Each cell dedicated to a part family Machines physically grouped by family Most efficient but requires major layout changes C. Virtual Cellular GT Logical grouping without physical reorganization Scheduling treats groups as cells Flexible approach without moving equipment

36. 36 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 7. Based on Industry-Specific Systems A. Automotive GT High-volume standardization Focus on platform sharing Modular component families B. Aerospace GT Strict material and tolerance families Certification-based grouping Complex part geometries C. Electronics GT PCB families Component packaging families High-variety, low-volume focus D. General Manufacturing GT Broad classification schemes Flexible systems like MICLASS or Opitz

37. 37 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

38. 38 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Sample Monocode

39. 39 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

40. 40 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Polycode or Chain type structure The meaning of each character is independent of all other digits. Each digit is used to completely classify some feature of the item. An example of an attribute code is given in Table Digit Feature Possible values 1 2 3 4 1 External shape Shape 1 Shape 2 Shape 3 Shape 4 2 Number of holes 1 – 3 4 - 6 > 6 3 Type of hole Axial Cross Axial/cross Other 4 Gear teeth Internal Spur External Spur Helical worm 5 Splines -- -- -- --

41. 41 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Comparison between Monocode & Polycode To distinguish the hierarchical and chain-type structures, consider a two-digit code number for a part, such as 15 or 25 . Suppose the first digit stands for the general shape of the part: 1 means the part is cylindrical (rotational), and 2 means the geometry is rectangular. In a hierarchical structure, the interpretation of the second digit depends on the value of the first digit. If preceded by 1, the 5 might indicate a length-to-diameter ratio; and if preceded by 2, the 5 indicates an aspect ratio between the length and width dimensions of the part. In the chain-type structure, the symbol 5 would have the same meaning whether preceded by 1 or 2. For example, it might indicate the overall length of the part. The advantage of the hierarchical structure is that in general more information can be included in a code of given number of digits

42. 42 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

43. 43 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

44. 44 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

45. 45 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

46. 46 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Most Common GT Systems Worldwide Opitz System (Germany) - 9 digits, most widely used MICLASS (Netherlands) - 12-30 digits, very detailed MDSI CODE System (USA) - 8 digits, manufacturing-focused KK-3 System (Japan) - 21 digits, comprehensive DCLASS (USA) - CAD-integrated system CUTPLAN (Sweden) - Process planning oriented

47. 47 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

48. 48 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

49. 49 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

50. 50 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

51. 51 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

52. 52 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Form code (digits 1-5) for rotational parts in the Opitz coding system. The overall length/diameter ratio, L/D = 1.6, so the first code = 1. The part is stepped on both ends with a screw thread on one end, so the second digit code would be 5 the third digit code is 1 because of the through hole. The fourth and fifth digits are both , since no surface machining is required and there are no auxiliary holes or gear teeth on the part. The complete form code in the Opitz system is “ 15100 ”.

53. 53 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

54. 54 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Develop the Opitz form code (first 5 digits) for the component 1 2 1 3 2 Part class: Rotational part, L/D = 2 External shape: Stepped to one end, thread Internal shape: Stepped to one end, No shape element Surface machining: External groove Auxiliary holes: Axial on pitch circle diameter

55. 55 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Develop the Opitz form code (first 5 digits) for the component Form Code: 1 3 1 6

56. 56 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

57. 57 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY The MICLASS classification number can range from 12 to 30 digits . The first 12 digits are universal code that can be applied to any part. Up to 18 additional digits can be used to code data that are specific to the particular company or industry. For example, lot size, piece time, cost data, and operation sequence might be included in the 18 supplementary digits. The component attributes coded in the first 12 digits of the MICLASS number are as follows:

58. 58 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

59. 59 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY One of the unique features of MICLASS system is that parts can be coded using a computer interactively. To classify a given part design, the user responds to a series of questions asked by the computer. The number of questions depends on the complexity of the part. For a simple part, as few as seven questions are needed to classify the part. For an average part, the number of questions ranges between 10 and 20. On the basis of responses to its questions, the computer assigns a code number to the part.

60. 60 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY CODE MDSI SYSTEM

61. 61 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY CODE MDSI SYSTEM The CODE system is a parts classification and coding system developed and marketed by Manufacturing Data System, Inc (MDSI), of Ann Arbor, Michigan . Its most universal application is in design engineering for retrieval of part design data, but also has applications in manufacturing process planning, purchasing, tool design, and inventory control. The code number has eight digits . For each digit, there are 16 possible values (zero through 9 and A through F) which are used to describe the parts design and manufacturing characteristics. The initial digit position indicates the basic geometry of the part and is called the major division of the code system. This digit would be used to specify whether the shape was cylinder, flat, block, or other. The interpretation of the remaining digits forms a chain-type structure. Hence the CODE system possesses a hybrid structure. 1 2 3 4 5 6 7 8 Major division Outer diameter or section Centre hole Holes (other than centre hole) Grooves, threads Miscellaneous Maximum outer diameter, or section across flats Maximum overall length

62. 62 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Implementation Phase Group technology has the following actions on the manufacturing process: Part Simplification Process Standardization Production Control Tighter Parts Control Close physical layout of machine groups Orderings tied to production

63. 63 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

64. 64 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Advantages of Group Technology The implementation of GT offers significant benefits across the entire enterprise: Reduced Setup Time:  Similar parts require similar setups. By processing a family of parts consecutively in a cell, setup times are dramatically reduced as machines require only minor adjustments between parts. Reduced Material Handling:  In a GT cell, machines are closely placed. Parts move very short distances, reducing handling time, cost, and the chance of damage. Shorter Lead Times & WIP:  With streamlined flow, parts move through the system much faster. This reduces Work-In-Process (WIP) inventory and shortens delivery times to customers. Improved Quality:  A cell is often managed by a small, dedicated team. This fosters ownership and accountability, making it easier to identify and correct quality issues at their source. Simplified Production Planning & Control:  Managing a few cells is far easier than scheduling hundreds of parts through a complex functional layout. Scheduling, monitoring, and control become more straightforward. Improved Tool & Fixture Design:  Standardized designs within a part family allow for the use of common, modular fixtures and tooling, reducing design costs and setup times. Enhanced Employee Morale:  Cell workers are cross-trained and see a product through from start to finish, leading to greater job satisfaction and a sense of accomplishment.

65. 65 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Limitations of Group Technology Despite its advantages, GT has some challenges: High Initial Implementation Cost:  The process of classifying and coding all parts, reorganizing the factory layout, and training personnel requires a significant upfront investment in time and money. Not Suitable for All Plants:  It is less effective for plants with a very high product mix and very low volume, where part similarity is low (e.g., a "job shop" making one-off prototypes). Vulnerability to Cell Breakdown:  If a key machine within a cell breaks down, the entire cell's production can halt, as the part family cannot be completed. (Redundancy or a "utility machine" is often needed). Difficulty in Part Family Formation:  Identifying the "right" part families and determining the optimal cell configuration can be a complex task. Resistance to Change:  Transitioning from a traditional functional layout to a cellular system represents a major cultural shift and can face resistance from employees and management.

66. 66 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Companies provide GT services/systems These are typically consulting firms and software developers that help manufacturers implement GT. Bureau van Dijk (formerly OIR):  The original developer of the MICLASS (Metal Institute Classification) system, a famous GT coding system. Various Lean Manufacturing & Industrial Engineering Consultancies:  Many consulting firms specialize in helping companies implement cellular manufacturing, which is the physical manifestation of GT. ERP & PLM Software Vendors:  Modern Enterprise Resource Planning (ERP) and Product Lifecycle Management (PLM) software often includes modules for part classification and family management, which are digital implementations of GT principles (e.g., SAP, Siemens Teamcenter).

67. 67 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Applications of Group Technology GT principles are applied in various manufacturing and engineering functions: Process Planning:  To create standard process plans for part families. Machine Cell Design:  To logically group machines for efficient production. Product Design:  To retrieve existing part designs, promoting part standardization and reducing design duplication. This is a key principle of  Concurrent Engineering . Estimating & Costing:  To provide more accurate cost estimates based on family data. Production Scheduling:  To schedule parts by family, optimizing the flow through cells. Companies known for using GT/Cellular Manufacturing principles (International) John Deere:  The agricultural machinery giant has long used GT and cellular manufacturing to produce a high variety of tractors and components efficiently. Caterpillar Inc.:  Uses GT to manage the production of a vast array of heavy machinery components. Boeing:  Applies GT principles in the manufacturing of aircraft components, where there are many similar structural parts. Toyota:  As a pioneer of the Toyota Production System (the foundation of Lean), cellular manufacturing (a direct application of GT) is a fundamental part of their operations. Harley-Davidson:  Famously reorganized its production into product-focused cells as part of its turnaround strategy, dramatically improving efficiency and quality. Many Automotive Sub-Suppliers:  Companies producing gears, shafts, pistons, and electronic components extensively use GT to serve major automakers.

68. 68 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY Major Indian Companies Known for Implementing GT 1. Automotive and Auto Components This sector is the largest adopter of GT and cellular manufacturing in India. Tata Motors:  As a leading automotive manufacturer, Tata Motors has extensively implemented cellular manufacturing in its plants (e.g., Pune, Jamshedpur) for producing engines, transmissions, and various sub-assemblies. They group similar components (e.g., gears, shafts, housings) into part families and produce them in dedicated cells. Mahindra & Mahindra (Automotive Division):  Known for its robust manufacturing system, Mahindra uses GT cells for machining components for their SUVs and tractors. This helps them manage a high mix of products efficiently. Ashok Leyland:  This major commercial vehicle manufacturer has implemented GT to streamline the production of engine parts, axle components, and other critical assemblies. TVS Motor Company:  A leader in two-wheeler manufacturing, TVS is a proponent of Lean and has numerous manufacturing cells for machining crankcases, cylinders, and other bike components. Sundaram-Clayton Ltd. (Brakes Division):  This company is a well-documented example from the 1990s. They implemented GT to reduce lead times and setup times for producing aluminum castings and machined brake components, achieving significant improvements. Bharat Forge:  One of the world's leading forging companies, Bharat Forge uses the principles of GT to organize its massive production floor. They group similar forged components (based on size, material, and process route) to optimize the use of their large presses and machining lines.

69. 69 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 2. Aerospace and Defense This industry deals with high-precision, low-volume, high-variety parts, making GT an ideal strategy. Hindustan Aeronautics Limited (HAL):  HAL has implemented GT in various divisions (e.g., Engine Division, Bangalore) to manufacture a vast family of aircraft components. Grouping similar structural parts, discs, and blades into families allows for standardized processes and reduced setup times. Bharat Electronics Limited (BEL):  While more focused on electronics, their mechanical manufacturing units for chassis and enclosures benefit from cellular layouts based on part similarity. 3. Electrical and Heavy Engineering Bharat Heavy Electricals Limited (BHEL):  BHEL has implemented GT in its plants (like Trichy, Haridwar) for machining components for turbines, boilers, and switchgears. Producing large, complex parts in low volumes, GT helps them manage complexity by grouping parts like nozzles, valves, and seals into families. Crompton Greaves (Now CG Power and Industrial Solutions):  Has used cellular manufacturing for producing electric motor components and switchgear parts. 4. Consumer Goods and Durables Asian Paints:  While primarily a process industry, their packaging lines and container manufacturing operations use GT principles to group similar sizes and types of containers for efficient filling and labeling. Various CNC Job Shops and SMEs:  Thousands of small and medium-sized enterprises (SMEs) serving larger OEMs (Original Equipment Manufacturers) have been compelled to adopt cellular manufacturing to meet the quality and delivery demands of their clients. These are often unsung heroes of GT implementation in industrial clusters like Pune, Chennai, Coimbatore, and Ludhiana.

70. 70 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY How Indian Companies Typically Implement GT The implementation in India often follows a pragmatic path: Driven by Lean Initiatives:  GT is rarely implemented in isolation. It is almost always a core component of a broader Lean Manufacturing or Operational Excellence program. Focus on Production Flow Analysis (PFA):  Many companies start with PFA because it's less data-intensive than a full-blown classification and coding system. They analyze their process route sheets to identify parts that can be grouped together. Pilot Projects:  Companies often start with a pilot cell in one department to demonstrate the benefits and build confidence before a plant-wide rollout. Overcoming Challenges:  Indian implementations often have to overcome specific challenges like: Resistance from a traditional workforce. Initial capital investment  for machine relocation. Lack of in-house expertise  in GT system design.

71. 71 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY System Origin Digits Focus Most Suitability Opitz Germany 9 Design geometry General manufacturing MICLASS Netherlands 12-30 Comprehensive Complex parts CODE USA 8 Manufacturing Production planning KK-3 Japan 21 Very detailed Automotive/precision DCLASS USA Variable CAD integration Modern CAD environments CUTPLAN Sweden 8+ Process planning Machine shops COMPARISON of GT

72. 72 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY COMPARISON of GT OBSERVATIONS Opitz gives you a quick, standardized code that anyone familiar with the system can interpret MICLASS provides the most detailed digit-based classification, capturing almost every feature CODE focuses on what you need to MAKE the part - very practical for production KK-3 is the most comprehensive digit system, capturing everything including heat treatment details DCLASS is the most modern - it doesn't use digits but extracts features directly from CAD and generates actionable manufacturing data CUTPLAN immediately tells you HOW to make the part and HOW MUCH it will cost

73. 73 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY DECISION FRAMEWORK Step 1: Assess Your Situation Ask yourself these key questions: A. Company Size & Complexity How many unique parts do you have? (100s, 1000s, 10,000s+) How many employees in engineering/manufacturing? Single facility or multiple plants? B. Technical Requirements Part complexity level? (Simple, moderate, highly complex) Precision requirements? (Standard, high precision, ultra-precision) Design variation? (High standardization vs. custom designs) C. Current Technology Do you use CAD software? Which one? CAM/CNC equipment level? ERP/PLM system in place? D. Primary Goals Reduce design time? Improve manufacturing efficiency? Better cost estimation? Inventory management? All of the above?

74. 74 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY INDUSTRY-SPECIFIC RECOMMENDATIONS 1. AUTOMOTIVE INDUSTRY Recommended Systems: KK-3 or MICLASS Why? High production volumes require detailed classification Complex assemblies with many part families Stringent quality and traceability requirements Need for platform sharing and standardization Use Case Example: Large OEM (Toyota, GM, Ford): KK-3 21-digit comprehensive coding Handles complex geometries Integrates with supply chain management Supports lean manufacturing initiatives Tier 1/2 Suppliers: MICLASS Flexible expansion (12-30 digits) Works across different customer requirements Good for mixed product lines Implementation Strategy: Start with high-volume part families (brackets, fasteners) Expand to powertrain components Finally include body panels and trim Timeline: 12-18 months for full implementation Expected ROI: 30-40% reduction in part variety 25% faster design retrieval 15-20% manufacturing cost savings.

75. 75 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 2. AEROSPACE & DEFENSE Recommended System: MICLASS + DCLASS Why? Extremely tight tolerances and specifications Extensive documentation requirements Long product lifecycles (20-30 years) High part complexity and low volumes Regulatory compliance (AS9100, ITAR) Use Case Example: Boeing, Airbus, Lockheed Martin MICLASS for comprehensive part classification DCLASS for CAD integration and automated documentation Custom extensions for material certifications and heat treatment Special Considerations: Must track material lot numbers Heat treatment batch tracking NDT (Non-Destructive Testing) requirements Configuration management for variants Implementation Strategy: Focus on critical flight hardware first Classify structural components (frames, ribs, spars) Expand to systems components (hydraulics, electrical) Timeline: 18-24 months with phased rollout Expected Benefits: 100% traceability for safety-critical parts 35% reduction in engineering change orders Faster obsolescence management Improved supplier quality

76. 76 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 3. GENERAL MACHINING / JOB SHOPS Recommended System: OPITZ or CODE Why? Wide variety of parts, low to medium volumes Need simple, quick classification Limited IT infrastructure Fast quote turnaround essential Mix of industries served Use Case Example: Small-Medium Job Shop (10-100 employees) OPITZ: Easy to learn and implement Can be done manually or with basic software Helps group similar jobs for efficiency Production Shop with CNC Equipment CODE system: Direct link to manufacturing processes Helps with capacity planning and scheduling Better cost estimation Implementation Strategy: Start with existing part database (even Excel works initially) Train 1-2 people as GT champions Classify top 20% of parts (80/20 rule) Gradually expand over 6-12 months Use simple software or even spreadsheets initially Expected Benefits: 20-30% faster quote generation Better machine utilization (15-25%) Reduced setup times (20-30%) Improved on-time delivery Cost: Low ($5,000-$25,000 for software + training)

77. 77 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 4. ELECTRONICS MANUFACTURING Recommended System: DCLASS or Custom System Why? Rapid design cycles and product updates High part variety, high volumes PCB-focused with unique requirements Need for BOM (Bill of Materials) integration Component obsolescence management critical Use Case Example: Consumer Electronics (Samsung, Apple suppliers) DCLASS integrated with Altium/Cadence Automatic classification from PCB design files Links to component databases ( Digikey , Mouser) Special Features Needed: SMT component classification (resistors, capacitors, ICs) PCB complexity levels (2-layer, 4-layer, flex, rigid-flex) Connector families Housing/enclosure variants Implementation Strategy: Integrate with existing PLM system (Arena, Windchill) Classify passive components first (easiest, highest volume) Active components and ICs Mechanical components (housings, brackets) Timeline: 6-12 months Expected Benefits: 40% faster component selection Reduced obsolescence issues Better vendor management 25% reduction in unique BOM items

78. 78 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 5. MEDICAL DEVICES Recommended System: MICLASS + Custom Extensions Why? FDA/ISO 13485 compliance requirements Extensive documentation and validation Mix of high precision and biocompatible materials Long product lifecycles with design controls Traceability critical Use Case Example: Orthopedic Implant Manufacturer MICLASS for geometric classification Custom codes for biocompatibility Material certification tracking Sterilization method classification Special Codes Needed: Material biocompatibility class (ISO 10993) Sterilization method (autoclave, EtO , radiation) Regulatory class (Class I, II, III) Patient contact type (implant, external, short-term) Implementation Strategy: Start with design history files (DHF) organization Classify existing validated designs Create design families for 510(k) submissions Link to device master records (DMR) Timeline: 12-18 months with validation Expected Benefits: Faster 510(k)/PMA submissions Better design control compliance 30% reduction in validation testing (family approach) Improved supplier audits

79. 79 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 6. HEAVY EQUIPMENT / CONSTRUCTION Recommended System: CODE or CUTPLAN Why? Large, complex weldments and fabrications Mix of castings, forgings, machined parts Focus on build-to-order and customization Long product lifecycles Service parts management critical Use Case Example: Caterpillar, John Deere, Komatsu CODE for manufacturing focus Emphasis on welding/fabrication processes Integration with MRP for service parts Special Considerations: Weldment classification (structural vs. light fabrication) Large casting families (engine blocks, frames) Hydraulic component standardization Field serviceability requirements Implementation Strategy: Focus on high-runner service parts first Classify hydraulic components (cylinders, valves) Structural fabrications and weldments Expand to powertrain components Timeline: 12-18 months Expected Benefits: 35% reduction in service part inventory Better aftermarket support 20% faster custom configuration quotes Improved parts interchangeability across models

80. 80 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 7. PLASTIC INJECTION MOLDING Recommended System: Custom Opitz Variant Why? Unique classification needs (cavities, gating, draft angles) Mold design reuse critical Material families important (ABS, PC, PP, etc.) Cycle time and tooling cost estimation Use Case Example: Consumer Products Manufacturer Modified Opitz focusing on molding parameters Mold complexity classification Part geometry for moldability Special Codes Needed: Number of cavities (single, multi-cavity, family mold) Gate type (edge, pin, hot runner) Undercuts and side actions Material shrinkage characteristics Cosmetic requirements (Class A surface, textured) Implementation Strategy: Classify existing mold library first Group parts by similar mold features Standardize gating and cooling Create design guidelines for moldability Timeline: 6-9 months Expected Benefits: 40% reduction in mold design time Better mold cost estimation (±10%) Reduced tooling inventory Faster quote-to-production cycle

81. 81 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY 8. SHEET METAL FABRICATION Recommended System: CODE or Modified Opitz Why? Focus on bending, punching, laser cutting operations Material thickness and type critical Nesting and material utilization important Simple geometry but high variety Use Case Example: Sheet Metal Job Shop CODE system emphasizing fabrication processes Link to nesting software ( SigmaNEST , etc.) Bend sequence optimization Special Codes Needed: Material thickness ranges Number and complexity of bends Hole patterns and features Welding requirements Finishing (powder coat, plating, painting) Implementation Strategy: Classify by material type and thickness Group by fabrication complexity (simple/medium/complex) Link to laser cutting programs Integrate with ERP for costing Timeline: 4-6 months Expected Benefits: 30% better material utilization 25% reduction in setup times Faster job grouping for batch processing Improved delivery times (15-20%)

82. 82 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

83. 83 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY

84. 84 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM GROUP TECHNOLOGY THANK YOU Questions & Queries THANK YOU Questions & Queries