Integrated setup planning and operation sequencing (ISOS) using genetic algorithm

Process planning is an essential component for linking design and manufacturing process. Setup planning and operation sequencing are two most important functions in the implementation of CAD/CAPP/CAM integration. Many researches solved these two problems separately. Considering the fact that the two functions are complementary, it is necessary to integrate them more tightly so that performance of a manufacturing system can be improved economically and competitively. This paper presents a generative system and genetic algorithm (GA) approach to process plan the given part. The proposed approach and optimization methodology analysis constraints such as TAD?(tool?approach?direction), tolerance relation between features and feature precedence relations to generate all possible setups and operations using workshop resource database. Tolerance relation analysis has a significant impact in setup planning for obtaining the part accuracy. Based on technological constraints, the GA algorithm approach, which adopts the feature-based representation, simultaneously optimizes the setup plan and sequence of operations using cost indices. Case studies show that the developed system can generate satisfactory results in optimizing the integrated setup planning and operation sequencing in feasible condition.