Automated Process Planning

This application area focuses on automatically generating and adapting manufacturing process plans directly from product and production data. Instead of relying on slow, expert-intensive manual planning, systems ingest CAD/PLM models, machine capabilities, material data, and historical process outcomes to propose detailed routing, operations, and parameter settings. They can recompute plans quickly when designs, resources, or constraints change, drastically reducing engineering effort and lead time from design to shop-floor execution. AI is applied to learn process models, optimal machine settings, and topology of manufacturing steps from historical data and simulations, replacing brittle, fixed rule systems. Data-driven models capture complex, nonlinear relationships between materials, processes, and quality outcomes, and can be re-trained or adapted when conditions shift. This enables more robust and flexible planning, supports mass customization, and improves consistency in quality and throughput across changing products and environments.

The Problem

Generate and re-optimize manufacturing process plans from product + plant data

Organizations face these key challenges:

1

Process plans depend on a few experts; planning becomes a bottleneck for quotes and launches

2

Re-planning after design ECOs or machine downtime takes days and introduces errors

3

Best-practice parameters live in tribal knowledge; quality drifts across shifts/sites

4

Routing and capacity decisions are made without feedback from actual yield/scrap/cycle-time data

Impact When Solved

Accelerated process planning cyclesEnhanced consistency across shiftsReduced rework and errors in production

The Shift

Before AI~85% Manual

Human Does

  • Creating routings and operation sheets
  • Validating feasibility through manual checks
  • Handling changes via emails and rework

Automation

  • Basic data entry from product designs
  • Static rule-based optimization
With AI~75% Automated

Human Does

  • Final approvals of process plans
  • Strategic oversight of manufacturing operations
  • Handling edge cases and exceptions

AI Handles

  • Generating optimized process plans
  • Learning from historical outcomes
  • Re-optimizing plans in real-time
  • Predicting outcomes based on past data

Solution Spectrum

Four implementation paths from quick automation wins to enterprise-grade platforms. Choose based on your timeline, budget, and team capacity.

1

Quick Win

Rulebook Routing Generator

Typical Timeline:Days

Implements a configurable ruleset to map part attributes (material, dimensions, tolerance class) and available workcenters into a draft routing with standard operations and default parameters. Planners review and edit the output, but the system standardizes templates and enforces basic constraints (machine capability, tooling availability, allowed sequences). Best for fast validation and establishing a baseline digital process planning workflow.

Architecture

Rendering architecture...

Key Challenges

  • Capturing tacit planning logic into maintainable rules
  • Keeping capability data accurate (machines, tooling, fixtures)
  • Handling exceptions (special processes, customer-specific requirements)
  • Versioning of routings/templates when standards change

Vendors at This Level

Small job shops (general)Contract manufacturers (general)Automotive tier suppliers (general)

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Market Intelligence

Technologies

Technologies commonly used in Automated Process Planning implementations:

Real-World Use Cases