Generating Production Routings Automatically

Our software classmate PLAN allows you to quickly and reliably generate production routings directly from CAD models,

providing a streamlined and automated process.

Kostenkalkulation Maschinenbau

Minimize the burden of work preparation.

A routing outlines the technical and economic sequence for executing work processes in production. By automating the creation of routings, your employees can devote more time to complex tasks. Furthermore, work planning is standardized and documented. The routing can be integrated directly into ERP or MES systems, enabling optimal utilization in digital workflows.

What are the advantages of automatically generating routings?

Saving Time

  • Automation instead of manual processes:
    Routings are generated directly from the CAD data – in a matter of seconds.
  • Fast change adaptation:
    Changes to the CAD model are automatically transferred to the routing, speeding up iterations.

Higher accuracy

  • Avoidance of human error:
    Automated processes minimize transmission and interpretation errors that can occur with manual input. No work step is forgotten.
  • Precise data integration:
    Dimensions, tolerances and material data from the CAD model flow precisely into the routing.

Consistency and standardization

  • Standardized processes:
    Routings are always created according to the same rules, which leads to a consistent result.
  • Standardization of production instructions:
    All departments receive standardized, clearly defined instructions.

Cost efficiency

  • Reduced planning effort:
    Employees can focus on more complex, value-adding tasks as less time is needed to create routings.
  • Less waste:
    More accurate plans and data lead to fewer manufacturing errors and reduced costs due to rework.

Improved collaboration

  • Better communication between departments:
    Design and production work with the same data and clearly understand requirements.
  • Easy integration into digital workflows:
    The routing can be integrated directly into ERP or MES systems, allowing information to flow seamlessly.

Support for Industry 4.0

  • Database for digital twins:
    Automated routings are a key component for the realization of digital twins.
  • A prerequisite for smart manufacturing:
    Integration into networked, intelligent manufacturing systems is made much easier thanks to standardized data.

generating production routings automatically

Generating production routings automatically – and beyond

classmate PLAN is a powerful tool that generates production routings automatically, but its capabilities extend beyond that.

To optimize the production process, classmate PLAN can be used to perform preliminary costing and work scheduling, providing valuable insights for efficient operations.

Creating routings with classmate PLAN – how it works in detail:

  • Geometric analysis

    The initial stage of the process involves the analysis of geometric data for the product to be manufactured. All details available in the 3D CAD model, including text, geometric information, and product manufacturing information (PMI), are automatically ascertained and can be used for automatic routing generation, eliminating the need for further manual entries.

    The rules developed by simus systems in classmate PLAN use this information to automatically determine the required work steps in a logical sequence, e.g., sawing, turning, milling. In the case of a turned part with a nut, classmate PLAN considers it more efficient to mill the nut after turning, rather than the other way around.

  • Connecting technology databases

    classmate PLAN provides access to technology databases that are tailored to your company’s specific requirements. These databases contain detailed information on the available machines, including their capabilities, tools, cutting parameters, materials, and other relevant details. A variety of versions can be calculated, including those for adding materials or comparing production processes across different sites. For companies with a low degree of vertical manufacturing, the option is available to set up “virtual” machine parks for their manufacturing partners. In this way, users can set up work plans for a partner in Germany or Asia, for instance, and not only can the various cost rates be calculated, but the different production methods can also be considered. While the 4-axis machining center could be used for this purpose, different manually-operated and simple machines might be used in China.

  • classmate PLAN determines processes and costs

    In a matter of seconds, the system identifies all potential manufacturing alternatives, taking into account the available parameters. The user is then able to select the alternative they wish to proceed with. Which option offers the lowest planned costs, the fewest machine changes, or the shortest cycle times?

    After calculating suitable machines, tools, and production times using the REFA method (a time study technique for determining manufacturing costs commonly used in Germany), classmate PLAN uses the hourly rates and factors stored in the technology database to determine the manufacturing costs and perform calculations on marginal and full costing. In addition to a comprehensive work plan and manufacturing cost information, users also receive guidance on the pricing strategies to adopt with manufacturing partners, whether based on full costs or marginal costs.

    The results can be presented visually on the graphic interface, classmate FINDER. You can save, search for, and compare multiple results. It is possible to compare the effects of different structural solutions, for example, a steel version followed by zinc coating in comparison to another version in stainless steel, or the effects of a fit or a change of radius. All of these changes can be implemented in a matter of seconds. The various versions can be performed in the CAD model or, if unavailable, in the Viewer, which is integrated in classmate FINDER and provides detailed information. Cost drivers or problem areas can be identified in list view, as well as through an automatic color coding in the viewer model.

  • Routing is generated and exported automatically

    From the user’s perspective, the most cost-effective or logical product version can be selected with ease. The determined sequence of technologies, machines, setups, and job times are transferred to a routing.

    This plan, along with the calculation results, can be exported from classmate PLAN to various systems, including Excel or ASCII/CSV via interfaces. Transmission of results to an ERP system is also a simple process. The routing can be transferred to SAP automatically via a standard simus interface.

More than 250 companies trust in simus systems on their way to data excellence

Körber

“For around 80 percent of our components, simus classmate calculates the manufacturing costs in advance with a hit rate of 95 percent. The designers build up their own knowledge and achieve their cost targets better without our support.”

“The fact that all material master data can be found quickly simplifies and speeds up the various maintenance and repair tasks.”

Koch Pac-Systeme

“We are very taken with the solution’s versatility and see classmate PLAN as a centerpiece for our efforts to make the manufacturing process leaner, more flexible and more cost effective.”

more testimonials »

Our simus classmate solution stands for data transparency and excellent data structure in the manufacturing industry.

Produktübersicht simus classmate

We prepare your data in a flexible, efficient and systematic way for the best possible use in sophisticated digital processes. Surprise yourself with the potential of your data! We are happy to advise you on designing innovative and sustainable data processes.

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