Development of a Variant Process-Planning Tool: A Case Study

Purpose: This study addresses the development of a variant process planning tool, following the Knowledge-Based Variant Process Planning methodology, applied in a case study and presents the gains achieved. Methodology/Approach: Case study supported by six steps: (1) Feature Analysis, (2) Knowledge Retrieval, (3) Inference, (4) Plan Adaptation, (5) Knowledge Update, and (6) Plan Validation/Optimisation.. Findings: The implementation of the Knowledge-Based Variant Process Planning tool led to significant improvements: planner time reduced by 70%, analyst workload by 90%, and process plan errors to 0%. Results show this approach significantly improves process planning in customised production. Research Limitation/Implication: The limitations are associated with the specificity of the case study problem – the electric engine production systems. Originality/Value of paper: This study helps fill the gap in case studies on the Variant Process Planning approach, specifically for electric engine production systems, paving the way for similar companies to adopt Knowledge-Based Variant Process Planning.