ORIGINAL ARTICLE Optimization of operation sequencing in CAPP using simulated annealing technique (SAT) G. Nallakumarasamy & P. S. S. Srinivasan & K. Venkatesh Raja & R. Malayalamurthi Received: 13 November 2009 / Accepted: 4 October 2010 / Published online: 20 October 2010 # Springer-Verlag London Limited 2010 Abstract Computer-aided process planning (CAPP) is an important interface between computer-aided design (CAD) and computer-aided manufacturing (CAM) in computer- integrated manufacturing environment. A problem in traditional CAPP system is that the multiple planning tasks are treated in a linear approach. This leads to an over constrained overall solution space and the final solution is normally far from optimal or even non-feasible. The operation-sequencing problem in process planning is considered to produce a part with the objective of minimizing the sum of machine, setup and tool change costs. In general, the problem has combinatorial character- istics and complex precedence relations, which makes the problem more difficult to solve. In this paper, the feasible sequences of operations are generated based on the precedence cost matrix and reward–penalty matrix using simulated annealing technique (SAT), a meta-heuristic. A number of benchmark case studies are carried out to demonstrate the feasibility and robustness of the proposed algorithm. This algorithm performs well on all the test problems, exceeding or matching the solution quality of the results reported in the literature for most problems. The main contribution of this work focuses on reducing the optimal cost with a lesser computational time along with generation of more alternate optimal feasible sequences. The proposed SAT integrates robustness, convergence and trapping out of local minima. Keywords Operation sequencing . Simulated annealing . Computer-aided process planning (CAPP) . Operation sequencing . Heuristics 1 Introduction With the deep application of computer-aided process planning, a wealth of process data has been accumulated in the manufacturing enterprises. CAPP is considered the key technology for computer-aided design/manufacturing (CAD/CAM) integration. It consists of the determination of processes and parameters required to convert a block into a finished product. The process planning activity includes interpretation of design data, selection and sequencing of operation to manufacture the part, selec- tion of machines and cutting tools, determination of cutting parameters, choice of jigs and fixtures, calcula- tion of machining times and costs. To elucidate the process planning, parts are represented by manufacturing features. There are two basic approaches to CAPP, variant and generative. The variant approach uses group technology concepts like classification and coding sys- tems to select a generic process plan from the existing master process plans developed for each part family, and edits to suit the requirement of the part. In the generative approach, a process plan is generated by synthesizing the part data with the information from manufacturing databases and decision rules. In any CAPP system, G. Nallakumarasamy : K. Venkatesh Raja (*) Department of Automobile Engineering, K.S.R. College of Engineering, Tiruchengode 637215 Tamil Nadu, India e-mail: kvenkateshraja@hotmail.com P. S. S. Srinivasan Knowledge Institute of Technology, Salem, Tamil Nadu, India R. Malayalamurthi Mechanical Engineering, Government College of Engineering, Salem, Tamil Nadu, India Int J Adv Manuf Technol (2011) 54:721–728 DOI 10.1007/s00170-010-2977-8