Cost estimates to guide pre-selection of processes

A process is a method of shaping, joining or surface-treating a material. Process selection has three steps. The first is to identify from the ‘menu’ of all available processes, the subset, which can give a chosen material the desired shape with the desired detail, precision and finish. The second is to choose, from among these, the ones that will do so at the lowest cost. The final step is to investigate the most promising processes in depth, exploring considerations such as availability, in-house experience, safety and environmental issues. The first two steps can be thought of as process pre-selection. Components have to be assembled and finished to create products. Here too, the ability to rank by cost, however crudely, helps guide pre-selection. Cost models are reviewed from the perspective of material and process selection. An approximate model is useful provided it has generality—that is, it must allow comparison of very different processes. Many approaches fail in this. One that works, based on resource consumption, is developed here and its use for selection is illustrated. It has been implemented as part of a tool that allows rapid pre-selection from a database of 112 processes.