E1: 34: Master Planning Schedule - Multiple Plant - R3483 Triggers Planning Messages that Are Not Meeting Future Demand (Doc ID 2834517.1)

Last updated on JANUARY 19, 2022

Applies to:

Symptoms

When planning the messages for a manufactured top parent item that does not have the Minimum Order Quantity defined, the system triggers O - order messages, D - defer messages, L or G messages but the supply messages are not enough, therefore the Quantity Available at the end of the planning horizon goes negative.
This occurs when the demand is generated by both W line type sales order detail lines and forecast demand and if some of the related orders attached to the sales order detail lines are past due.

The issue can be reproduced at will with the following steps:

1. P4101 / P41026 – Define a parent item (Stk Ty = M, Ln Ty = W)
2. P41026 – Addl Sys Info tab - Set the parent item with OPC = 1 – Lot for Lot, Planning Fence Rule = C, Planning Fence = 60 day, Freeze Fence = 30 days, Leadtime Level = 20 days, Fixed leadtime
3. P41026 – Quantities tab – Minimum Reorder Quantity, Maximum Reorder Quantity, Multiple Order Quantity and Safety Stock = blank
4. P3002 / P3003 – Create BOM and Item Routing for parent item
5. P3460 – Create weekly forecast records for the parent item; Set Requested forecast quantity to either 3250 EA or 2600 EA.
6. P4210 – Create 4 W line type sales orders having 2 sales order detail lines each; all sales orders have future dates set for Requested Date, Scheduled Pick Date, Promised Ship Date and Promised Delivery Date:
   SO # 1: Requested Quantity = 7488 EA (first sales order detail line) and 7488 EA (second sales order detail line), respectively
   SO # 2: Requested Quantity = 7800 EA and 7800 EA, respectively
   SO # 3 and SO # 4: Requested Quantity = 7488 EA and 7488 EA, respectively
7. P48013 – Note the WO numbers generated through W line type sales orders
   Both WO # 1 and WO # 2 related to SO # 1 have the Quantity Ordered = 7488
   WO # 3 related to SO # 2: Quantity Ordered = 15600 EA
   WO # 4 related to SO # 2: Quantity Ordered = 14976 EA
   WO # 5 related to SO # 3: Quantity Ordered = 14976 EA
   WO # 6 related to SO # 3: Quantity Ordered = 2600 EA
   Both WO # 7 and WO # 8 related to SO # 4: Quantity Ordered = 2600 EA
8. BV: R3483 – Data select the parent item and B/P; make sure MRP is run with a past due bucket to include the past due supply orders correctly
9. P3411 – Review the MRP messages:
   Two T - Past Due Order messages for the 2 past due orders WO # 1 and WO # 2 related to SO # 1
   Five D – Defer messages for WO # 4 related to SO # 2, WO # 5 & WO # 6 related to SO # 3 and WO # 7 & WO # 8 related to SO # 4.
   One G - Increase Order Quantity to message is triggered against WO # 6 related to SO # 3; Required Quantity = 14976 EA
   and
   one L - Decrease Order Quantity to message is generated against WO # 7 related to SO # 4 for a Required Quantity = 3250 EA
   The system completely disregards WO # 3 related to SO # 2 and does not trigger any action messages against it.
   The system also generates 25 O – order messages for Required Quantity set to either 3250 EA or 2600 EA, to meet the future forecast demand
10. P4021 – The Quantity Available at the end of the planning horizon is – 13650 EA
11. P3413 – Time series show one +PLO bucket of 7800 EA and 5 buckets of 13000 EA each. The planning results are incorrect
     

Changes

Cause

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