DRP Plan Goes Below Safety Stock/PAB (Projected Available Balance) For Rebalance Organizations (Doc ID 1483840.1)

Last updated on APRIL 04, 2025

Applies to:

Symptoms

Users are on 12.1.3 and have applied 12.1.3.3 patch 10389190 with no one offs using HP Itanium 64-bit MSONWHPIA64.exe 120.3.12010000.37. Users are running a DRP Plan with 150 daily buckets with 0 weeks. Safety stock does not seem to be honored early in the plan for items which leads to PAB (Projected Available Balance) going below safety stock. It does get better later in the plan but early on it's a concern. Example from an internal instance:

Item = JMDRP
Orgs involved:
M1 - Mfg Org Supplies M2 and M3
M2 - Dist Center - Demand org - this is where safety stock is setup - rebalance rule with M3
M3 - Dist Center - no demand - only has on hand - rebalance rule wih VXU
Hard INV safety stock qty = 10 in Org M2
On hand in Org M2 = 20


Demand/Supply Org M2 demand org:
=============================
Two forecast demands on 28-MAY-2012 Qty total = -7 (on hand/PAB down to 13)
Two forecast demands on 04-JUN-2012 Qty total = -5 (on hand/PAB down to 8 - now dipped below safety stock qty = 10 - here's where the problem shows up)
There's a requested inbound shipment qty = 2 showing up on 04-JUN-2012 but this shipment is way late in the future which I'll discuss later in Org M3
Then there's another forecast demand due on 11-JUN-2012 Qty = -13
There's a Planned Inbound Shipment for supply due on 11-JUN-2011 Qty = 13 (These two match up but PAB/Onhand is still +8 below Safety Stock = 10

We don't get back to safety stock = 10 until 02-JUL-2012 when we finally get the Qty = 2 from Org = VZU with planned inbound shipment. There seems to be an exception "Order lead time constraint" on this qty =2 planned inbound shipment but we don't understand why there could be one other than intransit which is 10 days. Plus other Planned inbound shipments get between these two rebalancing organizations faster than this qty = 2.

Demand/Supply Org M3 demand org:
=============================
On hand = 20 and remember there's no demand for this item in this Org, purely rebalance with Org M2
Requested outbound shipment qty = -2 on 25-MAY-2012. This would be for the 04-JUN-2012 need for the safety stock. However the Planned inbound shipment in this org isn't shipping until 22-JUN-2012 to arrive on 02-JUL-2012 with the 10 day intransit between the two orgs. But there's two earlier Planned inbound shipments on 01-JUN-2012 and 08-JUN-2012 for qty = 13 and 5 respectively. Why did this qty of 2 get pushed all the way out to 22-JUN-2012

If the problem were purely 10 day intransit, that would be acceptable, but inbound shipment won't be available until 02-JUL-2012 when it's needed on 04-JUN-2012. That's alot more than 10 days intransit

Other Setups/Profiles:
=================
Only had Demand Time Fence, Planning Time Fence, and Append Planned Orders enabled (found this was disabled but had then enable but didn't help) - Minimum Trip Utilization % = 0 - Maximum = 100. Plan has 150 daily buckets.
Trip Consolidation Days = 1
Infinite Time Fence Horizon Days = 365
End Item Substitution is Setup as well

MSC: Make Safety Stock Transient = No
MSC: Inventory Rebalancing Surplus Inventory Basis = 2 = Safety Stock
MSC: Ignore Safety Stock calculation inside Time Fence was NULL but we set it to No but it didn't help
MSC: Use FIFO Pegging = No, tried Yes but did not help

STEPS:
1. Run DRP plan
2. Review inbound/outbound shipments and find early in the plan, PAB goes below safety stock

Cause

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