Manufacturing Plan (MRP) Is Creating New Planned Orders For Some Master Plan (MPP) Items (Doc ID 1495695.1)

Last updated on MARCH 29, 2016

Applies to:

Oracle Advanced Supply Chain Planning - Version 12.1.3 to 12.1.3.7 [Release 12.1]
Information in this document applies to any platform.

Symptoms

Users are on 12.1.3.7 code line after upgrading from 11.5.10.2. They use 64 bit AIX MBP executable MSONWA64/MSCNWA64 120.16.12010000.69 which comes with this code with no one offs. The problem also did not occur in 11.5.10 but does on 12.1.3.

Background:

A. In 11.5.10 they have DRP plans (what they were called in this APP version), Production/MPS plans and Manufacturing/MRP plans and here's how they defined the usage:

- We are using MPS/Production plan only for the top level items (Finished Goods).
- We are using DRP plan for the top level items and assemblies (Finished Goods and Subassemblies).
- We are using MRP/Manufacturing plan to obtain the material requirements for manufacturing those top level items and Subassemblies (Buy Item).

Items in the DRP plan were setup as DRP/MPS planned in the Org item attributes. They fed the MPS/Production plan to the DRP plan and the DRP plan to the MRP/Manufactuing plan as demand schedules and they had no problems with this scenario back in 11.5.10

B. Now they've upgraded to 12.1.3 and latest VCP code 12.1.3.7. In R12 DRP was broken out separately for Distribution Planning and in ASCP the plan names form this was changed from a Distribution Plan to a Master/MPP plan. When they migrated the data then for items that used to be DRP/MPS planned, these became MPP/MPS planned in the item attributes. So based on this their usage of the plan types changed to the following:

- We are using MPS/Production plan only for the top level items (Finished Goods).
- We are using Master/MPP plan for the top level items and assemblies (Finished Goods and Subassemblies).
- We are using MRP/Manufacturing plan to obtain the material requirements for manufacturing those top level items and Subassemblies (Buy Item).

C. What they have found in 12.1.3 is when they run the Master/MPP plan using End Item Substitution, the output is not a problem and the substitution works just fine. However when they attach the Master/MPP plan as a demand schedule to the Manufacturing/MRP plan, the Manufacturing plan is changing the demand for the MPP end item from the substitute back to the original forecast item. When this happens, it also generates new planned orders for the MPP item in the Manufacturing plan and this should not occur. Example:

There's two items in Org A01:AVC (Org Id = 101)
JMPrimary - This is the primary item - MPS/MPP Planned
JMSubst - This is End Item Substitute - MPS/MPP Planned

1. When the Master/MPP plan is run with MDS Demand Schedules here's the output and note the end item substitution change and the fact their are firm wip jobs for the substitute already released:

Org Item Firm Order Type Sugg Due Date Qty/Rate
TST:M1 JMPrimary Sales order MDS 7/10/2012 0:00 -5
TST:M1 JMPrimary Sales order MDS 7/10/2012 0:00 -100
TST:M1 JMPrimary Sales order MDS 7/10/2012 0:00 -3
TST:M1 JMPrimary Manual Demand 7/10/2012 23:59 0
TST:M1 JMPrimary On Hand 7/11/2012 10:25 117
TST:M1 JMSubst Manual Demand 7/16/2012 0:00 -6
TST:M1 JMPrimary Manual Demand 7/16/2012 0:00 -9
TST:M1 JMSubst * Work order 8/1/2012 8:06 10
TST:M1 JMSubst Manual Demand 8/20/2012 0:00 -6
TST:M1 JMSubst * Work order 9/5/2012 8:10 17
TST:M1 JMSubst Manual Demand 9/17/2012 0:00 -15

We did notice end item substitution has occurred and there are 2 firm wip jobs that will cover all the demand for the substitute. This output for the Master/MPP plan is fine and not a problem. But notice there are no planned orders for either of the above items

2. When the Master/MPP plan is fed as a demand schedule to the Manufacturing/MRP plan, this is where the substitute item demand is changed back to the original primary item demand and because of this, there's not enough available supply for primary item = TC-P60ST50X and thus planned orders are created to satisfy. Two things here:

a. The demand should not be changed in the Mfg/MRP plan for an MPS/MPP planned item
b. There should not be new planned orders created in Mfg/MRP plan for an MPS/MPP planned item

Here's the supply demand for the Mfg/MRP plan for these two items:

Org Item Firm Order Type Sugg Due Date Qty/Rate
TST:M1 JMPrimary Sales order MDS 7/27/2012 23:59 -3
TST:M1 JMPrimary Manual Demand 7/27/2012 23:59 -15
TST:M1 JMPrimary Manual Demand 7/27/2012 23:59 0
TST:M1 JMPrimary Sales order MDS 7/27/2012 23:59 -5
TST:M1 JMPrimary Sales order MDS 7/27/2012 23:59 -100
TST:M1 JMPrimary On Hand 7/30/2012 0:00 117
TST:M1 JMPrimary Planned order 7/30/2012 18:45 6
TST:M1 JMSubst * Work order 8/1/2012 8:06 10
TST:M1 JMPrimary Manual Demand 8/20/2012 0:00 -6
TST:M1 JMPrimary Planned order 9/5/2012 8:04 6
TST:M1 JMSubst * Work order 9/5/2012 8:10 17
TST:M1 JMPrimary Manual Demand 9/17/2012 0:00 -15
TST:M1 JMPrimary Planned order 3/31/2013 23:59 15

Notice the 3 planned orders created for primary item = JMPrimary. Notice there are no demands now for the substitute item = JMSubst but only for primary item = JMPrimary. Also note since the WIP jobs for the substitute are firm they have action of none but they just peg to excess

Things we tried:
=============
We found if users use a Production/MPS plan for the above items, this does not have a problem when attached as demand schedule to Mfg/MRP plan

Cause

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