Roll Flow Schedules Creating Negative Or Illogical Build Sequences For Flow Schedules (Doc ID 2091392.1)

Last updated on JULY 14, 2017

Applies to:

Oracle Flow Manufacturing - Version 12.2.1 to 12.2.5 [Release 12.2]
Information in this document applies to any platform.

Symptoms

ACTUAL BEHAVIOR

After a Roll Forward of Flow Schedules, schedules that have been missed (not completed) have a negative build sequence.

EXPECTED BEHAVIOR

Build sequence should be positive (and correct)

STEPS

The issue can be reproduced at will with the following steps:
Process to recreate negative build sequences.
1. Each week Flow Lines are scheduled for Monday through Friday up to the line’s daily capacity.
2. On Monday flow schedules and build sequences are all positive and what is expected.
3. If flow schedules for Monday are missed, the remaining quantities are rolled forward using the Roll Flow Schedules concurrent request with submission parameters:
a. Option: Roll with Details
b. Output: Report and Update
c. From Start Date (System Date – 3 days) cover weekends
d. From End Date (System Date – 1 day)
e. To Start Date: (System Date)
f. To End Date: Null
g. Lines From: Null
h. Lines To: Null
i. Items From: Null
j. Items To: Null
k. Category Set: Null
l. Categories From: Null
m. Categories To: Null
4. The roll forward process results in overloading the line and the rest of the week
5. As the roll forward program creates new build sequence numbers for flow schedules which were rolled and existing flow schedules, negative build sequences are assigned to flow schedules that were originally scheduled but the line will be over capacity by the time that schedule should be built on the line.
6. We have also observed scenarios where the line is overloaded for the day but not for the week and the build sequences continue to be positive and will stay positive until a roll forward process overloads the line for the balance of the week.
7. Negative build sequences are not acceptable because flow schedules need to be sorted by build sequence and the negative build sequences are sorted before the missed roll forward flow schedules from previous days. Also the order is inverted on the negative flow schedules. The build sequence appears to retain the initial/correct order and then a negative applied.


Additional comments about rolling forward missed flow schedules:
1. The act of rolling forward flow schedules should only be concerned with changing the date.
2. The Roll forward program should not be concerned about capacity checks and inserting negatives.
3. Once a line has been sequenced for the week, the roll forward should not change that order/sequence. The build sequence numbers can change, but the overall order should not change
4. The oldest missed flow schedules should be the earliest build sequences
5. Negatives only inject confusion and prevent sorting correctly.



Cause

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