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I see a strange "feature" in AX 2012 capability planning function, when running operation scheduling in master planning.
Let's say I have a resource group DM, with 3 drilling machines. One of them can drill material up to 10mm, and the other two can drill up to 20mm.
I create two features called "Drilling <10" and "Drilling <20" and assign Drilling <10 to resource M1, M2 and M3 and Drilling <20 to M2 and M3.
In my routes for 11 to 20 mm items, I add the "Drilling <20" resource requirement, and on items up to 10mm I add "Drilling <10".
Let's say I have a scenario with sales orders for only 11 to 20 mm items.
When running master planning (in operations scheduling mode) I get planned productions orders and capacity reservations on resource group DM, not on resource M2 and M3. This cannot be correct, AX knows that only machine M2 and M3 can drill the holes. Of course AX is using the calendar from the resource group, but that will also cause problems when firming the planned order. The capacity on group level could be sufficient but M2 and M3 could be full.
What am I missing? I hope I don't get the answer "You must use job scheduling in master planning" since this will take too long time to run.
Hi Henrik, I don't know the answer, but I've just started to look at using Capabilities for a project I'm working on, but Iexpect that the answer is the one you don't want. Capabilities look to me like the Task Group that was available in AX2009 - and they only worked with job scheduling.
Hi TIm, It cannot be that bad. When they allowed moving resource from one group to an other, the group concept won't be logic to use, in my opinion.
Are the resource groups stated as a requirement or are you only using the capabilities?
And how long does your planning take to run?
I have a customer planning close up to a thousand production orders in 7 levels with primary and secondary resources with capabilities using job planning... It takes a full MRP 1 hour...
The resource group is not stated in the route, only the capability.
We've just upgraded to AX2012. In 2009 the coverage time fence was set to 196 days and 196 days finite capacity. It took about 20 minutes. In AX2012 I've had to reduce to 90 days (60 days finite capacity). Even though I reduced the time fence, it takes about 1 hour, 800 order rows, 2500 forecast rows, 9000 items in 5 levels.
1. How many helpers are you using and how many cores on your AOS?
2. What is your batch size set to? (Master planning > Setup)
3. What timeout settings do you have on your scheduling settings (Sys admin > Setup > Scheduling)
4. Are you processing and actually using action messages and futures? Even though they are turned off in master plan they still get processed. I have a tip to not getting them processed if you're not using them.
1. Only one helper, if more the batchjob hangs. 8 cores.
2. Batch size? don't know where to set that
3. Timeout setting? don't know where to set that
4. Yes, we have enabled both futures and actions and we use both types on a daily basis.
2. This is the number of tasks given to each parallel processing task (helper). I believe it is located in the master planning parameters.
3. There are two settings. One for general processing and one for optimization. I normally turn these down to 2 and 0. Optimization is very process intensive and can take a long time. You find these settings in either sys admin or org. manag. I never get these right. Under setup. Quite far down the list. Scheduling parameters.
4. Most times I find it not necessary to use these to the extent of the horizon. Maybe just 2x the longest lead time... These aren't very much the issue... You can check the processing time for all of these under the master plan statistics.
Sorry, in TEST-environment it was set to 90 days coverage and 60 days finite capacity, in PROD I use 150 (60). In PRD that plan takes about 1 hour.
I tried changing to 90 days coverage, 60 days finite capacity, and futures also set to 90 (in PROD). With job scheduling it took only, 15 minutes. Futures only took 2 minutes. As, you said the future messages could be the "problem".
2. Aha, you mean that. It's set to 50 and use of cache is set to Maximum.
3. They were both inactivated. You think I should activate and set to 2 and 0? I'll try that.
4. Actions just take 1 minute but futures takes 18 minute. I have set futures = coverage (right now 90 days). The lead time for material purchase is about 100 days, and average production lead time is 15 days.
How long does it take to run a job scheduling as opposed to the operation scheduling you're doing now?
2. You could increase them to see if that has any effect. Good with Max cache if plan is run outside business hours.
3. Try activate and set what I have suggested. Maybe start with 5 and 0. This might also solve your deadlock with more helpers...
4. Futures are almost like a full MRP run through, while action messages are only one/two parameter lookups (lead time + calendars)
Check you usage of futures. No use in reporting something in 90 days is going to be delayed of you only focus/able to make changes in the next 30 days and that is what your sales activities entail. It shouldn't be any longer then the longest time you can perform changes to organisation or effects on outbound sales. But also depend on purchase lead times. Tough thing to adjust if you're not certain.
We have an other problem after the upgrade (which is reported to MS). We get a lot of "Not enough capacity" and this problem increased when I was running job-scheduling, so right no I cannot compare the times I'm afraid.
We've always used finite capacity the whole coverage period and used futures messages to se if we manage to deliver on forecasts up to 1 year a head. This plan run every night, but maybe it's better to use finite capacity for the time period we can affect, lets say 60-90 days, and then run a long term plan once a week with finite capacity and futures for the whole period. Or maybe use infinite capacity and say if the resources are overloaded 6 months a way, it's time to hire more people or buy new machines.
Are all your calendars in order?
What is the load on your resources any that is 100% booked?
The calendars are ok, however they are divided into short periods due to breaks, I've read it's not the best configuration. We have this problem when rescheduling jobs for a certain resource, in Dispatch form, as well (not only MRP, maybe it's two different problem). The dispatch form problem occur when process time is planned on one day and the setup time should be planned on a day before where there is no capacity. In this form we reschedule filter on process job (not setup) and then reschedule (normally, forward from planning date). In some way I can understand why the problem occurs, we tell the system to reschedule on process job (even though there is a setup job), AX tries to schedule the job as early as possible, and finds free capacity exactly when the calendar "opens", when the setup job is to be scheduled there is no open calendar. Hard to explain, and I really think AX should schedule the setup job first even though we plan on process jobs.
Regarding same problem in MRP I now tried with infinite capacity, which seems to work. I don't get the messages. But shouldn't MRP change direction if it cannot find capacity when it's going backwards until today. In that case I don't se how the capacity could run out.
Calendars are part of the issue, but I am guessing it is your split calendar and how AX is trying to efficiently schedule based upon reduction of gaps between operations - there was an early issue in AX2012 where it would start today then wait 180 days then start operation 2 which was due to how it was scheduling and we had configured it, and this is the key, there are lots of configuration inputs impacting this. Anyway try some checking on this blog:
I agree with Tim and the job scheduling requirement to hit capabilities.
Ah... Got any answer from MS on this issue?
For the issue with planning direction and finding capacity. Try increase the optimization timeout to 2. See if it tries to improve it and move some stuff around.
How far into the future have you created calendars?
The answer we got from MS was that they thought we should move the start of the production order so the setup time would "fit". Not an answer we accepted so they will proceed.
I tried your suggestion about increasing the timeout to 2 sec. Now everything works much better. With tall he changes you have suggested the MRP in job scheduling mode, takes about 15 minutes! Thanks a lot for your help!
I have found what cause the error message "Not enough capacity". As I mentioned in an earlier post, our calendars are split in many lines to match the work schedule. Typically it could look like this:
06.00-09.00 - 100%
09.00-09.30 - 0%
09.30-12.00 - 100%
12.00-12.30 - 0%, and so on.
When I removed the rows with 0% efficiency all problems were gone. No I can reschedule forward and backward, and no issues with capacity.
Thanks for all your suggested solutions, I've learned a lot about planning, tuning and logging...
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