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Planning Worksheets - 'Calculating Regenerative Plan' suggests creating "non-expected" supply lines

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Posted on by BelenSA 50
Hello, 
 
We encountered an unexpected behavior while calculating the Regenerative Plan in the Planning Worksheets, which suggests creating /non-expected/ supply lines. We believe that this issue arises specifically when utilizing the /free entry/ item tracking code in the item, since we have not observed it with lot or serial number specific tracking configurations.
 
Here you can find the description of the use case, reproduced in a Docker BC 23.4 environment, in the Cronus Company. No custom extensions are installed.
 
New item with the following settings:
  • Replenishment system: Prod. Order
  • Manufacturing Policy: Make-to-order
  • Reordering Policy: Order
  • Reserve: Optional
  • Order Tracking Policy: None
  • Item Tracking Code: FREEENTRY
  • New Routing with a single routing line
Create a sales order with a single line for this item, quantity = 10
  • Release the sales order
  • Plan the sales order: Planning worksheets / Calculate Regenerative Plan / Filter by item 
  • Check the action message of the generated line and carry out action message.
  • A production order is created with a Prod. Order Line for the item Q=10
  • The sales order line quantity is reserved against this new Prod. Order Line
Change the production order status to Released and post a partial quantity assigning a Lot Number to the output quantity using the lines grid / Line / Production Journal
  • Set the output quantity of the Output line to 6
  • Assign the 6 quantities to be posted a Lot Number: Line / Item Tracking Lines / Lot No. = LOT1, Quantity (Base) = 6 , close the page to save the changes
  • Post the journal lines. As a result, we get in the Prod Order Line: Finished Qty = 6, Remaining Qty = 4
At this point launch the planning worksheets again: Planning worksheets / Calculate Regenerative Plan / Filter by item
  • The system “unexpectedly” suggests a new prod order of Q=4
If we carry out the action and create the order that the worksheet suggests, we get a situation in which the sales order line has a Reserved Quantity greater than the Line Quantity itself...

After outlining the case, could this behavior be considered unusual? Is there any reason behind the planning worksheet behaving this way?
 
Thanks in advance and best regards,
 
--
Belén

 
  • BelenSA Profile Picture
    BelenSA 50 on at
    Planning Worksheets - 'Calculating Regenerative Plan' suggests creating "non-expected" supply lines
    Hello,
     
    I have recorded a short video of the issue just in case there is something weird in the process I follow to reproduce it:
    Hope anyone can help us determine if this behavior can be considered unusual (or a bug) of if there is any reason behind the planning worksheet behaving this way.
     
    Thanks again and regards,
     
    --
    Belen
  • BelenSA Profile Picture
    BelenSA 50 on at
    Planning Worksheets - 'Calculating Regenerative Plan' suggests creating "non-expected" supply lines
    Hello,
     
    Thanks for trying in 23.5 version but I am afraid that I am reproducing the issue in that version, too.
    I have repeated the use case in a Docker environment with version W1 23.5 (Platform 23.0.17191.0 + Application 23.5.16502.17205). Also, I have tested the 24 preview version in a Sandbox environment, getting the same issue.
  • LarsStromValsted Profile Picture
    LarsStromValsted 7 on at
    Planning Worksheets - 'Calculating Regenerative Plan' suggests creating "non-expected" supply lines
    I have just tried to reproduce this in BC 23.5.16589 in the Cronus company, and I cannot reproduce the situation. The Planning Worksheet stays empty after running Calculate Regenerative plan as expected.
  • BelenSA Profile Picture
    BelenSA 50 on at
    Planning Worksheets - 'Calculating Regenerative Plan' suggests creating "non-expected" supply lines
    Thanks for the answer. However this seems not to be the case.
     
    I have set the requested delivery date of the sales order to 2024/03/31. I can also see that the shipment date of the sales line is also on 2024/03/31. Then, when the production order is created, the due date is set to this same date. Here you can see the Prod Order Line detail:

     
    So, it does not seem anything about not meeting the dates of the sales order. What's more, the "unexpected" order that is suggested in the planning worksheet for the 4 quantities that haven't been manufactured yet has also the same due date: 2024/03/31.
     
    As far as we can see it has to be somehow related to the item tracking code "FREEENTRY" that is set in the item (and how the priorities are set when the demand and supply is paired when calculating the plan in the planning worksheets).
     
    If we create a copy of the initial item, change the item tracking code to one of specific lot tracking (LOTALL) and repeat the same use case the planning worksheet does not suggest to create a new prod order for the 4 quantities that have not been manufactured yet.
     
    Regards,
     
    --
    Belen
  • Suggested answer
    Ben Baxter Profile Picture
    Ben Baxter 5,058 Super User 2024 Season 2 on at
    Planning Worksheets - 'Calculating Regenerative Plan' suggests creating "non-expected" supply lines
    Everything you outline are the correct steps.  The only thing I can think of is your demand date (Sales Order) is conflicting with the Prod. Order's Finish Date, where the remaining 4 units won't be produced in time to meet the Shipment Date of the Sales Order.  Normally you would get two suggestions in the Planning Worksheet, 1) To Cancel the existing Prod. Order; 2) To create the new Prod. Order.  However, since the existing Prod. Order has already been transacted on you can't cancel the order.

    I would say a typical Make-to-Order environment would have a future "Requested Delivery Date" input on the Sales Header.  This gives the operations team a little breathing room to make the product before it is needed for shipment.  Even pushing the date out a day could resolve your issue, and an easy Extension to write to auto-populate the "Requested Delivery Date" based on a "1D" or "2D" calculation.
     
    If you are expecting same day shipment, you may want to use a Lot-for-Lot policy with a little Safety Stock Quantity.
     
    Hope this helps in some way.
     
    Best Regards,
    Ben Baxter
    Accent Software Inc
     
     

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