Capacity Leveling Pushes Planned order out to end of Data View

[Former Member]

Yet again....

Dears,

I am using the standard SAP heuristic to do capacity leveling for a single resource that is over loaded in wk1 (the start of my data view), hoping it splits between wk2 and wk1 but this entire quantity (comprising multiple planned orders) is pushed the the right most bucket wk10 of data view.

This happens only for some products

Resources are identical.

Master data for the prod x loc is identical

No production or any other horizons are maintained in Prod x Loc Master.

No other planned / production orders are overloading the resource.

If I extend the data view to infinity, it still pushes out the planned order to last bucket.

SNP Global settings Opt: Lot Formt is set to do not consider lot size settings.

No User Parameters in action

No other Z animals.

What could be the root cause?

Thanks

Amit

[former_member244427 · Accepted solution]

Hello Amit,

Only way I was able to simulate the results described by your statement " orders are created at the end of bucket by capacity leveling heuristics" was having the minimum lot size greater than what could be produced in a bucket. Example min lot size is 1000 and as per my routing I need 25 HRs to run this lot, and my SNP bucket capacity in the planning book is only 24 HRs per bucket it will shift the orders at the end of the horizon.

My as per my thinking this seems to be standard behavior for SNP finite capacity planning. I was not able to find any solution to this other than reducing minimum lot size or making the planning book for capacity leveling with bigger buckets, in your case i think its daily bucket, try with weekly buckets in the planning book.

Also in past i have seen this behavior when in finite capacity planning when it is not able to schedule the finite capacity resource due to holidays in the calendar, for example due to my unique routing and calendar setup always the capacity operations falls on a Sunday and there is holiday on sundays for this calendar in the resource, so it will again create the order at the end of the bucket. So in conclusion if its not able to resolve a cap scheduling conflict it pushes orders at the end of the bucket.

IMHO if you are not able to adjust the minimum lot size or the buckets in the planning book, please raise a ticket with SAP.

Regards,

Abhishek

[former_member244427 · Accepted solution]

Hello

In the resource master SNP tab there is tick mark for Cross period activity, test with this setting as well.

Regards,

Abhishek

[Former Member]

abhishek.rai

I concur with your observations.

I postulate thus for the benefit of SAPtards like me.

• For SNP Capacity leveling to work partially or fully, the minimum lot size in product master should be strictly less than the maximum possible production in a bucket.
• For SNP Capacity Leveling to work fully, with 100% utilization of available capacity, the minimum lot size must be an integer factor of Planned order quantity.
• If the residual quantity (as resultant of partial capacity leveling) is not exactly equal to minimum lot size in product master, it is moved to last bucket as the CL heuristic does not understand what to do with it.

• Capacity Leveling without any lot size settings will always level capacity in the event of 'overload'
• All else being same, capacity Leveling in weekly buckets will level capacity more often than capacity leveling in daily buckets.
• It does not make sense to do Capacity leveling after SNP Optimizer run.. lot size or no lot size.

What capacity leveling should have done is to group the planned orders to multiples of lot size. This bit needs perhaps another program. This is the reason most do capacity leveling. esp. if Detailed Scheduling is not implemented.

Thanks

Amit

[Former Member]

"Is the cap requirement for your min lot size greater than the avail cap for one bucket?"

Yes it is.

My bucket is a day. I have plenty of capacity following 5 days. The optimizer however does not consider the minimum lot size (set not to). Which means in some buckets the load is more than the minimum lot size. In some buckets it is less the load required for minimum lot size. Either cases violating the available hours in some buckets. My lot size strategy in product master is lot for lot. So my question is why should minimum lot size be playing any role at all?

Thanks

Amit

[Former Member]

Thanks Abhishek

I will abandon this. Not worth the headache. I wonder why would capacity be leveled in larger buckets like weeks or why would anyone tinker with lot size. Lot size is lot size. The minimum lot size is the only field in the product master that drives the lot size of process orders.

[Former Member]

Somewhere deep from the jungle of help.sap

"You have to run the SNP heuristic before capacity leveling. Running capacity leveling after an SNP optimization run or Capable-to-Match (CTM) run is possible but it would not usually make sense to do this."

"https://help.sap.com/doc/saphelp_scm41/4.1/en-US/90/d9733b570d474bba36bf443f7927c0/content.htm?no_cache=true"

This is a bit inconsistent approach of SAP. You run Linear optimizer ignoring lot sizes and then you run capacity leveling heuristic that calls lot sizes by hard design. i.e. there is no global setting to ignore lot size during capacity leveling but you can do so for SNP Optimizer. Here too the documentation is unclear as to under what conditions is the lot size data read to begin with. Fixed lot, lot for lot. If latter then minimum lot size has no real meaning.

Notwithstanding the science part of it, the least that capacity leveling is supposed to do is move the orders to buckets where there is plenty of capacity available. Like 100000 times the capacity needed for lot size and/or planned order quantity. But that is not happening.

Thanks

Amit

[former_member244427]

Hello,

But, the statement from SAP makes sense, If you are using optimizer or CTM it should create a plan which is already constrained to capacity. Then it makes no sense to run capacity leveling. In this case the right question is what is the purpose of running capacity leveling, was optimizer not able to create a constrained plan in your case?

Also you have not answered the question. "Is the cap requirement for your min lot size greater than the avail cap for one bucket?"

Regards

Abhishek

[Former Member]

Hi Rupesh,

I think the real question I should be asking is wrt the design of capacity leveling Heuristic. So here I paraphrase with some Arithmetic. SNP Optimizer refers to SNP Linear Optimizer.

- IF there are unfixed planned orders overload of 190% on Bucket1, 120% on Bucket4 and 110% on Bucket20 and no load on all other buckets, with each bucket having the same available capacity from Bucket1 to Bucket50.

- IF Minimum Lot Size of 5000 is maintained in Product x Location master

- IF a rounding value of 500 is maintained in Product x Location Master

- IF NO product priority is maintained in SNP2 tab of Prod x Loc master.

- IF A Single Resource used by a Single Product is being leveled

- IF PDS (only one exists) is correctly maintained to compute capacity consumption.

- IF PDS has a minimum Lot size of 1 and max of 9999999.

- IF (Production) Resource exists in live cache for the entire bucket duration and is available for 100% utilization for 24 hours x 7 days a week x 365 days a year for next 600 days.

- IF Capacity Leveling is now done with the Heuristic method with forward scheduling, 100% utilization target, No Priority.

Then

1) What results will Capacity Leveling Heuristic Produce?

2) IF I use SNP Optimizer and do not consider lot sizes maintained in product master, should I also use Capacity Leveling with Optimizer?

3) How does Capacity Leveling program- Heuristic or Optmizer, know what method was used to create planned orders?

4) What does it mean to have Capacity Leveling Heuristic always consider Lot sizes in product location master ( by hard design) and SNP optimizer set to ignore the (by choice in SNP global settings)?

5) What does "Do not consider Lot Size Settings ' in Lot Size formation really mean in SNP global settings? What does the word "Settings" means in "Lot Size Settings". Is this referring to Lot size strategy and lot size values in product location master or something more maintained elsewhere too?

6) Where else in the Config can I ignore or respect "Lot Size settings" in SNP Optimizer Profile? Over-riding SNP Global settings for Lot size formation. Can I?

7) If Capacity Leveling Heuristic Method is respecting Lot Size in Product x Location master, why isnt each planned orders rounded up to match minimum lot size?

😎 How does the capacity leveling compute the overload, (before I even execute the CL heuristic) that there is an overload based the planned order quantity which is less than the minimum lot size in product x location master?

9) Is Capacity leveling Heuristic run expected to create planned orders in exact multiples of minimum lot size? (Assuming Capacity leveling has no bug that I reported).

10) How does Capacity Leveling treat consecutive overloads or more generally the gap between overloaded buckets?

[Former Member]

PDS duration is non-zero

Capacity Consumption is precisely calculated - Planned Order Quantity x Rate per sec / 3600 sec = Hours consumed.

Order is neither firmed nor fixed

There is only one PDS that is the source of supply.

As long as the capacity consumption is a non-zero value it is fair to assume that settings related to PDS and resource are correct and that PDS has a valid resource whose capacity I am trying to level.

Thanks

Amit

[Former Member]

Oh I pasted the 'wrong' portion of screen shots. Planned orders were there in the future.

Here I attach another one.

Initial state: Overload 08/22....caplvl2.png

After Cap leveling. ...caplevltab2.png

Overload is not resolved despite available capacity.

For simplicity sake I chose a resource that is used only by a single product and whose PDS has a non-zero output in the activity / mode to compute capacity consumption.

What 5 things do I need to check in a) Resource b) PDS to ascertain root cause? I checked all I possibly could.

[rupesh_brahmankar]

Hello,

Please check PDS duration and capacity consumption.

Also check order has valid source of supply and order is not firmed.

Best Regards,

R.Brahmanakar

[Former Member]

initila-state.pngutltable.png

I used another example here. Little overload. Expecting the load to move to next bucket of 23/08. But it doesn't. See the table of utilization is as it is. Means capacity leveling is not leveling the load even though capacity is available. Now I am not sure on what 10 things is this driven.

I see more literature in SAP notes than in help documentation on capacity leveling. Many of them 15 year old notes that are not relevant to my release.

Thanks

Amit

[rupesh_brahmankar]

Hello,

Are you trying capacity planning for production order or PPDS planned order? Which is nor supported by SNP capacity planning heurestic.

I can not see any production planned order in SNP planned order key figure.

Best Regards,

R.Brahmankar

[Former Member]

caplvl.pngThanks Rupesh.

For the affected products, does have any minimum lot size or a rounding value?

There is lot size and rounding for all products but we ignore 'lot formation from SNP Global settings. The tip you gave some weeks ago. So Planned orders generated are no longer in multiples of minimum lot size.

Does order quantities before running the capacity leveling are in multiples of the output quantities of the PPM / PDS used?

There is no change to planned order quantities before and after running capacity leveling. Planned Order quantities generated by SNP only make up shortage. What and where do I need to specifically check here?

Also check application log of capacity leveling.

This is all green. This does not tell much. It tells that order has been pushed out to last bucket. Does not say why. There is no shortage of capacity the bucket next to overloaded bucket. The capacity leveling used is SAP standard HEU. No fixed orders.

See image below of log

[rupesh_brahmankar]

Hello,

Are you using daily bucket?

Your capacity requirement is too high 170 Hrs than the available capacity is only 129 Hrs. Apart from that what is lead time of product I can see order are push to 25/08.

Best Regards,

R.Brahmankar

[rupesh_brahmankar]

Hello,

For the affected products, does have any minimum lot size or a rounding value?

Does order quantities before running the capacity leveling are in multiples of the output quantities of the PPM / PDS used?

Also check application log of capacity leveling.

Best Regards,

R.Brahmankar