Continuous, Forward Scheduling Constraint CTM with PP/DS PPM - Multiple Modes Capacity underutilization

[Former Member]

Hello.

Right now we are running Constraint Continuous Planning Forward Scheduling CTM utilizing PP/DS PPM with Finite Resources as the source of supply. 

Our business requirement for Constraint Capacity scenario is a 100% utilization of all available Resources capacities, to satisfy as much demand as possible and minimize delays.

We could not use Bucket-Oriented planning due to the high Fixed Lots Size vs. Resource daily production rate.  As the result of Bucket-Oriented planning, Capacity utilization was much lower than desired 100%. That is why we are running Continuous Planning option based on PP/DS PPM for Finite scheduled Resources. Initially we tried to plan with Backward scheduling, and it did not provide us with the continuous 100% resource utilization. We observed gaps in Capacity utilization.  We did extensive analysis of this scenario and our understanding is that these gaps are normal result of Backward Scheduling logic.

We tested with two Late Demand Fulfilment options: Standard Procedure for Scheduling and Keep Lateness to a Minimum. In both tests we observed periodic gaps in Capacity utilization. 

Current CTM setup is completely satisfied business requirement, except when we use multiple Alternative Modes in PP/DS PPM.

The issue is: Constraint, Continuous Planning,  Forward Scheduling CTM using PP/DS PPM with Finite Scheduling Resource utilizing one Alternative Mode at 100% during the whole Planning Period.  However the same CTM with multiple (3) Alternative Modes, Mode2 and Mode3 Capacities are terminated prior to the end of Planning Period. At the same time we have the most of the demands delayed, partially fulfilled or not fulfilled at all.

Our expectation is that all three or four Alternative Modes should be 100% utilized during the whole Planning Period, as long as we have unsatisfied or delayed demand.

Any suggestion on how to deal with this issue would be greatly appreciated?

Thank you.

Lenny

[Former Member]

Hi Marius.

PP/DS PPM we use in CTM planning is simple: one Operation, one Activity and one Output product, no Components.  Could you please clarify how "PP/DS PPMs a primary resource must be defined".  We have three Modes and three corresponding Components. I tried to Assign Mode Priorities. It did not impact CTM planning results.

Thanks.

Lenny

[Former Member]

Hi Lenny,

From SAP Help - The capacity category is also only taken into account when the PPM and PDS is generated. Capacity relevant to scheduling is assigned to the modes of the associated activities as a primary resource. All other capacities are assigned as secondary resources.

For CTM PDS or PPM you need to have at last 1 component attached to your finished good! So, you will be able to respect the End - Start activity with output finished good as last activity.

Thanks,

Regards, Marius

[Former Member]

Hi Marius.

We are using PP/DS PPM's and continuous planning with forward scheduling  in CTM profile.

Thanks.

Lenny

[Former Member]

Hi Lenny,

What is your strategy for demand fulfillment?

Thanks, Marius

[Former Member]

Hi Marius.

Our CTM: Global Customizing Settings for Late Demand Fulfillment is 730 days:

With "Forward Scheduling" direction selected in CTM profile, the Late Demand Fulfillment Strategy is defaulted to "Use Standard Procedure for Scheduling"

Thanks.

Lenny

[Former Member]

Hello Lenny,

Please ensure that the below conditions are satisfied.

Also, ensure that the max lot size is big enough (like 99999999).

Do you have some messages in the Explanation for CTM planning run? 

Thanks, Marius

PPM/PDS in CTM Planning

The following constraints apply:

- Activities need to be in linear sequence

- Breaks between activities can only be modeled for PP/DS PPMs, except the function "Maximum interval between activities" allows a global break value in SNP PPM (The function can be found in the CTM Profile Tab Setting - Master Data Setting - Inhouse production)

- Activity relation only: END -START supported

- No support for set up matrixes; utilization parameter; set up activity

- The output of the head component, i.e. the output of the location-product for which the PPM/PDS was selected, needs to be at the last activity.

- PI Operations ( Process Industry Operations) are ignored

- No off set times supported; yield always available at the end of the activity

- For PP/DS PPMs a primary resource must be defined

- Unscheduled breaks NOT supported for time continuous resources.

[Former Member]

Hi Marius.

I tried to use three separate PP/DS PPMs, one for each mode, and observed the same system behavior of using only one mode for the duration of planning period and terminating utilization of remaining two modes before the end of planning period. I also tried to assign different priorities to modes and it did not make any difference. Only first mode is completely utilized regardless of modes priorities.

Thank you.

Lenny

[Former Member]

Hi Lenny,

Did you use continual consumption?

Maybe you can try to create separate PPM for each mode and then have priority based on the prefered mode!

Thanks,

Regards, Marius