Plan Analysis: Late Demand Diagnosis

Overview

You can use Rapid Planning late demand diagnosis to identify:

• Late and unmet demands

• The likely reasons for them: For example, was the total lead time required less than the time available?

• Their impact: For example, what specific resources and suppliers should I focus on to make the demand satisfied on time?

As it plans to satisfy a demand, the planning solver also searches these paths:

• Routing alternate resources

• Bill of material substitute components

• Alternate BOM and Routing

• Alternate sources on sourcing rules

• End item substitutes

It finds these constraint failure conditions and reports them when it cannot wholly satisfy a demand due to any of these conditions:

• Material Constraint: Lead Time

• Material Constraint: Planning Time Fence

• Material Constraint: Date Effectivity

• Material Constraint: WIP Window

• Resource Constraint

• Supplier Constraint

You can simulate solutions and finds the best responses.

Constraints

In this example:

• There is distribution center demand for the finished good

• The distribution center sources from manufacturing organization A, rank 1, and manufacturing organization B, rank 2.

• The planning solver tries to make it in organization A

• Organization A satisfies the demand two days late because of lead time constraints on components C1 and C2.

• The planning solver reports two constraints.

• The planning solver tries to make it in organization B.

• Organization B satisfies the demand three days late because of lead time constraints on components C1 and C2 and a resource constraint on resource R1.

• The planning solver reports three constraints.

• The planning solver recommends organization A because it is the least late.

Intermediate Level Reporting

The planning solver reports the root or leaf cause of a delay

x

• Finds a constraint failure on Sub Assembly because of a lead time constraint on Component C1.

• Does not report the constraint failure on Sub Assembly.

• Reports the lead time constraint on Component C1.

Partial Quantity Shortage Constraints

If the planning solver plans to satisfy partial quantities of a demand from multiple organizations, it reports failure constraints from all organizations involved.

In this example:

• FG sources from organizations M1 and M2

• The planning solver satisfies a partial demand quantity on time from organization M1. It can't satisfy the rest because of a lead time constraint on component C1.

• The planning solver tries to satisfy the remaining demand quantity form organization M2. It can't satisfy it because of a lead time constraint on component C1.

• It reports both failure constraints.

Material Constraint Caused by Resource Constraint

Sometimes, the report of a lead time material constraint is actually caused by resource unavailability. For example:

• A resource is not available on the day the planning solver needs it to complete a component.

• The resource is available earlier.

• The planning solver plans to use the resource earlier.

• Using the resource earlier causes a lead time material constraint on the component, because work on the component is scheduled to start in the past.

• The planning solver reports a lead time material constraint against the component and does not report a resource constraint against the resource. However, the resource availability is the root cause of the late demand.

• You can detect this situation by looking at the Pegging View and searching for time gaps.

Process

The late demand diagnosis process is:

• Copy the baseline plan to a simulation plan

• Run the simulation plan with parameter Snapshot – New demand changes and select launch option Calculate Lateness Constraints

• Analyze lateness using the view Analytics

• Compare the baseline and simulation plans

If you accept the latensses, continue analysis and release recommendations.

If you don't accept the latenesses, do this as many times as you need to accept the lateness. You can use more than one simulation plan and compare among them to choose the best solution:

• Check the constraints for key late demands

• Simulate corrections to fix root causes

• Re-run the simulation plan with parameter Snapshot – New demand changes and select launch option Calculate Lateness Constraints

• Analyze lateness using the view Analytics

• Compare the baseline and simulation plans

You can see the late demand information in any planning mode, but the information is most relevant in mode Constrained – Enforce capacity constraints

Viewing

You see late demand information in the view Constraint Details.

Troubleshooting

Since the planning solver calculates constraints on all paths, it makes run times longer when you use it.

The planning solver exhausts all possibilities for solving a late demand only on the primary path.

To find all upstream constraints along the primary path, use view Constraints Detail, do a query-by-example and filter by search path Primary.