Concurrent Session

Microsoft Dynamics AX Master Planning Tips and Tricks Christian Kemp DeveloperUlrik Mølgaard Honoré,Program ManagerMicrosoft Corporation

AX209

Agenda

Master planning projects are BPR projectsKey areas to focus on

Parameters and usageWork center

Finite / infinite capacityOperation schedule/ job scheduleTime fencesPositive/negative days

Multiple plansVery long, Long, Medium, short, very short. Dynamic / static

Master planning input & output

Dyn

am

ics

AXNet

Requirements

Dyn

am

ics

AXMaster

Scheduling• Material

Coverage• Capacity

planning

Dyn

am

ics

AXPlanned

orders

Master planning input & output

Dyn

am

ics

AXNet

Requirements

Dyn

am

ics

AXMaster

Scheduling• Material

Coverage• Capacity

planning

Dyn

am

ics

AXPlanned

orders

Masterl panning

parameters

Item setup

Resource setup

Capacity requirements planning

Firmed orders, Productions may be Job rescheduled

Time buckets starting from Today

Frozen Master plan

Operation scheduling

Estimated Lead times

days weeks months quarters

Workcenters

WC grouping – the higher aggregation level, the better. Set up as 1 work centergroup:

Fully alternative resources,Also machines, tools and workers which always operate together.

ConsiderEfficiency %,Operation scheduling %,Finite vs. Infinite capacity

Calendars

Do not define too long periodNo separate line for defining Breaks or Shift changes

Thomas: Prerequisites

Work center scheduling

demo

Operation vs Job scheduling

Operation scheduling is recommended for Master scheduling (rough-cut capacity plan)

Remember to set capacity time fence not to high.Please ensure that multiple plans are used.

Detailed or Job re-scheduling may be used in Production scheduling

ONLY if job scheduling is needed.

Time fences

Time fence is based on Requested ship dateOnly used for Master scheduling, ignored in Production schedulingCapacity and Explosion time fences have biggest impact on performanceMinimize them for daily schedulingShould not be less than longest purchase Lead time of materials ordered on a daily basisSubstitute to estimated Lead time for orders falling beyond Capacity time fence horizonAction, Futures - time horizon for analyzing messages

Finite vs Infinite capacity

Figure out the bottlenecks in Production shop floor:

Run Infinite time to time to see which Resources are most overloaded

Use seperate master plan for that purposeDo the same for long lead time purchase

Mark only bottleneck work centers as Finite capacity

0

10

20

30

ActualAvalible

Staffan: Scheduling

Futures and Action messages

Master scheduling Regeneration is run in 4 main loops:1. Reqs update (only in Regeneration, skipped in Net change)2. Coverage calculation3. Action messages generation4. Futures messages generation

Futures messages

Coverage planning searches for free Capacity backwards from Requested Delivery datePlanned order delay due to

- Material shortage - scheduled Start before Today’s date or - Workcenter overload

may trigger Futures re-scheduling loop, forward from Futures date

Futures conclusions

Master planning will search until free capacity is found going backwardsIf there was no enough free Capacity, it would search backwards and finally reserve Capacity before Today’s date!That would trigger Futures rescheduling forwardMeans, long time spent on searching for free Capacity backwards went in vain!

Futures setup #3 solutionSet Operations scheduling % to 50%

• This ensures that Operation scheduling reserves not more than 50% of Workcenter’s capacity for 1 Operation

• This is a way how to solve the conflict, leaving workcenter flexible to choose, or Production planner to fine-tune with the specific sequence depending on Priorities

• This % can be reduced also for Capacity buffering purposes or for scheduling several actual physical workcenters defined as 1 WC in the system

Thomas: Futures & Actions

Buffer capacity

Operation scheduling %The less, the more flexible WC isCan be used for scheduling several actual physical workcenters defined as 1 WC in the system

Efficiency %Don’t set to 100% everywhereTo be able to do re-work without hurting Delivery date in case of error in OperationTo be able to process extra Productions without overloadSetup a environment that is feasible ( I do know that there is a high load on minimizing lead-time and cost so no will accept to overbook capacity.

Alternative workcenters)

Buffer material

Safety stocksSize and frequency dependant on the price and material purchase lead timeTake advantage of using Safety stock journal, when demand history reaches 1 year

Multiple Qty Vs. Max order qty.Usage of Max order qty can lead to performance issues.

Request material for relevant Operation vs. all for the 1st operation

Buffers: Thomas

Freezing periods

Approving Planned orders vs. FirmingFreezing time fence:

For FG - the period within which you wouldn’t manage to Produce it from the scratch, if it is requested nowFor material – shortest possible Lead time

Switching between Master and Coverage groups setupDedicated Master plan (for example, quarterly run)

For long-term Raw material purchasingFor budgetingSend Master plan to your Vendors, letting them update their own plans and ensure stable supply

Capacity requirements planning

Firmed orders, Productions may be Job rescheduled

Time buckets starting from Today

Frozen Master plan

Operation scheduling

Estimated Lead times

days weeks months quarters

Staffan: Time fences

Explosion

Thomas: Net Change etc & Explosion

Negative daysBe aware of negative days. Do not set this to high, it will make lots of logs of Actions and futures. And decrease performance.

Dynamic Negative days

Lead timeNegative days

Neg Leadtime CalculationdynamicNegativeDays = leadTime + standardNegativeDays+todaysDate -reqDate;

OutcomeOld

OutcomeDynamic

2 6 8=6+2+1-1 New P2 Po at the 7th and sales order future set

The sales order would be matched to P1 and sales order future set to 5th.

Salesorder

Date

9/18/17/16/15/14/13/11/1 2/1

Old PO New PO

P1 P2

Dynamic neg days

Negative days

demo

Positive days

Staffan: + and - days

Master planning, no update planning

FDORD

RD

ORD

RD

FD

Leadtime

IM

RM

OM

OD

ORD FD

IM

RD

RD

RM

ORD

LeadtimeOM

OD

FD

Master planning, no update planning

Production scheduling

Material reqs can be replenished.Capacity reservations of Planned orders or Projects can be ignored.Group (Production pools)PrioritizeUse Sorting in prod schedulingOperation vs Job schedulingUrgent orders may use Infinite capacityBalance the number of Conflict solution qty and Max allowed job lead time

Operations Overlap

Set up Overlapping operations( new to 4.0 Transfer Batch VS overlap)

Links between operations

HardLink ensures shortest Production order lead timeSoftLink allows time gaps between Operations

Only used in production planning, not master planning.

Staffan: The scheduling stuff

Staffan: Helpers, other perf changes

questions?

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