How to create a weekly Master Schedule Plan

[ConePerez]

Hi,

I'm setting up frepple locally using the community version, it is running as expected. However, I'm not able to configure correctly to create a weekly master schedule plan. What I mean is to schedule manufacturer orders on a weekly basis respecting the capacity of the resource. I will later send this weekly plan to a detail scheduling to create the sequence of the orders and the start and end time of each one at the hour level.
I created my Resources as type Bucket_Week and assigned a maximum and available calendar and it is a constrained resource. However, when I see the workorders I see a lot of them starting in the same day but the capacity hours are exceeded. Hence, my question how can I make sure that it only schedules the manufacturer orders that fits within its capacity.

Here is my resource setup

This is the calendar setup

This is the available calendar

Here is one of those resources being used by the operation Make P005 on OPER001, one single order takes 4 days and there are several like that.

Any guidance is appreciated.

[jdetaeye]

What you see are the expected results.

Bucket_Week will only assure that on a weekly basis your capacity isn't exceeded.
Based on your calendar you have a total of eg 40 hr available per week. The plan must respect this number as a constraint, but it's ok to create a plan where all these hours are used on the Monday.
If you want the available hours per day to be respected, use "bucket_day" or "buckets" or "default".

If you don't want manufacturing orders to run for multiple days, you need to use a "default" resource with a max-calendar. The solver will then break big requirements into multiple smaller manufacturing orders.
In your current setup you will see multi-day manufacturing orders - the unavailable hours are correctly account for by "stretching" the duration of the manufacturing orders. You can see this in the difference between the "duration" (simply the difference between start and end dates) and "net duration" (considers only real working hours) of the manufacturing order.

[ConePerez]

I'm ok that the manufacturing orders run for multiple days, what I don't understand is why multiple manufactoring orders are scheduled the same days in the same resource. I thought that I set the resource with only 40 hrs per week available, hence I would expect that only one manufacturing order is scheduled on a given week. I ran the plan with constrains.

[jdetaeye]

Ah, then it's probably the "quantity" and "quantity_fixed" fields on the operation-resource records you need to look into.
On all bucketized resource types they define capacity consumption of your operation independent of the duration. Ie an operation can take 4 hours but only use 30 minutes of a certain resource.

Copying the values of the operation "duration" and "duration per" fields into the operation resource fields "quantity" and "quantity_fixed" may give the results you expect.

[ConePerez]

Thanks! It took me some time but I finally got it. The operation "duration" and "duration per" fields need to be converted to seconds through the operation resource fields "quantity" and "quantity_fixed". I mean, if the operation.duration_per is 12 minutes then the operation_resource.quantity will be set to 1260= 720. If the value is 2 hours and 12 minutes, then the quantity field should be set to 23600 + 12*60 = 7200 + 720 = 7920. The same applies to the operation.duration, in this case the field to convert is the operation_resource.quantity_fixed. Hope this helps to someone else.