void OperatorDelete::solve(const Buffer* b, void* v)
{
if (getLogLevel()>1)
logger << "Scanning " << b << " for excess" << endl;
Buffer::flowplanlist::const_iterator fiter = b->getFlowPlans().rbegin();
Buffer::flowplanlist::const_iterator fend = b->getFlowPlans().end();
if (fiter == fend)
return; // There isn't a single flowplan in the buffer
double excess = fiter->getOnhand() - fiter->getMin();
// Find the earliest occurence of the excess
fiter = b->getFlowPlans().begin();
while (excess > ROUNDING_ERROR && fiter != fend)
{
if (fiter->getQuantity() <= 0)
{
// Not a producer
++fiter;
continue;
}
FlowPlan* fp = nullptr;
if (fiter->getEventType() == 1)
fp = const_cast<FlowPlan*>(static_cast<const FlowPlan*>(&*fiter));
double cur_excess = b->getFlowPlans().getExcess(&*fiter);
if (!fp || fp->getOperationPlan()->getLocked() || cur_excess < ROUNDING_ERROR)
{
// No excess producer, or it's locked
++fiter;
continue;
}
assert(fp);
// Increment the iterator here, because it can get invalidated later on
while (
fiter != fend
&& fiter->getEventType() == 1
&& static_cast<const FlowPlan*>(&*fiter)->getOperationPlan()->getTopOwner()==fp->getOperationPlan()->getTopOwner()
)
++fiter;
if (cur_excess >= fp->getQuantity() - ROUNDING_ERROR)
{
// The complete operationplan is excess.
// Reduce the excess
excess -= fp->getQuantity();
// Add upstream buffers to the stack
pushBuffers(fp->getOperationPlan(), true);
// Log message
if (getLogLevel()>0)
logger << "Removing excess operationplan: '"
<< fp->getOperationPlan()->getOperation()
<< "' " << fp->getOperationPlan()->getDates()
<< " " << fp->getOperationPlan()->getQuantity()
<< endl;
// Delete operationplan
if (cmds)
cmds->add(new CommandDeleteOperationPlan(fp->getOperationPlan()));
else
delete fp->getOperationPlan();
}
else
{
// Reduce the operationplan
double newsize = fp->setQuantity(fp->getQuantity() - cur_excess, false, false);
if (newsize == fp->getQuantity())
// No resizing is feasible
continue;
// Add upstream buffers to the stack
pushBuffers(fp->getOperationPlan(), true);
// Reduce the excess
excess -= fp->getQuantity() - newsize;
if (getLogLevel()>0)
logger << "Resizing excess operationplan to " << newsize << ": '"
<< fp->getOperationPlan()->getOperation()
<< "' " << fp->getOperationPlan()->getDates()
<< " " << fp->getOperationPlan()->getQuantity()
<< endl;
// Resize operationplan
if (cmds)
cmds->add(new CommandMoveOperationPlan(
fp->getOperationPlan(), Date::infinitePast,
fp->getOperationPlan()->getDates().getEnd(), newsize)
);
else
fp->getOperationPlan()->setQuantity(newsize);
}
}
}
void OperationItemSupplier::trimExcess(bool zero_or_minimum) const
{
// This method can only trim operations not loading a resource
if (getLoads().begin() != getLoads().end())
return;
for (Operation::flowlist::const_iterator fliter = getFlows().begin();
fliter != getFlows().end(); ++fliter)
{
if (fliter->getQuantity() <= 0)
// Strange, shouldn't really happen
continue;
FlowPlan* candidate = nullptr;
double curmin = 0;
double oh = 0;
double excess_min = DBL_MAX;
for (Buffer::flowplanlist::const_iterator flplniter = fliter->getBuffer()->getFlowPlans().begin();
flplniter != fliter->getBuffer()->getFlowPlans().end();
++flplniter)
{
// For any operationplan we get the onhand when its successor
// replenishment arrives. If that onhand is higher than the minimum
// onhand value we can resize it.
// This is only valid in unconstrained plans and when there are
// no upstream activities.
if (flplniter->getEventType() == 3 && zero_or_minimum)
curmin = flplniter->getMin();
else if (flplniter->getEventType() == 1)
{
const FlowPlan* flpln = static_cast<const FlowPlan*>(&*flplniter);
if (oh - curmin < excess_min)
{
excess_min = oh - curmin;
if (excess_min < 0)
excess_min = 0;
}
if (flpln->getQuantity() > 0 && !flpln->getOperationPlan()->getLocked() && (!candidate || candidate->getDate() != flpln->getDate()))
{
if (candidate
&& excess_min > ROUNDING_ERROR
&& candidate->getQuantity() > excess_min + ROUNDING_ERROR
&& candidate->getQuantity() > getSizeMinimum() + ROUNDING_ERROR
)
{
// This candidate can now be resized
candidate->setQuantity(candidate->getQuantity() - excess_min, false);
candidate = nullptr;
}
else if (flpln->getOperation() == this)
candidate = const_cast<FlowPlan*>(flpln);
else
candidate = nullptr;
excess_min = DBL_MAX;
}
}
oh = flplniter->getOnhand();
}
if (candidate
&& excess_min > ROUNDING_ERROR
&& candidate->getQuantity() > excess_min + ROUNDING_ERROR
&& candidate->getQuantity() > getSizeMinimum() + ROUNDING_ERROR
)
// Resize the last candidate at the end of the horizon
candidate->setQuantity(candidate->getQuantity() - excess_min, false);
}
}
/** @todo The flow quantity is handled at the wrong place. It needs to be
* handled by the operation, since flows can exist on multiple suboperations
* with different quantities. The buffer solve can't handle this, because
* it only calls the solve() for the producing operation...
* Are there some situations where the operation solver doesn't know enough
* on the buffer behavior???
*/
void SolverMRP::solve(const Buffer* b, void* v)
{
// Call the user exit
SolverMRPdata* data = static_cast<SolverMRPdata*>(v);
if (userexit_buffer) userexit_buffer.call(b, PythonData(data->constrainedPlanning));
// Verify the iteration limit isn't exceeded.
if (data->getSolver()->getIterationMax()
&& ++data->iteration_count > data->getSolver()->getIterationMax())
{
ostringstream ch;
ch << "Maximum iteration count " << data->getSolver()->getIterationMax() << " exceeded";
throw RuntimeException(ch.str());
}
// Safety stock planning is refactored to a separate method
double requested_qty(data->state->q_qty);
if (requested_qty == -1.0)
{
solveSafetyStock(b,v);
return;
}
Date requested_date(data->state->q_date);
bool tried_requested_date(false);
// Message
if (data->getSolver()->getLogLevel()>1)
logger << indent(b->getLevel()) << " Buffer '" << b->getName()
<< "' is asked: " << data->state->q_qty << " " << data->state->q_date << endl;
// Store the last command in the list, in order to undo the following
// commands if required.
CommandManager::Bookmark* topcommand = data->setBookmark();
OperationPlan *prev_owner_opplan = data->state->curOwnerOpplan;
// Evaluate the buffer profile and solve shortages by asking more material.
// The loop goes from the requested date till the very end. Whenever the
// event date changes, we evaluate if a shortage exists.
Date currentDate;
const TimeLine<FlowPlan>::Event *prev = nullptr;
double shortage(0.0);
Date extraSupplyDate(Date::infiniteFuture);
Date extraInventoryDate(Date::infiniteFuture);
double cumproduced = (b->getFlowPlans().rbegin() == b->getFlowPlans().end())
? 0
: b->getFlowPlans().rbegin()->getCumulativeProduced();
double current_minimum(0.0);
double unconfirmed_supply(0.0);
for (Buffer::flowplanlist::const_iterator cur=b->getFlowPlans().begin();
; ++cur)
{
if(&*cur && cur->getEventType() == 1)
{
const FlowPlan* fplan = static_cast<const FlowPlan*>(&*cur);
if (!fplan->getOperationPlan()->getRawIdentifier()
&& fplan->getQuantity()>0
&& fplan->getOperationPlan()->getOperation() != b->getProducingOperation())
unconfirmed_supply += fplan->getQuantity();
}
// Iterator has now changed to a new date or we have arrived at the end.
// If multiple flows are at the same moment in time, we are not interested
// in the inventory changes. It gets interesting only when a certain
// inventory level remains unchanged for a certain time.
if ((cur == b->getFlowPlans().end() || cur->getDate()>currentDate) && prev)
{
// Some variables
Date theDate = prev->getDate();
double theOnHand = prev->getOnhand();
double theDelta = theOnHand - current_minimum + shortage;
// Evaluate the situation at the last flowplan before the date change.
// Is there a shortage at that date?
// We have 3 ways to resolve it:
// - Scan backward for a producer we can combine with to make a
// single batch.
// - Scan forward for producer we can replace in a single batch.
// - Create new supply for the shortage at that date.
// Solution one: we scan backward in time for producers we can merge with.
if (theDelta < -ROUNDING_ERROR
&& b->getMinimumInterval() >= 0L
&& prev
&& prev->getDate() >= theDate - b->getMinimumInterval())
{
Operation *prevOper = nullptr;
DateRange prevDates;
double prevQty = 0.0;
Buffer::flowplanlist::const_iterator prevbatchiter = b->getFlowPlans().end();
for (Buffer::flowplanlist::const_iterator batchiter = prev;
batchiter != b->getFlowPlans().end() && batchiter->getDate() >= theDate - b->getMinimumInterval();
prevbatchiter = batchiter--)
{
// Check if it is an unlocked producing operationplan
if (batchiter->getQuantity() <= 0) continue;
const FlowPlan* batchcandidate = nullptr;
if (batchiter->getEventType() == 1)
batchcandidate = static_cast<const FlowPlan*>(&*batchiter);
if (!batchcandidate || batchcandidate->getOperationPlan()->getLocked())
continue;
// Store date and quantity of the candidate
Date batchdate = batchcandidate->getDate();
double batchqty = batchcandidate->getOperationPlan()->getTotalFlow(b) - theDelta;
double consumed_in_window = b->getFlowPlans().getFlow(batchcandidate, b->getMinimumInterval(), true);
if (batchqty > consumed_in_window)
batchqty = consumed_in_window;
Operation* candidate_operation = batchcandidate->getOperationPlan()->getOperation();
DateRange candidate_dates = batchcandidate->getOperationPlan()->getDates();
double candidate_qty = batchcandidate->getOperationPlan()->getQuantity();
// Verify we haven't tried the same kind of candidate before
if (candidate_operation == prevOper
&& candidate_dates == prevDates
&& fabs(candidate_qty - prevQty) < ROUNDING_ERROR)
continue;
prevOper = candidate_operation;
prevDates = candidate_dates;
prevQty = candidate_qty;
// Delete existing producer, and propagate the deletion upstream
CommandManager::Bookmark* batchbookmark = data->setBookmark();
data->operator_delete->solve(batchcandidate->getOperationPlan());
// Create new producer
short loglevel = data->getSolver()->getLogLevel();
try
{
data->getSolver()->setLogLevel(0);
data->state->curBuffer = const_cast<Buffer*>(b);
data->state->q_qty = batchqty;
// We need to add the post-operation time, because the operation
// solver will subtract it again. For merging operationaplans we
// want to plan *exactly* at the date of the existing operationplan.
data->state->q_date =
batchdate + b->getProducingOperation()->getPostTime();
data->state->curOwnerOpplan = nullptr;
b->getProducingOperation()->solve(*this, v);
}
catch (...)
{
data->getSolver()->setLogLevel(loglevel);
throw;
}
data->getSolver()->setLogLevel(loglevel);
// Check results
if (data->state->a_qty < batchqty - ROUNDING_ERROR)
{
// It didn't work.
if (loglevel > 1)
logger << indent(b->getLevel())
<< " Rejected resized batch '" << candidate_operation
<< "' " << candidate_dates << " " << candidate_qty << endl;
data->rollback(batchbookmark);
// Assure batchiter remains valid
batchiter = prevbatchiter;
if (batchiter != b->getFlowPlans().end())
--batchiter;
}
else
{
// It worked.
if (loglevel > 1)
logger << indent(b->getLevel())
<< " Accepting resized batch '" << candidate_operation
<< "' " << candidate_dates << " " << candidate_qty << endl;
theDelta = 0.0;
break;
}
// Assure the prev pointer remains valid after this loop
Buffer::flowplanlist::const_iterator c = cur;
--c;
if (c == b->getFlowPlans().end())
{
c = b->getFlowPlans().rbegin();
if (c == b->getFlowPlans().end())
prev = nullptr;
else
prev = &*c;
}
else
prev = &*c;
}
}
// Solution two: we scan forward in time for producers we can replace.
if (theDelta < -ROUNDING_ERROR
&& b->getMinimumInterval() >= 0L
&& cur != b->getFlowPlans().end()
&& cur->getDate() <= theDate + b->getMinimumInterval())
{
Operation *prevOper = nullptr;
DateRange prevDates;
double prevQty = 0.0;
Buffer::flowplanlist::const_iterator prevbatchiter = b->getFlowPlans().end();
for (Buffer::flowplanlist::const_iterator batchiter = cur;
batchiter != b->getFlowPlans().end() && batchiter->getDate() <= theDate + b->getMinimumInterval();
prevbatchiter = batchiter++)
{
// Check if it is an unlocked producing operationplan
if (batchiter->getQuantity() <= 0) continue;
const FlowPlan* batchcandidate = nullptr;
if (batchiter->getEventType() == 1)
batchcandidate = static_cast<const FlowPlan*>(&*batchiter);
if (!batchcandidate || batchcandidate->getOperationPlan()->getLocked())
continue;
// Store date and quantity of the candidate
double batchqty = batchcandidate->getQuantity()- theDelta;
double consumed_in_window = b->getFlowPlans().getFlow(prev, b->getMinimumInterval(), true);
if (batchqty > consumed_in_window)
batchqty = consumed_in_window;
Operation* candidate_operation = batchcandidate->getOperationPlan()->getOperation();
DateRange candidate_dates = batchcandidate->getOperationPlan()->getDates();
double candidate_qty = batchcandidate->getOperationPlan()->getQuantity();
// Verify we haven't tried the same kind of candidate before
if (candidate_operation == prevOper
&& prevDates == candidate_dates
&& fabs(candidate_qty - prevQty) < ROUNDING_ERROR)
continue;
prevOper = candidate_operation;
prevDates = candidate_dates;
prevQty = candidate_qty;
// Delete existing producer, and propagate the deletion upstream
CommandManager::Bookmark* batchbookmark = data->setBookmark();
data->operator_delete->solve(batchcandidate->getOperationPlan());
// Create new producer
short loglevel = data->getSolver()->getLogLevel();
try
{
data->getSolver()->setLogLevel(0);
data->state->curBuffer = const_cast<Buffer*>(b);
data->state->q_qty = batchqty;
data->state->q_date = theDate;
data->state->curOwnerOpplan = nullptr;
b->getProducingOperation()->solve(*this, v);
}
catch (...)
{
data->getSolver()->setLogLevel(loglevel);
throw;
}
data->getSolver()->setLogLevel(loglevel);
// Check results
if (data->state->a_qty < batchqty - ROUNDING_ERROR)
{
// It didn't work.
if (loglevel > 1)
logger << indent(b->getLevel())
<< " Rejected joining batch with '" << candidate_operation
<< "' " << candidate_dates << " " << candidate_qty << endl;
data->rollback(batchbookmark);
// Assure batchiter remains valid
batchiter = prevbatchiter;
if (batchiter != b->getFlowPlans().end())
++batchiter;
}
else
{
// It worked.
if (loglevel > 1)
logger << indent(b->getLevel())
<< " Accepted joining batch with '" << candidate_operation
<< "' " << candidate_dates << " " << candidate_qty << endl;
theDelta = 0.0;
// Assure the cur iterator remains valid after this loop
cur = prev;
if (cur != b->getFlowPlans().end())
++cur;
break;
}
// Assure the cur iterator remains valid after this loop
cur = prev;
if (cur != b->getFlowPlans().end())
++cur;
}
}
// Solution three: create supply at the shortage date itself
if (theDelta < -ROUNDING_ERROR)
{
// Can we get extra supply to solve the problem, or part of it?
// If the shortage already starts before the requested date, it
// was not created by the newly added flowplan, but existed before.
// We don't consider this as a shortage for the current flowplan,
// and we want our flowplan to try to repair the previous problems
// if it can...
bool loop = true;
while (b->getProducingOperation() && theDate >= requested_date && loop)
{
// Create supply
data->state->curBuffer = const_cast<Buffer*>(b);
data->state->q_qty = -theDelta;
data->state->q_date = theDate;
// Check whether this date doesn't match with the requested date.
// See a bit further why this is required.
if (data->state->q_date == requested_date) tried_requested_date = true;
// Make sure the new operationplans don't inherit an owner.
// When an operation calls the solve method of suboperations, this field is
// used to pass the information about the owner operationplan down. When
// solving for buffers we must make sure NOT to pass owner information.
// At the end of solving for a buffer we need to restore the original
// settings...
data->state->curOwnerOpplan = nullptr;
// Note that the supply created with the next line changes the
// onhand value at all later dates!
b->getProducingOperation()->solve(*this,v);
// Evaluate the reply date. The variable extraSupplyDate will store
// the date when the producing operation tells us it can get extra
// supply.
if (data->state->a_date < extraSupplyDate
&& data->state->a_date > requested_date)
extraSupplyDate = data->state->a_date;
// If we got some extra supply, we retry to get some more supply.
// Only when no extra material is obtained, we give up.
// When solving for safety stock or when the parameter allowsplit is
// set to false we need to get a single replenishing operationplan.
if (data->state->a_qty > ROUNDING_ERROR
&& data->state->a_qty < -theDelta - ROUNDING_ERROR
&& ((data->getSolver()->getAllowSplits() && !data->safety_stock_planning)
|| data->state->a_qty == b->getProducingOperation()->getSizeMaximum())
)
theDelta += data->state->a_qty;
else
loop = false;
}
// Not enough supply was received to repair the complete problem
if (prev && prev->getOnhand() + shortage < -ROUNDING_ERROR)
{
// Keep track of the shorted quantity.
// Only consider shortages later than the requested date.
if (theDate >= requested_date)
shortage = -prev->getOnhand();
// Reset the date from which excess material is in the buffer. This
// excess material can be used to compute the date when the buffer
// can be asked again for additional supply.
extraInventoryDate = Date::infiniteFuture;
}
}
else if (theDelta > unconfirmed_supply + ROUNDING_ERROR)
// There is excess material at this date (coming from planned/frozen
// material arrivals, surplus material created by lotsized operations,
// etc...)
// The unconfirmed_supply element is required to exclude any of the
// excess inventory we may have caused ourselves. Such situations are
// possible when there are loops in the supply chain.
if (theDate > requested_date
&& extraInventoryDate == Date::infiniteFuture)
extraInventoryDate = theDate;
}
// We have reached the end of the flowplans. Breaking out of the loop
// needs to be done here because in the next statements we are accessing
// *cur, which isn't valid at the end of the list
if (cur == b->getFlowPlans().end()) break;
// The minimum has changed.
// Note that these limits can be updated only after the processing of the
// date change in the statement above. Otherwise the code above would
// already use the new value before the intended date.
// If the flag getPlanSafetyStockFirst is set, then we need to replenish
// up to the minimum quantity. If it is not set (which is the default) then
// we only replenish up to 0.
if (cur->getEventType() == 3 && (getPlanSafetyStockFirst() || data->safety_stock_planning))
current_minimum = cur->getMin();
// Update the pointer to the previous flowplan.
prev = &*cur;
currentDate = cur->getDate();
}
// Note: the variable extraInventoryDate now stores the date from which
// excess material is available in the buffer. The excess
// We don't need to care how much material is lying there.
// Check for supply at the requested date
// Isn't this included in the normal loop? In some cases it is indeed, but
// sometimes it isn't because in the normal loop there may still have been
// onhand available and the shortage only shows at a later date than the
// requested date.
// E.g. Initial situation: After extra consumer at time y:
// -------+ --+
// | |
// +------ +---+
// |
// 0 -------y------ 0 --y---x-----
// |
// +-----
// The first loop only checks for supply at times x and later. If it is not
// feasible, we now check for supply at time y. It will create some extra
// inventory, but at least the demand is met.
// @todo The buffer solver could move backward in time from x till time y,
// and try multiple dates. This would minimize the excess inventory created.
while (shortage > ROUNDING_ERROR
&& b->getProducingOperation() && !tried_requested_date)
{
// Create supply at the requested date
data->state->curBuffer = const_cast<Buffer*>(b);
data->state->q_qty = shortage;
data->state->q_date = requested_date;
// Make sure the new operationplans don't inherit an owner.
// When an operation calls the solve method of suboperations, this field is
// used to pass the information about the owner operationplan down. When
// solving for buffers we must make sure NOT to pass owner information.
// At the end of solving for a buffer we need to restore the original
// settings...
data->state->curOwnerOpplan = nullptr;
// Note that the supply created with the next line changes the onhand value
// at all later dates!
// Note that asking at the requested date doesn't keep the material on
// stock to a minimum.
if (requested_qty - shortage < ROUNDING_ERROR)
data->rollback(topcommand);
b->getProducingOperation()->solve(*this,v);
// Evaluate the reply
if (data->state->a_date < extraSupplyDate
&& data->state->a_date > requested_date)
extraSupplyDate = data->state->a_date;
if (data->state->a_qty > ROUNDING_ERROR)
shortage -= data->state->a_qty;
else
tried_requested_date = true;
}
// Final evaluation of the replenishment
if (data->constrainedPlanning && data->getSolver()->isConstrained())
{
// Use the constrained planning result
data->state->a_qty = requested_qty - shortage;
if (data->state->a_qty < ROUNDING_ERROR)
{
data->rollback(topcommand);
data->state->a_qty = 0.0;
}
data->state->a_date = (extraInventoryDate < extraSupplyDate) ?
extraInventoryDate :
extraSupplyDate;
// Monitor as a constraint if there is no producing operation.
// Note that if there is a producing operation the constraint is flagged
// on the operation instead of on this buffer.
if (!b->getProducingOperation() && data->logConstraints && shortage > ROUNDING_ERROR && data->planningDemand)
data->planningDemand->getConstraints().push(ProblemMaterialShortage::metadata,
b, requested_date, Date::infiniteFuture, shortage);
}
else
{
// Enough inventory or supply available, or not material constrained.
// In case of a plan that is not material constrained, the buffer tries to
// solve for shortages as good as possible. Only in the end we 'lie' about
// the result to the calling function. Material shortages will then remain
// in the buffer.
data->state->a_qty = requested_qty;
data->state->a_date = Date::infiniteFuture;
}
// Restore the owning operationplan.
data->state->curOwnerOpplan = prev_owner_opplan;
// Reply quantity must be greater than 0
assert( data->state->a_qty >= 0 );
// Increment the cost
// Only the quantity consumed directly from the buffer is counted.
// The cost of the material supply taken from producing operations is
// computed seperately and not considered here.
if (b->getItem() && data->state->a_qty > 0)
{
if (b->getFlowPlans().empty())
cumproduced = 0.0;
else
cumproduced = b->getFlowPlans().rbegin()->getCumulativeProduced() - cumproduced;
if (data->state->a_qty > cumproduced)
data->state->a_cost += (data->state->a_qty - cumproduced) * b->getItem()->getPrice();
}
// Message
if (data->getSolver()->getLogLevel()>1)
logger << indent(b->getLevel()) << " Buffer '" << b->getName()
<< "' answers: " << data->state->a_qty << " " << data->state->a_date << " "
<< data->state->a_cost << " " << data->state->a_penalty << endl;
}