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Why is there a gap between the start date of a parent DOP Order and the finish date of its component DOP Order?

24.1.1
Site Mfg. Calendar = 24/7 with all dates generated through 2030.
Site Picking LT = 0.
Each Work Center uses calendar 24/7 (1440 minutes/day) with capacity calculated through 2/15/2025.
Each Work Center has only one resource, valid from 1/1/2020.
All QPAs in every structure = 1.
All lead times have been calculated (manufacturing, purchasing, cumulative).
DOP Header is for 10,000 lb and is the only source of load for these work centers.
DOP Structure has been created but not released.
Each part consists of only one operation in a part-specific work center running at 1000 units/hour, so each level takes 10 hours.
CRP has been performed.

DOP Structure, all levels shown are manufactured parts.

 

DOP Gantt Chart

 

DOP Order details

 

CRP Load showing gaps

 

 

I was expecting the four DOP Orders to be slotted for one day each from 8/29 back to 8/26.

Can you take a screenshot showing Machine Load Details page for one of the DOP orders? I.e., to show during which period the DOP operation has been scheduled by CRP.

Also please show the Average and Demonstrated Capacity on the Work Center. I’m not completely sure, but I believe the DOP order lead time is calculated using the average capacity from the work center so make sure that is 24h. 

@Björn Hultgren

Machine Load Details with WC Average Capacity = 8, Demonstrated = 0, and Max Hours per Op = 24.

 

Machine Load Details with WC Average Capacity = 24, Demonstrated = 0, and Max Hours per Op = 24.

 

Machine Load Details looks correct. The DOP order operations are scheduled to take just one day. It’s the actual scheduling so hence, not affected by the Average Capacity on the WC.

However, if you set Average Capacity to 24h per day, does that make any difference on the DOP order lead times? (I would expect it to shrink with one day)

Set the WC Average Capacity to 24.

Cancelled the DOP and created a new one (200022) with the same structure as before.

Ran CRP.

There are no no gaps in the order finish/start dates and load is on 4 sequential days, 10 hours per day.

DOP Orders for the manufacturing parts.

 

Machine Load Details

 

Visual CRP

 

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