There are alternative solutions to this issue:
Solution 1
Search for the relevant works order from the order planner, on the left hand pane of the plan.
Double-click the works order that are planning to future years and Edit Tasks will launch on left hand pane of the plan.
Select the resources tab and note the figure for the labour resource
Select resources from the main menu
Select Default Shift Pattern Assignment
Select Quantity Adjustment tab and click Edit.
The relevant labour resource will have a quantity of 1. Change to match the unit figure under the resources tab of edit tasks in step 1.
Go back to the order planner and right click the relevant works order and select unplan.
Click Add To Plan from the order planner and the works order will not plan to the correct year on the Gantt chart.
Solution 2
Delete the relevant tasks for the orders that are planned too far in the future
Save plan
Run another data import
Plan the relevant order(s) again from the order planner
Solution 3
Late works orders may plan too far into the future because of older works orders (WO) having a shortage. They were planned into the future but that was consuming available stock now. By the time we got to the WO's we could plan now, the stock had already been consumed by WO's in the future. The planning logic is working as designed.
Solution 4
The planning logic is working as designed. When backward planning, it plans the task just before the deadline date.For example, WO 12345 has a deadline of Jan 20th. Planning backwards will plan just before this date.
To resolve this issue, untick 'Check Downstream Planned Usages' from the order planner (click the button with a multi-coloured icon - next to New, Edit, Delete for the filter) and click the button to plan backwards (grey staple symbol button with blue arrow pointing left).
Check Downstream Planned Usages is only available in backwards planning. This option checks that the works order is planned in time to feed another works order/sales order that requires it.
Solution 5 (Orchestrate version 7.65 or below)
'Search For Unpegged Material' is ticked and the other options are unticked, from the order planner. If you untick this option and then tick 'check downstream planned usages', unplan and replan the works order, it plans to the correct section of the gantt chart.
Solution 6 (Orchestrate version 7.66 or above)
Lots of works orders and purchase orders were planned in the past without having 'Check availability of made items when planning', and 'check availability of purchased items when planning ticked'. Delete all the orders from the plan and run a import. Plan all the orders after ticking the relevant planning options:
Tools
Options
Planning (Tab)
Search For Unpegged Material
Tick check availability of made items when planning
Tick check availability of purchased items when planning
Solution 7
Some of the components listed in task KPIs have a really long supplier lead time, so, this will delay the material requirements to fulfil the works order. To see the list of components/assembly details and the supplier lead time, please complete the following steps:-
Double-click the relevant task on the Gantt Chart
Select Prod/Usage tab from Edit Tasks (left-hand pane)
You will see a list of components descriptions e.g. Comp01 Usage (Planned)
Widen the prod/usage window and scroll to the right to see the Supplier Lead Time (days), as well as other columns. unplanned value, stock usage, stock, Applies e.g. start of task etc.
Solution 8
When adding travel time to routing operations (from Production, Manufacturing Route Maintenance within FactoryMaster), the allow a time of at least 'TIME FIELD' to elapse after the scheduled end time of this operation before scheduling, the next operation, needs to be a time period within the shift pattern hours, the works order is planning too. For example, if you have a travel time of 12 hours and the shift pattern on the resource is 8 hours (in Orchestrate), the works orders will jump years ahead when imported and planned. If the travel time is reduced to 6 hours, the works orders will then plan fine.