Difference in query plan

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I have a database in a production server (8.1.9) with to schema containing the sames table same index, same every thing, but with different data. When I execute a query in one schema, it take much more time to execute then the other schema. I've issue the query plan and it's different from one schema to the other. I was assuming that is was because the contents of the table where different so I've try the query into a test database into another server (8.3.3) and with both schema, I get the same query plan and they both work fine

I'm wondering where to start searching to fix this problem

Here is my query:

  SELECT bd.component_item_id AS item_id,
rspec('schema_name', bd.component_item_id, bd.component_control_id) AS control_id, adjustdate(m.date_due - avior.item_leadtime('schema_name', bd.item_id, bd.control_id, 0)*7, m.date_due) AS date_due,
         bd.item_id AS to_item_id,
bd.control_id AS to_control_id, m.quantity * totalquantity(bd.quantity,
                                                                    CASE
WHEN substring(bd.component_item_id, 1, 1) = 'F' THEN bd.size1 + 1 ELSE bd.size1
                                                                    END,
CASE WHEN substring(bd.component_item_id, 1, 1) = 'F' THEN bd.size2 + 1 ELSE bd.size2 END) / bd.quantity_produce * i.mfg_conv_factor AS quantity
  FROM schema_name.mrp m
  JOIN schema_name.bom_detail bd
     ON bd.item_id = m.item_id
     AND bd.control_id = rspec('schema_name', m.item_id, m.control_id)
     AND NOT bd.rework,
       schema_name.item i
  WHERE i.item_id=m.item_id
    AND NOT bd.item_supplied
    AND bd.component_item_id = 'some value' ;


Production server schema 1 query plan:
QUERY PLAN ------------------------------------------------------------------------------------------------------------------------------------------------- Nested Loop (cost=569.23..634.43 rows=1 width=121) (actual time=1032.811..1032.811 rows=0 loops=1) -> Merge Join (cost=569.23..628.36 rows=1 width=127) (actual time=1032.806..1032.806 rows=0 loops=1) Merge Cond: (("outer"."?column5?" = "inner".item_id) AND ("outer"."?column6?" = "inner".control_id)) -> Sort (cost=488.89..503.62 rows=5892 width=39) (actual time=1032.736..1032.736 rows=1 loops=1) Sort Key: (m.item_id)::text, (rspec('granby'::text, m.item_id, m.control_id))::text -> Seq Scan on mrp m (cost=0.00..119.92 rows=5892 width=39) (actual time=0.343..939.462 rows=5892 loops=1) -> Sort (cost=80.34..80.39 rows=21 width=97) (actual time=0.059..0.059 rows=0 loops=1)
              Sort Key: bd.item_id, bd.control_id
-> Bitmap Heap Scan on bom_detail bd (cost=2.08..79.87 rows=21 width=97) (actual time=0.038..0.038 rows=0 loops=1) Recheck Cond: ((component_item_id)::text = 'C294301-1'::text)
                    Filter: ((NOT rework) AND (NOT item_supplied))
-> Bitmap Index Scan on i_bomdetail_component (cost=0.00..2.08 rows=23 width=0) (actual time=0.031..0.031 rows=0 loops=1) Index Cond: ((component_item_id)::text = 'C294301-1'::text) -> Index Scan using pkey_item on item i (cost=0.00..6.01 rows=1 width=31) (never executed)
        Index Cond: (i.item_id = ("outer".item_id)::text)
Total runtime: 1034.204 ms
(16 rows)

Production server schema 2 query plan:
QUERY PLAN ------------------------------------------------------------------------------------------------------------------------------------------------- Nested Loop (cost=133.42..793.12 rows=1 width=123) (actual time=0.130..0.130 rows=0 loops=1) -> Merge Join (cost=133.42..787.05 rows=1 width=130) (actual time=0.126..0.126 rows=0 loops=1)
        Merge Cond: (("outer".item_id)::text = "inner".item_id)
Join Filter: ("inner".control_id = (rspec('laval'::text, "outer".item_id, "outer".control_id))::text) -> Index Scan using pkey_mrp on mrp m (cost=0.00..634.29 rows=7501 width=40) (actual time=0.013..0.013 rows=1 loops=1) -> Sort (cost=133.42..133.51 rows=34 width=99) (actual time=0.105..0.105 rows=0 loops=1)
              Sort Key: bd.item_id
-> Bitmap Heap Scan on bom_detail bd (cost=2.13..132.56 rows=34 width=99) (actual time=0.099..0.099 rows=0 loops=1) Recheck Cond: ((component_item_id)::text = 'C294301-1'::text)
                    Filter: ((NOT rework) AND (NOT item_supplied))
-> Bitmap Index Scan on i_bomdetail_component (cost=0.00..2.13 rows=37 width=0) (actual time=0.093..0.093 rows=0 loops=1) Index Cond: ((component_item_id)::text = 'C294301-1'::text) -> Index Scan using pkey_item on item i (cost=0.00..6.01 rows=1 width=29) (never executed)
        Index Cond: (i.item_id = ("outer".item_id)::text)
Total runtime: 0.305 ms
(15 rows)


Test server schema 1 query plan:
QUERY PLAN ------------------------------------------------------------------------------------------------------------------------------------------- Nested Loop (cost=3.43..367.63 rows=1 width=92) (actual time=0.248..0.248 rows=0 loops=1) -> Nested Loop (cost=3.43..360.30 rows=1 width=98) (actual time=0.243..0.243 rows=0 loops=1) Join Filter: ((rspec('granby'::text, m.item_id, m.control_id))::text = bd.control_id) -> Bitmap Heap Scan on bom_detail bd (cost=3.43..62.59 rows=21 width=74) (actual time=0.240..0.240 rows=0 loops=1)
              Recheck Cond: ((component_item_id)::text = 'C294301-1'::text)
              Filter: ((NOT rework) AND (NOT item_supplied))
-> Bitmap Index Scan on i_bomdetail_component (cost=0.00..3.43 rows=23 width=0) (actual time=0.234..0.234 rows=0 loops=1) Index Cond: ((component_item_id)::text = 'C294301-1'::text) -> Index Scan using i_mrp_mrp_itm on mrp m (cost=0.00..9.14 rows=19 width=30) (never executed)
              Index Cond: ((m.item_id)::text = bd.item_id)
-> Index Scan using pkey_item on item i (cost=0.00..6.27 rows=1 width=24) (never executed)
        Index Cond: (i.item_id = bd.item_id)
Total runtime: 0.717 ms
(13 rows)

Test server schema 2 query plan:
QUERY PLAN ------------------------------------------------------------------------------------------------------------------------------------------- Nested Loop (cost=3.54..381.94 rows=1 width=92) (actual time=0.273..0.273 rows=0 loops=1) -> Nested Loop (cost=3.54..374.61 rows=1 width=100) (actual time=0.269..0.269 rows=0 loops=1) Join Filter: ((rspec('laval'::text, m.item_id, m.control_id))::text = bd.control_id) -> Bitmap Heap Scan on bom_detail bd (cost=3.54..99.80 rows=33 width=75) (actual time=0.265..0.265 rows=0 loops=1)
              Recheck Cond: ((component_item_id)::text = 'C294301-1'::text)
              Filter: ((NOT rework) AND (NOT item_supplied))
-> Bitmap Index Scan on i_bomdetail_component (cost=0.00..3.53 rows=36 width=0) (actual time=0.259..0.259 rows=0 loops=1) Index Cond: ((component_item_id)::text = 'C294301-1'::text) -> Index Scan using i_mrp_mrp_itm on mrp m (cost=0.00..6.74 rows=6 width=31) (never executed)
              Index Cond: ((m.item_id)::text = bd.item_id)
-> Index Scan using pkey_item on item i (cost=0.00..6.28 rows=1 width=21) (never executed)
        Index Cond: (i.item_id = bd.item_id)
Total runtime: 0.498 ms
(13 rows)


I'm also wondering why in the production server schema 1 query plan, I'm getting "outer"."?column5?" instead of "outer"."item_id"

It's also to note that schema 1 contain far less date then schema 2 in the order of 1 to 4

thanks
begin:vcard
fn;quoted-printable:Patrice B=C3=A9liveau
n;quoted-printable:B=C3=A9liveau;Patrice
org;quoted-printable:AVIOR Produits Int=C3=A9gr=C3=A9s Inc.
adr;quoted-printable:;;1001, autoroute 440 ouest;Laval;Qu=C3=A9bec;H7L 3W3;Canada
email;internet:pbeliveau@xxxxxxxx
title:Directeur IT
tel;work:(450) 629-6200 #410
tel;fax:(514) 324-6241
x-mozilla-html:FALSE
url:www.avior.ca
version:2.1
end:vcard

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