feat(manufacturing): create material request for raw materials from work order (#56980)

* feat(manufacturing): create material request for raw materials from work order

* test(manufacturing): cover work order material request flow

erpnext/manufacturing/doctype/work_order/test_work_order.py

@@ -18,6 +18,7 @@ from erpnext.manufacturing.doctype.work_order.work_order import (
 	StockOverProductionError,
 	close_work_order,
 	make_job_card,
+	make_material_request,
 	make_stock_entry,
 	make_stock_return_entry,
 	stop_unstop,
@@ -1547,6 +1548,65 @@ class TestWorkOrder(ERPNextTestSuite):
 		work_order.reload()
 		self.assertEqual(work_order.material_transferred_for_manufacturing, 2.0)
 
+	def test_work_order_material_request_and_bom_details(self):
+		from erpnext.stock.doctype.material_request.material_request import (
+			make_stock_entry as mr_to_stock_entry,
+		)
+
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=2, source_warehouse="Stores - _TC"
+		)
+
+		mr = make_material_request(work_order.name)
+		mr.schedule_date = today()
+		for item in mr.items:
+			item.schedule_date = today()
+		mr.submit()
+		self.assertEqual(mr.work_order, work_order.name)
+
+		ste = mr_to_stock_entry(mr.name)
+		self.assertEqual(ste.purpose, "Material Transfer for Manufacture")
+		self.assertEqual(ste.work_order, work_order.name)
+		self.assertEqual(ste.from_bom, 1.0)
+		self.assertEqual(ste.bom_no, work_order.bom_no)
+		self.assertEqual(ste.fg_completed_qty, 0.0)
+
+	def test_status_in_process_when_only_one_required_item_transferred_via_material_request(self):
+		"""Same bottleneck scenario as the Pick List flow, but the intermediate document is a
+		Material Request created directly from the Work Order: min-fraction keeps
+		material_transferred_for_manufacturing at 0, but the work order must still move to
+		In Process because material is already in WIP.
+		"""
+		from erpnext.stock.doctype.material_request.material_request import (
+			make_stock_entry as mr_to_stock_entry,
+		)
+
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=2, source_warehouse="Stores - _TC"
+		)
+		test_stock_entry.make_stock_entry(
+			item_code="_Test Item", target="Stores - _TC", qty=10, basic_rate=5000.0
+		)
+		test_stock_entry.make_stock_entry(
+			item_code="_Test Item Home Desktop 100", target="Stores - _TC", qty=10, basic_rate=1000.0
+		)
+
+		mr = make_material_request(work_order.name)
+		mr.schedule_date = today()
+		# request only _Test Item; the other required item is left off this material request
+		mr.items = [item for item in mr.items if item.item_code == "_Test Item"]
+		for item in mr.items:
+			item.schedule_date = today()
+		mr.submit()
+
+		stock_entry = frappe.get_doc(mr_to_stock_entry(mr.name))
+		self.assertEqual(stock_entry.fg_completed_qty, 0.0)
+		stock_entry.submit()
+
+		work_order.reload()
+		self.assertEqual(work_order.material_transferred_for_manufacturing, 0.0)
+		self.assertEqual(work_order.status, "In Process")
+
 	def test_backflushed_batch_raw_materials_based_on_transferred(self):
 		frappe.db.set_single_value(
 			"Manufacturing Settings",

erpnext/manufacturing/doctype/work_order/work_order.js

@@ -813,6 +813,10 @@ erpnext.work_order = {
 							erpnext.work_order.create_pick_list(frm);
 						});
 
+						frm.add_custom_button(__("Material Request"), function () {
+							erpnext.work_order.make_material_request(frm);
+						});
+
 						var start_btn = frm.add_custom_button(__("Start"), function () {
 							erpnext.work_order.make_se(frm, "Material Transfer for Manufacture");
 						});
@@ -1151,6 +1155,13 @@ erpnext.work_order = {
 		}
 	},
 
+	make_material_request: function (frm) {
+		frappe.model.open_mapped_doc({
+			method: "erpnext.manufacturing.doctype.work_order.work_order.make_material_request",
+			frm,
+		});
+	},
+
 	create_pick_list: function (frm, purpose = "Material Transfer for Manufacture") {
 		const max = this.get_max_transferable_qty(frm, purpose);
 

erpnext/manufacturing/doctype/work_order/work_order.py

@@ -677,7 +677,11 @@ class WorkOrder(Document):
 		elif self.docstatus == 1:
 			if status not in ["Closed", "Stopped"]:
 				status = "Not Started"
-				if flt(self.material_transferred_for_manufacturing) > 0 or self.skip_transfer:
+				if (
+					flt(self.material_transferred_for_manufacturing) > 0
+					or self.skip_transfer
+					or self._has_transferred_material()
+				):
 					status = "In Process"
 
 				precision = frappe.get_precision("Work Order", "produced_qty")
@@ -711,6 +715,57 @@ class WorkOrder(Document):
 
 		return status
 
+	def _has_transferred_material(self):
+		"""True if any raw material transferred against this work order via a pick list or a
+		material request is still, net of returns, in WIP (these leave
+		material_transferred_for_manufacturing at 0 via the min-fraction rule)."""
+		ste = frappe.qb.DocType("Stock Entry")
+		ste_child = frappe.qb.DocType("Stock Entry Detail")
+		mr_ste = frappe.qb.DocType("Stock Entry")
+		mr_child = frappe.qb.DocType("Stock Entry Detail")
+		# Stock Entry only carries `material_request` at the child-row level, so a Stock
+		# Entry is "MR-sourced" if *any* of its rows link back to a Material Request against
+		# this work order; the join to mr_ste keeps this scoped to this work order's entries
+		# instead of scanning every Material-Request-linked row in the system.
+		mr_sourced_stock_entries = (
+			frappe.qb.from_(mr_child)
+			.inner_join(mr_ste)
+			.on(mr_ste.name == mr_child.parent)
+			.select(mr_child.parent)
+			.where(
+				(mr_child.material_request.isnotnull())
+				& (mr_ste.work_order == self.name)
+				& (mr_ste.docstatus == 1)
+				& (mr_ste.purpose == "Material Transfer for Manufacture")
+			)
+		)
+		common_filters = (
+			(ste.work_order == self.name)
+			& (ste.docstatus == 1)
+			& (ste.purpose == "Material Transfer for Manufacture")
+		)
+		transferred_qty = (
+			frappe.qb.from_(ste)
+			.inner_join(ste_child)
+			.on(ste_child.parent == ste.name)
+			.select(Sum(ste_child.transfer_qty))
+			.where(
+				common_filters
+				& (ste.is_return == 0)
+				& (ste.pick_list.isnotnull() | ste.name.isin(mr_sourced_stock_entries))
+			)
+		).run()[0][0]
+		# Returns don't carry their own pick_list/material_request reference, so net every
+		# return against this work order to correctly clear WIP after a full return.
+		returned_qty = (
+			frappe.qb.from_(ste)
+			.inner_join(ste_child)
+			.on(ste_child.parent == ste.name)
+			.select(Sum(ste_child.transfer_qty))
+			.where(common_filters & (ste.is_return == 1))
+		).run()[0][0]
+		return flt(transferred_qty) - flt(returned_qty) > 0
+
 	def update_work_order_qty(self):
 		"""Update **Manufactured Qty** and **Material Transferred for Qty** in Work Order
 		based on Stock Entry"""
@@ -3014,6 +3069,40 @@ def get_reserved_qty_for_production(
 	return query.run()[0][0] or 0.0
 
 
+@frappe.whitelist()
+def make_material_request(source_name: str, target_doc: str | dict | None = None):
+	frappe.has_permission("Material Request", "create", throw=True)
+
+	doc = get_mapped_doc("Work Order", source_name, _material_request_mapping(), target_doc)
+	doc.material_request_type = "Material Transfer"
+	return doc
+
+
+def _material_request_mapping():
+	return {
+		"Work Order": {
+			"doctype": "Material Request",
+			"validation": {"docstatus": ["=", 1]},
+			"field_map": {"name": "work_order"},
+		},
+		"Work Order Item": {
+			"doctype": "Material Request Item",
+			"field_map": [
+				("stock_uom", "uom"),
+				("source_warehouse", "from_warehouse"),
+			],
+			"postprocess": _set_material_request_item,
+			"condition": lambda doc: abs(doc.transferred_qty) < abs(doc.required_qty),
+		},
+	}
+
+
+def _set_material_request_item(source, target, source_parent):
+	target.warehouse = source_parent.wip_warehouse
+	target.qty = flt(source.required_qty) - flt(source.transferred_qty)
+	target.schedule_date = nowdate()
+
+
 @frappe.whitelist()
 def make_stock_return_entry(work_order):
 	from erpnext.stock.doctype.stock_entry.stock_entry import get_available_materials

erpnext/stock/doctype/material_request/material_request.py

@@ -717,7 +717,7 @@ def make_supplier_quotation(source_name, target_doc=None):
 
 
 @frappe.whitelist()
-def make_stock_entry(source_name, target_doc=None):
+def make_stock_entry(source_name: str, target_doc: str | dict | None = None):
 	def update_item(obj, target, source_parent):
 		qty = (
 			flt(flt(obj.stock_qty) - flt(obj.ordered_qty)) / target.conversion_factor
@@ -753,6 +753,9 @@ def make_stock_entry(source_name, target_doc=None):
 		if source.job_card:
 			target.purpose = "Material Transfer for Manufacture"
 
+		if source.work_order:
+			target.purpose = "Material Transfer for Manufacture"
+
 		if source.material_request_type == "Customer Provided":
 			target.purpose = "Material Receipt"
 
@@ -772,6 +775,18 @@ def make_stock_entry(source_name, target_doc=None):
 				target.fg_completed_qty = job_card_details[0].for_quantity
 				target.from_bom = 1
 
+		if source.work_order:
+			work_order_details = frappe.db.get_value(
+				"Work Order", source.work_order, ["bom_no", "use_multi_level_bom"], as_dict=True
+			)
+
+			if work_order_details:
+				target.bom_no = work_order_details.bom_no
+				target.use_multi_level_bom = work_order_details.use_multi_level_bom
+				target.from_bom = 1
+				# not fg-qty-driven, mirrors the Pick List -> Stock Entry transfer for this Work Order
+				target.fg_completed_qty = 0
+
 	doclist = get_mapped_doc(
 		"Material Request",
 		source_name,