fix: safety stock and MOQ over-ordering in Production Plan raw materials

erpnext/manufacturing/doctype/production_plan/services/material_request.py

@@ -489,9 +489,8 @@ def get_material_request_items(
 	consumed_qty,
 ):
 	required_qty = _required_qty_for_mr(
-		doc, row, ignore_existing_ordered_qty, warehouse, bin_dict, consumed_qty
+		doc, row, ignore_existing_ordered_qty, warehouse, bin_dict, consumed_qty, include_safety_stock
 	)
-	required_qty = _adjust_required_qty_for_uom(row, required_qty, include_safety_stock)
 	item_group_defaults = get_item_group_defaults(row.item_code, company)
 	conversion_factor = _mr_purchase_conversion_factor(row)
 	return _material_request_item_row(
@@ -499,24 +498,31 @@ def get_material_request_items(
 	)
 
 
-def _required_qty_for_mr(doc, row, ignore_existing_ordered_qty, warehouse, bin_dict, consumed_qty):
-	if not ignore_existing_ordered_qty or bin_dict.get("projected_qty", 0) < 0:
-		required_qty = flt(row.get("qty"))
-	else:
-		key = (row.get("item_code"), warehouse)
-		available_qty = flt(bin_dict.get("projected_qty", 0)) - consumed_qty[key]
-		if available_qty > 0:
-			required_qty = max(0, flt(row.get("qty")) - available_qty)
-			consumed_qty[key] += min(flt(row.get("qty")), available_qty)
-		else:
-			required_qty = flt(row.get("qty"))
+def _required_qty_for_mr(
+	doc, row, ignore_existing_ordered_qty, warehouse, bin_dict, consumed_qty, include_safety_stock
+):
+	safety_stock = flt(row["safety_stock"]) if include_safety_stock else 0
+	qty = flt(row.get("qty"))
 
-	if doc.get("consider_minimum_order_qty") and 0 < required_qty < row["min_order_qty"]:
-		required_qty = row["min_order_qty"]
+	if not ignore_existing_ordered_qty or bin_dict.get("projected_qty", 0) < 0:
+		required_qty = _apply_minimum_order_qty(doc, row, qty + safety_stock)
+		return _adjust_required_qty_for_uom(row, required_qty)
+
+	key = (row.get("item_code"), warehouse)
+	available_qty = flt(bin_dict.get("projected_qty", 0)) - consumed_qty[key]
+	required_qty = _apply_minimum_order_qty(doc, row, max(0, qty - (available_qty - safety_stock)))
+	required_qty = _adjust_required_qty_for_uom(row, required_qty)
+	consumed_qty[key] += qty - required_qty
 	return required_qty
 
 
-def _adjust_required_qty_for_uom(row, required_qty, include_safety_stock):
+def _apply_minimum_order_qty(doc, row, required_qty):
+	if doc.get("consider_minimum_order_qty") and 0 < required_qty < row["min_order_qty"]:
+		return row["min_order_qty"]
+	return required_qty
+
+
+def _adjust_required_qty_for_uom(row, required_qty):
 	if not row["purchase_uom"]:
 		row["purchase_uom"] = row["stock_uom"]
 
@@ -531,8 +537,6 @@ def _adjust_required_qty_for_uom(row, required_qty, include_safety_stock):
 
 	if frappe.db.get_value("UOM", row["purchase_uom"], "must_be_whole_number"):
 		required_qty = ceil(required_qty)
-	if include_safety_stock:
-		required_qty += flt(row["safety_stock"])
 	return required_qty
 
 

erpnext/manufacturing/doctype/production_plan/test_production_plan.py

@@ -1586,6 +1586,53 @@ class TestProductionPlan(ERPNextTestSuite):
 		after_cancel = flt(frappe.db.get_value("Bin", bin_name, "reserved_qty_for_production_plan"))
 		self.assertEqual(after_cancel, before_qty)
 
+	def _plan_with_shared_raw_material(self, rm_item, qty_per_order):
+		fg_item = make_item(properties={"is_stock_item": 1}).name
+		make_bom(item=fg_item, raw_materials=[rm_item], source_warehouse="_Test Warehouse - _TC")
+
+		pln = create_production_plan(
+			item_code=fg_item,
+			ignore_existing_ordered_qty=1,
+			do_not_save=1,
+			skip_getting_mr_items=1,
+		)
+		pln.get_items_from = "Sales Order"
+		for _ in range(2):
+			so = make_sales_order(item_code=fg_item, qty=qty_per_order)
+			pln.append(
+				"sales_orders",
+				{
+					"sales_order": so.name,
+					"sales_order_date": so.transaction_date,
+					"customer": so.customer,
+					"grand_total": so.grand_total,
+				},
+			)
+		pln.get_items()
+		return pln
+
+	def test_safety_stock_added_once_for_repeated_raw_material(self):
+		rm_item = make_item(properties={"is_stock_item": 1, "safety_stock": 10, "valuation_rate": 100}).name
+		make_stock_entry(item_code=rm_item, qty=100, rate=100, target="_Test Warehouse - _TC")
+
+		pln = self._plan_with_shared_raw_material(rm_item, qty_per_order=50)
+		pln.include_safety_stock = 1
+
+		items = get_items_for_material_requests(pln.as_dict())
+		quantities = sorted(flt(d.get("quantity")) for d in items if d.get("item_code") == rm_item)
+		self.assertEqual(quantities, [0, 10])
+
+	def test_minimum_order_qty_surplus_covers_later_rows(self):
+		rm_item = make_item(properties={"is_stock_item": 1, "min_order_qty": 100, "valuation_rate": 100}).name
+		make_stock_entry(item_code=rm_item, qty=40, rate=100, target="_Test Warehouse - _TC")
+
+		pln = self._plan_with_shared_raw_material(rm_item, qty_per_order=50)
+		pln.consider_minimum_order_qty = 1
+
+		items = get_items_for_material_requests(pln.as_dict())
+		quantities = sorted(flt(d.get("quantity")) for d in items if d.get("item_code") == rm_item)
+		self.assertEqual(quantities, [0, 100])
+
 	def test_from_warehouse_for_purchase_material_request(self):
 		from erpnext.stock.doctype.warehouse.test_warehouse import create_warehouse
 		from erpnext.stock.utils import get_or_make_bin