fix: work order finish dialog with process loss qty from job card (backport #58256) (#58262)

* fix(manufacturing): cap job card completed qty by previous operation and show process loss on finish dialog

* fix: avoid double booking process loss on partial manufacture entries

erpnext/manufacturing/doctype/job_card/job_card.py

@@ -150,6 +150,8 @@ class JobCard(Document):
 		self.set_onload("job_card_excess_transfer", excess_transfer)
 		self.set_onload("work_order_closed", self.is_work_order_closed())
 		self.set_onload("has_stock_entry", self.has_stock_entry())
+		if self.docstatus == 0:
+			self.set_onload("max_completable_qty", self.get_max_completable_qty())
 
 	def on_discard(self):
 		self.db_set("status", "Cancelled")
@@ -1374,12 +1376,7 @@ class JobCard(Document):
 
 		current_operation_qty += flt(self.total_completed_qty)
 
-		previous_operations = frappe.get_all(
+		previous_operations = self.get_previous_operations()
-			"Work Order Operation",
-			fields=["name", "operation", "status", "completed_qty", "sequence_id", "finished_good"],
-			filters={"docstatus": 1, "parent": self.work_order, "sequence_id": ("<", self.sequence_id)},
-			order_by="sequence_id, idx",
-		)
 
 		message = "Job Card {}: As per the sequence of the operations in the work order {}".format(
 			bold(self.name), bold(get_link_to_form("Work Order", self.work_order))
@@ -1443,6 +1440,41 @@ class JobCard(Document):
 
 		return dict(data)
 
+	def get_previous_operations(self):
+		return frappe.get_all(
+			"Work Order Operation",
+			fields=["name", "operation", "status", "completed_qty", "sequence_id", "finished_good"],
+			filters={"docstatus": 1, "parent": self.work_order, "sequence_id": ("<", self.sequence_id)},
+			order_by="sequence_id, idx",
+		)
+
+	def get_current_operation_completed_qty(self):
+		current_operation_qty = 0.0
+		data = self.get_current_operation_data()
+		if data and len(data) > 0:
+			current_operation_qty = flt(data[0].completed_qty)
+
+		return current_operation_qty + flt(self.total_completed_qty)
+
+	def get_max_completable_qty(self):
+		if self.is_corrective_job_card or not (self.work_order and self.sequence_id):
+			return None
+
+		previous_operations = self.get_previous_operations()
+		if not previous_operations:
+			return None
+
+		if self.track_semi_finished_goods:
+			totals = self.get_manufactured_qty_per_operation([row.name for row in previous_operations])
+			for row in previous_operations:
+				row.manufactured_qty = flt(totals.get(row.name))
+
+		qty_field = "manufactured_qty" if self.track_semi_finished_goods else "completed_qty"
+		min_completed_qty = min(flt(row.get(qty_field)) for row in previous_operations)
+
+		precision = self.precision("total_completed_qty")
+		return flt(min_completed_qty - self.get_current_operation_completed_qty(), precision)
+
 	def validate_previous_operation_manufactured_qty(self, row, current_operation_qty):
 		manufactured_qty = flt(row.manufactured_qty)
 

erpnext/manufacturing/doctype/job_card/test_job_card.py

@@ -915,6 +915,146 @@ class TestJobCard(ERPNextTestSuite):
 		self.assertEqual(wo_doc.process_loss_qty, 2)
 		self.assertEqual(wo_doc.status, "Completed")
 
+	def make_two_operation_work_order(self, qty=10):
+		from erpnext.manufacturing.doctype.routing.test_routing import (
+			create_routing,
+			setup_bom,
+			setup_operations,
+		)
+		from erpnext.stock.doctype.item.test_item import make_item
+		from erpnext.stock.doctype.warehouse.test_warehouse import create_warehouse
+
+		operations = [
+			{"operation": "Test Operation A1", "workstation": "Test Workstation A", "time_in_mins": 30},
+			{"operation": "Test Operation B1", "workstation": "Test Workstation A", "time_in_mins": 20},
+		]
+
+		warehouse = create_warehouse("Test Warehouse 123 for Job Card")
+		setup_operations(operations)
+
+		item_code = "Test Job Card Process Qty Item"
+		for item in [item_code, item_code + "RM 1", item_code + "RM 2"]:
+			if not frappe.db.exists("Item", item):
+				make_item(item, {"item_name": item, "stock_uom": "Nos", "is_stock_item": 1})
+
+		routing_doc = create_routing(routing_name="Testing Route", operations=operations)
+		bom_doc = setup_bom(
+			item_code=item_code,
+			routing=routing_doc.name,
+			raw_materials=[item_code + "RM 1", item_code + "RM 2"],
+			source_warehouse=warehouse,
+		)
+
+		for row in bom_doc.items:
+			make_stock_entry(item_code=row.item_code, target=row.source_warehouse, qty=qty, basic_rate=100)
+
+		return make_wo_order_test_record(
+			production_item=item_code,
+			bom_no=bom_doc.name,
+			qty=qty,
+			skip_transfer=1,
+			wip_warehouse=warehouse,
+			source_warehouse=warehouse,
+		)
+
+	def test_completion_qty_capped_by_previous_operation(self):
+		wo_doc = self.make_two_operation_work_order()
+		job_cards = frappe.get_all(
+			"Job Card",
+			filters={"work_order": wo_doc.name},
+			fields=["name", "sequence_id"],
+			order_by="sequence_id",
+		)
+
+		jc1 = frappe.get_doc("Job Card", job_cards[0].name)
+		self.assertIsNone(jc1.get_max_completable_qty())
+
+		jc1.append(
+			"time_logs",
+			{"from_time": now(), "to_time": add_to_date(now(), minutes=30), "completed_qty": 8},
+		)
+		jc1.save()
+		jc1.submit()
+		self.assertEqual(jc1.process_loss_qty, 2)
+
+		jc2 = frappe.get_doc("Job Card", job_cards[1].name)
+		self.assertEqual(jc2.get_max_completable_qty(), 8)
+
+		jc2.append("time_logs", {"from_time": add_to_date(now(), minutes=40)})
+		jc2.save()
+
+		self.assertRaises(
+			frappe.ValidationError,
+			jc2.complete_job_card,
+			qty=10,
+			for_quantity=10,
+			pending_qty=0,
+			process_loss_qty=0,
+			end_time=add_to_date(now(), minutes=70),
+		)
+
+		self.complete_second_operation_and_finish(wo_doc, jc2.name)
+
+	def complete_second_operation_and_finish(self, wo_doc, job_card):
+		from erpnext.manufacturing.doctype.work_order.work_order import (
+			make_stock_entry as make_stock_entry_for_wo,
+		)
+
+		jc2 = frappe.get_doc("Job Card", job_card)
+		jc2.time_logs[0].completed_qty = 7
+		jc2.time_logs[0].to_time = add_to_date(now(), minutes=70)
+		jc2.save()
+		self.assertEqual(jc2.process_loss_qty, 3)
+		jc2.submit()
+
+		se = frappe.get_doc(make_stock_entry_for_wo(wo_doc.name, "Manufacture", 10))
+		se.submit()
+
+		self.assertEqual(se.process_loss_qty, 3)
+		fg_qty = sum(d.qty for d in se.items if d.is_finished_item)
+		self.assertEqual(flt(fg_qty), 7)
+
+		wo_doc.reload()
+		self.assertEqual(wo_doc.produced_qty, 7)
+		self.assertEqual(wo_doc.process_loss_qty, 3)
+		self.assertEqual(wo_doc.status, "Completed")
+
+	def test_process_loss_booked_once_across_partial_entries(self):
+		from erpnext.manufacturing.doctype.work_order.work_order import (
+			make_stock_entry as make_stock_entry_for_wo,
+		)
+
+		wo_doc = self.make_two_operation_work_order()
+		job_cards = frappe.get_all(
+			"Job Card", filters={"work_order": wo_doc.name}, fields=["name"], order_by="sequence_id"
+		)
+
+		for index, row in enumerate(job_cards):
+			jc = frappe.get_doc("Job Card", row.name)
+			from_time = add_to_date(now(), minutes=index * 40)
+			jc.append(
+				"time_logs",
+				{"from_time": from_time, "to_time": add_to_date(from_time, minutes=30), "completed_qty": 7},
+			)
+			jc.save()
+			jc.submit()
+			self.assertEqual(jc.process_loss_qty, 3)
+
+		se1 = frappe.get_doc(make_stock_entry_for_wo(wo_doc.name, "Manufacture", 5))
+		se1.submit()
+		self.assertEqual(se1.process_loss_qty, 3)
+		self.assertEqual(flt(sum(d.qty for d in se1.items if d.is_finished_item)), 2)
+
+		se2 = frappe.get_doc(make_stock_entry_for_wo(wo_doc.name, "Manufacture", 5))
+		se2.submit()
+		self.assertEqual(flt(se2.process_loss_qty), 0)
+		self.assertEqual(flt(sum(d.qty for d in se2.items if d.is_finished_item)), 5)
+
+		wo_doc.reload()
+		self.assertEqual(wo_doc.process_loss_qty, 3)
+		self.assertEqual(wo_doc.produced_qty, 7)
+		self.assertEqual(wo_doc.status, "Completed")
+
 	def get_first_job_card(self, work_order):
 		return frappe.get_doc(
 			"Job Card",

erpnext/manufacturing/doctype/work_order/work_order.js

@@ -1021,6 +1021,15 @@ erpnext.work_order = {
 		return flt(max, precision("qty"));
 	},
 
+	get_pending_operation_process_loss: (frm) => {
+		if (!(frm.doc.operations || []).length) {
+			return 0;
+		}
+
+		const total_loss = Math.max(...frm.doc.operations.map((row) => flt(row.process_loss_qty)));
+		return flt(Math.max(total_loss - flt(frm.doc.process_loss_qty), 0), precision("qty"));
+	},
+
 	show_disassembly_prompt: function (frm) {
 		let max_qty = flt(frm.doc.produced_qty - frm.doc.disassembled_qty);
 
@@ -1077,6 +1086,11 @@ erpnext.work_order = {
 
 	show_prompt_for_qty_input: function (frm, purpose, qty, additional_transfer_entry) {
 		let max = !additional_transfer_entry ? this.get_max_transferable_qty(frm, purpose) : qty;
+		if (purpose === "Manufacture") {
+			max = flt(Math.max(max - flt(frm.doc.process_loss_qty), 0), precision("qty"));
+		}
+		const pending_process_loss =
+			purpose === "Manufacture" ? this.get_pending_operation_process_loss(frm) : 0;
 
 		let fields = [
 			{
@@ -1085,23 +1099,36 @@ erpnext.work_order = {
 				fieldname: "qty",
 				description: __("Max: {0}", [max]),
 				default: max,
+				onchange: function () {
+					if (pending_process_loss && frm.qty_prompt) {
+						frm.qty_prompt.set_value(
+							"finished_good_qty",
+							flt(Math.max(flt(this.value) - pending_process_loss, 0), precision("qty"))
+						);
+					}
+				},
 			},
 		];
 
-		if (!additional_transfer_entry) {
+		if (pending_process_loss) {
-			fields.push({
+			fields.push(
-				fieldtype: "Check",
+				{
-				label: __("Consider Process Loss"),
+					fieldtype: "Float",
-				fieldname: "consider_process_loss",
+					label: __("Process Loss Qty"),
-				default: 0,
+					fieldname: "process_loss_qty",
-				onchange: function () {
+					default: pending_process_loss,
-					if (this.value) {
+					read_only: 1,
-						frm.qty_prompt.set_value("qty", max - frm.doc.process_loss_qty);
+					description: __("Process loss booked against the operations of this work order."),
-					} else {
-						frm.qty_prompt.set_value("qty", max);
-					}
 				},
-			});
+				{
+					fieldtype: "Float",
+					label: __("Finished Good Qty"),
+					fieldname: "finished_good_qty",
+					default: flt(Math.max(max - pending_process_loss, 0), precision("qty")),
+					read_only: 1,
+					description: __("Actual quantity of the finished good that will be manufactured."),
+				}
+			);
 		}
 
 		return new Promise((resolve, reject) => {

erpnext/stock/doctype/stock_entry/stock_entry.py

@@ -3323,7 +3323,7 @@ class StockEntry(StockController, SubcontractingInwardController):
 
 	def get_pending_process_loss_qty(self):
 		"""Loss this entry should still book: the job card's unbooked loss when the entry
-		belongs to one, else the largest operation loss on the work order (legacy flow)."""
+		belongs to one, else the unbooked portion of the largest operation loss on the work order."""
 		if self.job_card:
 			job_card = frappe.get_doc("Job Card", self.job_card)
 			return max(flt(job_card.process_loss_qty) - flt(job_card.get_consumed_process_loss()), 0)
@@ -3334,7 +3334,9 @@ class StockEntry(StockController, SubcontractingInwardController):
 				filters={"parent": self.work_order},
 				fields=[{"MAX": "process_loss_qty", "as": "process_loss_qty"}],
 			)
-			return flt(data[0].process_loss_qty) if data else 0
+			max_operation_loss = flt(data[0].process_loss_qty) if data else 0
+			booked_loss = flt(frappe.db.get_value("Work Order", self.work_order, "process_loss_qty"))
+			return max(max_operation_loss - booked_loss, 0)
 
 		return 0