fix(job_card): reject a completion split that cannot add up (#57687)

* fix(job_card): reject a completion split that cannot add up

The completion dialogs silently dropped a recalculation whose result went
negative, so entering a pending qty larger than what is left of the qty to
manufacture kept the contradiction (3 to manufacture, 3 completed, 2 pending)
and the job card only failed much later, on submission.

Keep the split consistent while it is entered: reset the pending qty when the
qty to manufacture changes, and refuse a completed, pending or process loss qty
that leaves the others negative. complete_job_card validates the same rule, so
the shop floor and the API cannot store a split that will never submit.

Also name the three parts in the submission error instead of calling their sum
the Total Completed Qty, which read as a contradiction of the field itself.

* test(job_card): cover the completion qty split guard

(cherry picked from commit 7bffd84482)

# Conflicts:
#	erpnext/manufacturing/doctype/job_card/job_card.py
#	erpnext/manufacturing/doctype/job_card/test_job_card.py
#	erpnext/public/js/shop_floor/shop_floor.js

erpnext/manufacturing/doctype/job_card/job_card.js

@@ -250,6 +250,7 @@ frappe.ui.form.on("Job Card", {
 				change() {
 					const dialog = frm.job_completion_dialog;
 					dialog.set_value("completed_qty", dialog.get_value("for_quantity"));
+					dialog.set_value("pending_qty", 0);
 					dialog.set_value("process_loss_qty", 0);
 				},
 			},
@@ -261,8 +262,21 @@ frappe.ui.form.on("Job Card", {
 				default: pending_qty,
 				change() {
 					const dialog = frm.job_completion_dialog;
-					const remaining = dialog.get_value("for_quantity") - dialog.get_value("completed_qty");
-					if (remaining > 0 && remaining != dialog.get_value("pending_qty")) {
+					const remaining =
+						dialog.get_value("for_quantity") -
+						dialog.get_value("completed_qty") -
+						dialog.get_value("process_loss_qty");
+
+					if (remaining < 0) {
+						const max_completed_qty =
+							flt(dialog.get_value("for_quantity")) - flt(dialog.get_value("process_loss_qty"));
+						dialog.set_value("completed_qty", max_completed_qty);
+						frappe.throw(
+							__("Completed Quantity cannot be greater than {0}", [max_completed_qty])
+						);
+					}
+
+					if (remaining != dialog.get_value("pending_qty")) {
 						dialog.set_value("pending_qty", remaining);
 					}
 				},
@@ -278,7 +292,18 @@ frappe.ui.form.on("Job Card", {
 						dialog.get_value("for_quantity") -
 						dialog.get_value("completed_qty") -
 						dialog.get_value("pending_qty");
-					if (process_loss_qty >= 0 && process_loss_qty != dialog.get_value("process_loss_qty")) {
+
+					if (process_loss_qty < 0) {
+						dialog.set_value("pending_qty", 0);
+						frappe.throw(
+							__("Pending Quantity cannot be greater than {0}", [
+								flt(dialog.get_value("for_quantity")) -
+									flt(dialog.get_value("completed_qty")),
+							])
+						);
+					}
+
+					if (process_loss_qty != dialog.get_value("process_loss_qty")) {
 						dialog.set_value("process_loss_qty", process_loss_qty);
 					}
 				},
@@ -293,7 +318,18 @@ frappe.ui.form.on("Job Card", {
 						dialog.get_value("for_quantity") -
 						dialog.get_value("completed_qty") -
 						dialog.get_value("process_loss_qty");
-					if (remaining >= 0 && remaining != dialog.get_value("pending_qty")) {
+
+					if (remaining < 0) {
+						dialog.set_value("process_loss_qty", 0);
+						frappe.throw(
+							__("Process Loss Quantity cannot be greater than {0}", [
+								flt(dialog.get_value("for_quantity")) -
+									flt(dialog.get_value("completed_qty")),
+							])
+						);
+					}
+
+					if (remaining != dialog.get_value("pending_qty")) {
 						dialog.set_value("pending_qty", remaining);
 					}
 				},

erpnext/manufacturing/doctype/job_card/job_card.py

@@ -895,12 +895,13 @@ class JobCard(Document):
 					)
 
 		precision = self.precision("total_completed_qty")
-		total_completed_qty = flt(
+		accounted_qty = flt(
 			flt(self.total_completed_qty, precision)
 			+ flt(self.process_loss_qty, precision)
 			+ flt(self.pending_qty, precision)
 		)
 
+<<<<<<< HEAD
 		if self.for_quantity and flt(total_completed_qty, precision) != flt(self.for_quantity, precision):
 			total_completed_qty_label = bold(_("Total Completed Qty"))
 			qty_to_manufacture = bold(_("Qty to Manufacture"))
@@ -911,6 +912,17 @@ class JobCard(Document):
 					bold(flt(total_completed_qty, precision)),
 					qty_to_manufacture,
 					bold(self.for_quantity),
+=======
+		if self.for_quantity and flt(accounted_qty, precision) != flt(self.for_quantity, precision):
+			frappe.throw(
+				_(
+					"Total Completed Qty ({0}), Process Loss Qty ({1}) and Pending Qty ({2}) must add up to the Qty to Manufacture ({3})."
+				).format(
+					bold(flt(self.total_completed_qty, precision)),
+					bold(flt(self.process_loss_qty, precision)),
+					bold(flt(self.pending_qty, precision)),
+					bold(flt(self.for_quantity, precision)),
+>>>>>>> 7bffd84482 (fix(job_card): reject a completion split that cannot add up (#57687))
 				)
 			)
 
@@ -1515,6 +1527,7 @@ class JobCard(Document):
 			kwargs = frappe._dict(kwargs)
 
 		self.validate_complete_job_card_qty(kwargs)
+		self.set_for_quantity(kwargs)
 
 	def validate_docstatus(self):
 		if self.docstatus == 2:
@@ -1533,9 +1546,36 @@ class JobCard(Document):
 		if flt(kwargs.pending_qty) and flt(kwargs.pending_qty) > self.for_quantity:
 			frappe.throw(_("Pending quantity cannot be greater than the for quantity."))
 
+<<<<<<< HEAD
 		self.pending_qty = flt(kwargs.pending_qty)
 		self.process_loss_qty = flt(kwargs.process_loss_qty)
 
+=======
+		self.validate_completion_qty_split(kwargs)
+
+	def validate_completion_qty_split(self, kwargs):
+		if not flt(kwargs.for_quantity):
+			return
+
+		precision = self.precision("total_completed_qty")
+		accounted_qty = flt(kwargs.qty) + flt(kwargs.pending_qty) + flt(kwargs.process_loss_qty)
+
+		if flt(accounted_qty, precision) == flt(kwargs.for_quantity, precision):
+			return
+
+		frappe.throw(
+			_(
+				"Completed Quantity ({0}), Pending Quantity ({1}) and Process Loss Quantity ({2}) must add up to the Qty to Manufacture ({3})."
+			).format(
+				bold(flt(kwargs.qty, precision)),
+				bold(flt(kwargs.pending_qty, precision)),
+				bold(flt(kwargs.process_loss_qty, precision)),
+				bold(flt(kwargs.for_quantity, precision)),
+			)
+		)
+
+	def add_completion_time_logs(self, kwargs):
+>>>>>>> 7bffd84482 (fix(job_card): reject a completion split that cannot add up (#57687))
 		if kwargs.end_time:
 			self.add_time_logs(
 				to_time=kwargs.end_time,

erpnext/manufacturing/doctype/job_card/test_job_card.py

@@ -1879,3 +1879,94 @@ def create_semi_fg_bom(semi_fg_item, raw_item, inspection_required):
 	bom.append("items", {"item_code": raw_item, "qty": 1})
 	bom.submit()
 	return bom.name
+<<<<<<< HEAD
+=======
+
+
+class TestJobCardLogic(ERPNextTestSuite):
+	"""Field-level validations and pure quantity/capacity helpers, exercised on the
+	document directly so they don't need a Work Order / BOM (the integration suite does)."""
+
+	def test_processing_a_submitted_or_cancelled_card_is_blocked(self):
+		submitted = frappe.new_doc("Job Card")
+		submitted.docstatus = 1
+		self.assertRaises(frappe.ValidationError, submitted.validate_docstatus)
+
+		cancelled = frappe.new_doc("Job Card")
+		cancelled.docstatus = 2
+		self.assertRaises(frappe.ValidationError, cancelled.validate_docstatus)
+
+	def test_complete_job_card_qty_guards(self):
+		jc = frappe.new_doc("Job Card")
+		jc.for_quantity = 5
+		jc.validate_complete_job_card_qty(frappe._dict(pending_qty=3))  # within range -> passes
+		self.assertRaises(
+			frappe.ValidationError, jc.validate_complete_job_card_qty, frappe._dict(pending_qty=-1)
+		)
+		self.assertRaises(
+			frappe.ValidationError, jc.validate_complete_job_card_qty, frappe._dict(process_loss_qty=-1)
+		)
+		self.assertRaises(
+			frappe.ValidationError, jc.validate_complete_job_card_qty, frappe._dict(pending_qty=10)
+		)
+
+	def test_completion_qty_split_must_add_up(self):
+		jc = frappe.new_doc("Job Card")
+		jc.for_quantity = 5
+
+		# 3 completed + 2 pending + 0 lost == 5 to manufacture -> passes
+		jc.validate_complete_job_card_qty(
+			frappe._dict(for_quantity=5, qty=3, pending_qty=2, process_loss_qty=0)
+		)
+
+		self.assertRaises(
+			frappe.ValidationError,
+			jc.validate_complete_job_card_qty,
+			frappe._dict(for_quantity=3, qty=3, pending_qty=2, process_loss_qty=0),
+		)
+
+	def test_completed_qty_must_reconcile_with_for_quantity(self):
+		jc = frappe.new_doc("Job Card")
+		jc.for_quantity = 10
+		jc.total_completed_qty = 6
+		jc.process_loss_qty = 0
+		jc.pending_qty = 0
+		# 6 + 0 + 0 != 10 -> throws
+		self.assertRaises(frappe.ValidationError, jc.validate_completed_qty_matches_for_quantity)
+		# completed + loss + pending == for_quantity -> passes
+		jc.pending_qty = 4
+		jc.validate_completed_qty_matches_for_quantity()
+
+	def test_set_process_loss(self):
+		jc = frappe.new_doc("Job Card")
+		jc.for_quantity = 10
+		jc.total_completed_qty = 6
+		jc.pending_qty = 1
+		jc.set_process_loss()
+		self.assertEqual(jc.process_loss_qty, 3)  # 10 - 6 - 1
+
+		# no loss when nothing completed yet
+		nothing_done = frappe.new_doc("Job Card")
+		nothing_done.for_quantity = 10
+		nothing_done.total_completed_qty = 0
+		nothing_done.set_process_loss()
+		self.assertEqual(nothing_done.process_loss_qty, 0)
+
+	def test_capacity_overlap_detection(self):
+		jc = frappe.new_doc("Job Card")
+		sequential = [
+			{"from_time": "2026-01-01 10:00:00", "to_time": "2026-01-01 11:00:00"},
+			{"from_time": "2026-01-01 11:00:00", "to_time": "2026-01-01 12:00:00"},
+		]
+		overlapping = [
+			{"from_time": "2026-01-01 10:00:00", "to_time": "2026-01-01 11:00:00"},
+			{"from_time": "2026-01-01 10:30:00", "to_time": "2026-01-01 11:30:00"},
+		]
+		# sequential logs share one capacity slot; overlapping logs need two
+		self.assertEqual(len(jc.get_alloted_capacity(sequential)), 1)
+		self.assertEqual(len(jc.get_alloted_capacity(overlapping)), 2)
+		# capacity 1 overlaps with any log; capacity 2 only when both slots are taken
+		self.assertTrue(jc.has_overlap(1, sequential))
+		self.assertFalse(jc.has_overlap(2, sequential))
+		self.assertTrue(jc.has_overlap(2, overlapping))
+>>>>>>> 7bffd84482 (fix(job_card): reject a completion split that cannot add up (#57687))