fix(job_card): require the previous operation to be manufactured (#57684)

* fix(job_card): block next operation until previous operation is manufactured

With track semi finished goods, Work Order Operation completed_qty is set from
the submitted job cards' total completed qty, so a job card of the next
operation could be started and completed even when no Manufacture entry existed
for the previous operation. The semi-finished goods it consumes were never
produced.

Validate the sequence against the qty actually manufactured against the previous
operations' job cards (Manufacture entries / Subcontracting Receipts) when the
work order tracks semi finished goods.

* test(job_card): cover manufactured qty check across previous operations

Work order with operations A and B at sequence 1 and C at sequence 2, tracking
semi finished goods. C stays blocked while A's job card is submitted but its
Manufacture entry is missing, and once A is manufactured for 3, C can only be
completed for 3.

erpnext/manufacturing/doctype/job_card/job_card.py

@@ -1418,15 +1418,46 @@ class JobCard(Document):
 
 		current_operation_qty = self.get_current_operation_completed_qty()
 
+		for row in self.get_previous_operations():
+			if self.track_semi_finished_goods:
+				self.validate_previous_operation_manufactured_qty(row, current_operation_qty)
+			else:
+				self.validate_previous_operation(row, current_operation_qty)
+
+	def get_previous_operations(self):
 		previous_operations = frappe.get_all(
 			"Work Order Operation",
-			fields=["operation", "status", "completed_qty", "sequence_id"],
+			fields=["name", "operation", "status", "completed_qty", "sequence_id"],
 			filters={"docstatus": 1, "parent": self.work_order, "sequence_id": ("<", self.sequence_id)},
 			order_by="sequence_id, idx",
 		)
 
-		for row in previous_operations:
-			self.validate_previous_operation(row, current_operation_qty)
+		if self.track_semi_finished_goods and previous_operations:
+			manufactured_qty = self.get_manufactured_qty_per_operation(
+				[row.name for row in previous_operations]
+			)
+
+			for row in previous_operations:
+				row.manufactured_qty = flt(manufactured_qty.get(row.name))
+
+		return previous_operations
+
+	def get_manufactured_qty_per_operation(self, operation_ids):
+		job_card = frappe.qb.DocType("Job Card")
+
+		data = (
+			frappe.qb.from_(job_card)
+			.select(job_card.operation_id, Sum(job_card.manufactured_qty))
+			.where(
+				(job_card.work_order == self.work_order)
+				& (job_card.docstatus == 1)
+				& (IfNull(job_card.is_corrective_job_card, 0) == 0)
+				& (job_card.operation_id.isin(operation_ids))
+			)
+			.groupby(job_card.operation_id)
+		).run()
+
+		return dict(data)
 
 	def get_current_operation_completed_qty(self):
 		current_operation_qty = 0.0
@@ -1462,6 +1493,35 @@ class JobCard(Document):
 				)
 			)
 
+	def validate_previous_operation_manufactured_qty(self, row, current_operation_qty):
+		manufactured_qty = flt(row.manufactured_qty)
+
+		if not manufactured_qty:
+			frappe.throw(
+				_(
+					"Job Card {0}: As per the sequence of the operations in the work order {1}, submit the manufacturing entry for the operation {2} before the operation {3}."
+				).format(
+					bold(self.name),
+					bold(get_link_to_form("Work Order", self.work_order)),
+					bold(row.operation),
+					bold(self.operation),
+				),
+				OperationSequenceError,
+			)
+
+		if manufactured_qty < current_operation_qty:
+			frappe.throw(
+				_(
+					"The completed quantity {0} of an operation {1} cannot be greater than the manufactured quantity {2} of a previous operation {3}. Submit the manufacturing entry for the operation {3} first."
+				).format(
+					bold(current_operation_qty),
+					bold(self.operation),
+					bold(manufactured_qty),
+					bold(row.operation),
+				),
+				OperationSequenceError,
+			)
+
 	def validate_work_order(self):
 		if self.is_work_order_closed():
 			frappe.throw(_("You cannot make any changes to Job Card since Work Order is closed."))

erpnext/manufacturing/doctype/job_card/test_job_card.py

@@ -10,6 +10,7 @@ from frappe.utils.data import add_to_date, now, today
 
 from erpnext.manufacturing.doctype.job_card.job_card import (
 	JobCardOverTransferError,
+	OperationSequenceError,
 	OverlapError,
 )
 from erpnext.manufacturing.doctype.job_card.mapper import (
@@ -1289,6 +1290,144 @@ class TestJobCard(ERPNextTestSuite):
 			8,
 		)
 
+	def test_semi_fg_sequence_needs_previous_operations_manufactured(self):
+		from erpnext.manufacturing.doctype.operation.test_operation import make_operation
+		from erpnext.stock.doctype.item.test_item import make_item
+
+		warehouse = "Stores - _TC"
+		rm1 = make_item("Sequence Check RM 1", {"is_stock_item": 1}).name
+		rm2 = make_item("Sequence Check RM 2", {"is_stock_item": 1}).name
+		sfg1 = make_item("Sequence Check SFG 1", {"is_stock_item": 1}).name
+		sfg2 = make_item("Sequence Check SFG 2", {"is_stock_item": 1}).name
+		fg = make_item("Sequence Check FG 1", {"is_stock_item": 1}).name
+
+		semi_fg_boms = {}
+		for semi_fg_item, raw_material in ((sfg1, rm1), (sfg2, rm2)):
+			bom = frappe.new_doc("BOM", company="_Test Company", item=semi_fg_item, quantity=1)
+			bom.append("items", {"item_code": raw_material, "qty": 1})
+			bom.insert()
+			bom.submit()
+			semi_fg_boms[semi_fg_item] = bom.name
+
+		fg_bom = frappe.new_doc(
+			"BOM",
+			company="_Test Company",
+			item=fg,
+			quantity=1,
+			with_operations=1,
+			track_semi_finished_goods=1,
+		)
+
+		operations = [
+			{
+				"operation": "Sequence Check Op A",
+				"finished_good": sfg1,
+				"bom_no": semi_fg_boms[sfg1],
+				"sequence_id": 1,
+			},
+			{
+				"operation": "Sequence Check Op B",
+				"finished_good": sfg2,
+				"bom_no": semi_fg_boms[sfg2],
+				"sequence_id": 1,
+			},
+			{
+				"operation": "Sequence Check Op C",
+				"finished_good": fg,
+				"is_final_finished_good": 1,
+				"sequence_id": 2,
+			},
+		]
+
+		for row in operations:
+			row.update(
+				{
+					"workstation": "_Test Workstation A",
+					"finished_good_qty": 1,
+					"time_in_mins": 60,
+					"source_warehouse": warehouse,
+					"fg_warehouse": warehouse,
+					"skip_material_transfer": 1,
+				}
+			)
+
+			make_workstation(row)
+			make_operation(row)
+			fg_bom.append("operations", row)
+
+		fg_bom.append("items", {"item_code": sfg1, "qty": 1, "operation_row_id": 3})
+		fg_bom.append("items", {"item_code": sfg2, "qty": 1, "operation_row_id": 3})
+		fg_bom.insert()
+		fg_bom.submit()
+
+		work_order = make_wo_order_test_record(
+			item=fg,
+			qty=5,
+			source_warehouse=warehouse,
+			fg_warehouse=warehouse,
+			bom_no=fg_bom.name,
+			skip_transfer=1,
+			do_not_save=True,
+		)
+
+		for row in work_order.operations:
+			row.time_in_mins = 60
+
+		work_order.save()
+		work_order.submit()
+
+		make_stock_entry(item_code=rm1, target=warehouse, qty=10, basic_rate=100)
+		make_stock_entry(item_code=rm2, target=warehouse, qty=10, basic_rate=100)
+
+		def get_job_card(operation):
+			return frappe.get_doc(
+				"Job Card",
+				frappe.db.get_value(
+					"Job Card",
+					{"work_order": work_order.name, "operation": operation, "docstatus": 0},
+					"name",
+				),
+			)
+
+		def add_time_log(job_card, day, qty):
+			job_card.append(
+				"time_logs",
+				{
+					"from_time": f"2024-01-{day} 08:00:00",
+					"to_time": f"2024-01-{day} 09:00:00",
+					"completed_qty": qty,
+				},
+			)
+
+		jc_a = get_job_card("Sequence Check Op A")
+		jc_a.for_quantity = 3
+		add_time_log(jc_a, "01", 3)
+		jc_a.submit()
+
+		jc_b = get_job_card("Sequence Check Op B")
+		add_time_log(jc_b, "02", jc_b.for_quantity)
+		jc_b.submit()
+		frappe.get_doc(jc_b.make_stock_entry_for_semi_fg_item()).submit()
+
+		jc_c = get_job_card("Sequence Check Op C")
+		jc_c.for_quantity = 3
+		add_time_log(jc_c, "03", 3)
+		self.assertRaises(OperationSequenceError, jc_c.save)
+
+		frappe.get_doc(jc_a.make_stock_entry_for_semi_fg_item()).submit()
+
+		jc_c.reload()
+		jc_c.for_quantity = 4
+		add_time_log(jc_c, "03", 4)
+		self.assertRaises(OperationSequenceError, jc_c.save)
+
+		jc_c.reload()
+		jc_c.for_quantity = 3
+		add_time_log(jc_c, "03", 3)
+		jc_c.submit()
+
+		self.assertEqual(jc_c.docstatus, 1)
+
 	def test_semi_fg_batch_auto_pull_on_manufacture(self):
 		"""Batch produced by an operation should auto-pull into the next operation's
 		semi-finished consumption row (skip-transfer Manufacture entry)."""