From 5822cef1d98a6b8d082921fbb62d92f804f92c25 Mon Sep 17 00:00:00 2001
From: Mihir Kandoi <kandoimihir@gmail.com>
Date: Fri, 7 Aug 2026 22:55:51 +0530
Subject: [PATCH] feat(manufacturing): prompt for qty when creating material
 request from work order (#57855)

---
 .../doctype/work_order/mapper.py              | 134 +++++--
 .../work_order/services/required_items.py     |  92 +++++
 .../doctype/work_order/test_work_order.py     | 353 ++++++++++++++++++
 .../doctype/work_order/work_order.js          |  76 +++-
 .../work_order_item/work_order_item.json      |  20 +-
 .../work_order_item/work_order_item.py        |   2 +
 erpnext/patches.txt                           |   1 +
 ...set_work_order_requested_and_picked_qty.py |  38 ++
 .../material_request/material_request.json    |   5 +-
 .../material_request/material_request.py      |  30 ++
 .../stock/doctype/pick_list/pick_list.json    |   5 +-
 erpnext/stock/doctype/pick_list/pick_list.py  |  59 +++
 12 files changed, 769 insertions(+), 46 deletions(-)
 create mode 100644 erpnext/patches/v16_0/set_work_order_requested_and_picked_qty.py

diff --git a/erpnext/manufacturing/doctype/work_order/mapper.py b/erpnext/manufacturing/doctype/work_order/mapper.py
index c726b9e38fc..7287a9ecb74 100644
--- a/erpnext/manufacturing/doctype/work_order/mapper.py
+++ b/erpnext/manufacturing/doctype/work_order/mapper.py
@@ -9,6 +9,7 @@ the controller; work_order.py re-exports them for backward compatibility.
 """
 
 import json
+import math
 from functools import partial
 
 import frappe
@@ -476,42 +477,104 @@ def create_pick_list(
 ):
 	frappe.has_permission("Pick List", "create", throw=True)
 
-	for_qty = for_qty or frappe.parse_json(target_doc).get("for_qty")
-	max_finished_goods_qty = frappe.db.get_value("Work Order", source_name, "qty")
-	postprocess = partial(
-		_set_pick_list_item_qty, for_qty=for_qty, max_finished_goods_qty=max_finished_goods_qty
-	)
+	if for_qty is None:
+		for_qty = frappe.parse_json(target_doc or "{}").get("for_qty")
 
-	doc = get_mapped_doc("Work Order", source_name, _pick_list_mapping(postprocess), target_doc)
+	for_qty = _validated_for_qty(for_qty)
+	work_order = frappe.get_doc("Work Order", source_name)
+	allocation = _allocate_material_demand(work_order, for_qty / flt(work_order.qty))
+	postprocess = partial(_set_pick_list_item_qty, allocation_by_item=allocation)
+
+	doc = get_mapped_doc("Work Order", source_name, _pick_list_mapping(postprocess, allocation), target_doc)
+	_validate_material_is_pending(doc.locations)
 	doc.purpose = "Material Transfer for Manufacture"
 	doc.for_qty = for_qty
 	doc.set_item_locations()
 	return doc
 
 
-def _pick_list_mapping(postprocess):
+def _pick_list_mapping(postprocess, allocation):
 	return {
 		"Work Order": {"doctype": "Pick List", "validation": {"docstatus": ["=", 1]}},
 		"Work Order Item": {
 			"doctype": "Pick List Item",
 			"field_no_map": ["transferred_qty"],
 			"postprocess": postprocess,
-			"condition": lambda doc: abs(doc.transferred_qty) < abs(doc.required_qty),
+			"condition": lambda doc: _allocation_key(doc) in allocation,
 		},
 	}
 
 
-def _set_pick_list_item_qty(source, target, source_parent, for_qty, max_finished_goods_qty):
-	pending_to_issue = flt(source.required_qty) - flt(source.transferred_qty)
-	desire_to_transfer = flt(source.required_qty) / max_finished_goods_qty * flt(for_qty)
+def _allocate_material_demand(work_order, fraction):
+	"""Fraction of each (item, warehouse, operation row) group's requirement, capped
+	at the group's proportional share of the item's pending pool."""
+	required_by_item = {}
+	covered_by_item = {}
+	required_by_group = {}
+	for row in work_order.required_items:
+		required_by_item[row.item_code] = required_by_item.get(row.item_code, 0.0) + flt(row.required_qty)
+		covered_by_item.setdefault(
+			row.item_code,
+			flt(row.transferred_qty) + flt(row.requested_qty) + flt(row.picked_qty),
+		)
+		key = _allocation_key(row)
+		required_by_group[key] = required_by_group.get(key, 0.0) + flt(row.required_qty)
 
-	qty = 0
-	if desire_to_transfer <= pending_to_issue:
-		qty = desire_to_transfer
-	elif pending_to_issue > 0:
-		qty = pending_to_issue
+	pending_pool = {
+		item_code: required_qty - covered_by_item[item_code]
+		for item_code, required_qty in required_by_item.items()
+	}
 
-	if not qty:
+	allocation = {}
+	for key, required_qty in required_by_group.items():
+		item_code = key[0]
+		if required_by_item[item_code] <= 0:
+			continue
+
+		pool_share = pending_pool[item_code] * required_qty / required_by_item[item_code]
+		qty = min(required_qty * fraction, pool_share)
+		if qty > 0:
+			allocation[key] = qty
+	return allocation
+
+
+def _allocation_key(row):
+	"""Manual rows have no operation_row_id; their operation label splits them."""
+	return (row.item_code, row.source_warehouse, cint(row.operation_row_id) or row.operation)
+
+
+def _merge_allocation_per_item(allocation):
+	"""Material Request rejects repeated item codes unless Buying Settings allows them."""
+	merged = {}
+	key_by_item = {}
+	for key, qty in allocation.items():
+		item_code = key[0]
+		if item_code in key_by_item:
+			merged[key_by_item[item_code]] += qty
+		else:
+			key_by_item[item_code] = key
+			merged[key] = qty
+	return merged
+
+
+def _validated_for_qty(for_qty):
+	qty = flt(for_qty)
+	if not math.isfinite(qty) or qty <= 0:
+		frappe.throw(_("Quantity must be greater than zero."))
+	return qty
+
+
+def _validate_material_is_pending(rows):
+	if not rows:
+		frappe.throw(
+			_("All required items have already been transferred, requested or picked."),
+			title=_("No Pending Materials"),
+		)
+
+
+def _set_pick_list_item_qty(source, target, source_parent, allocation_by_item):
+	qty = allocation_by_item.pop(_allocation_key(source), 0.0)
+	if qty <= 0:
 		target.delete()
 		return
 
@@ -523,15 +586,32 @@ def _set_pick_list_item_qty(source, target, source_parent, for_qty, max_finished
 
 
 @frappe.whitelist()
-def make_material_request(source_name: str, target_doc: str | dict | Document | None = None):
+def make_material_request(
+	source_name: str, target_doc: str | dict | Document | None = None, for_qty: float | None = None
+):
 	frappe.has_permission("Material Request", "create", throw=True)
 
-	doc = get_mapped_doc("Work Order", source_name, _material_request_mapping(), target_doc)
+	if for_qty is None and frappe.flags.args:
+		for_qty = frappe.flags.args.for_qty
+
+	work_order = frappe.get_doc("Work Order", source_name)
+	fraction = 1.0
+	if for_qty is not None:
+		fraction = _validated_for_qty(for_qty) / flt(work_order.qty)
+
+	allocation = _allocate_material_demand(work_order, fraction)
+	if not cint(frappe.db.get_single_value("Buying Settings", "allow_multiple_items")):
+		allocation = _merge_allocation_per_item(allocation)
+	postprocess = partial(_set_material_request_item, allocation_by_item=allocation)
+	doc = get_mapped_doc(
+		"Work Order", source_name, _material_request_mapping(postprocess, allocation), target_doc
+	)
+	_validate_material_is_pending(doc.items)
 	doc.material_request_type = "Material Transfer"
 	return doc
 
 
-def _material_request_mapping():
+def _material_request_mapping(postprocess, allocation):
 	return {
 		"Work Order": {
 			"doctype": "Material Request",
@@ -541,19 +621,23 @@ def _material_request_mapping():
 		"Work Order Item": {
 			"doctype": "Material Request Item",
 			"field_map": [
-				("required_qty", "qty"),
 				("stock_uom", "uom"),
 				("source_warehouse", "from_warehouse"),
 			],
-			"postprocess": _set_material_request_item,
-			"condition": lambda doc: abs(doc.transferred_qty) < abs(doc.required_qty),
+			"postprocess": postprocess,
+			"condition": lambda doc: _allocation_key(doc) in allocation,
 		},
 	}
 
 
-def _set_material_request_item(source, target, source_parent):
+def _set_material_request_item(source, target, source_parent, allocation_by_item):
+	qty = allocation_by_item.pop(_allocation_key(source), 0.0)
+	if qty <= 0:
+		target.delete()
+		return
+
 	target.warehouse = source_parent.wip_warehouse
-	target.qty = flt(source.required_qty) - flt(source.transferred_qty)
+	target.qty = qty
 	target.schedule_date = nowdate()
 
 
diff --git a/erpnext/manufacturing/doctype/work_order/services/required_items.py b/erpnext/manufacturing/doctype/work_order/services/required_items.py
index c1c55977583..09f0e3ab32c 100644
--- a/erpnext/manufacturing/doctype/work_order/services/required_items.py
+++ b/erpnext/manufacturing/doctype/work_order/services/required_items.py
@@ -9,6 +9,7 @@ callers and the whitelisted entry point keep working unchanged.
 """
 
 import frappe
+from frappe import _
 from frappe.utils import flt
 from pypika import functions as fn
 
@@ -198,6 +199,97 @@ class RequiredItemsService:
 		for row in self.doc.required_items:
 			row.db_set("returned_qty", (returned_dict.get(row.item_code) or 0.0), update_modified=False)
 
+	def validate_incoming_material_demand(self, incoming_qty_by_item):
+		"""Reject demand exceeding the pending requirement; callers must hold the
+		work order row lock (for_update=True)."""
+		required_by_item = {}
+		uom_by_item = {}
+		for row in self.doc.required_items:
+			required_by_item[row.item_code] = required_by_item.get(row.item_code, 0.0) + flt(row.required_qty)
+			uom_by_item.setdefault(row.item_code, row.stock_uom)
+
+		transferred = self._material_transfer_qty_by_item(is_return=0)
+		requested = self._material_request_pending_qty_by_item()
+		picked = self._pick_list_pending_qty_by_item()
+
+		for item_code, incoming_qty in incoming_qty_by_item.items():
+			if item_code not in required_by_item:
+				continue
+
+			pending = (
+				required_by_item[item_code]
+				- flt(transferred.get(item_code))
+				- flt(requested.get(item_code))
+				- flt(picked.get(item_code))
+			)
+			if flt(incoming_qty - pending, 6) > 0:
+				frappe.throw(
+					_("Only {0} {1} of {2} is pending in Work Order {3}.").format(
+						max(pending, 0.0), uom_by_item[item_code], item_code, self.doc.name
+					),
+					title=_("Exceeds Pending Qty"),
+				)
+
+	def update_requested_qty_for_required_items(self):
+		"""Refresh per-row qty requested via open Material Requests but not yet transferred."""
+		requested_items = self._material_request_pending_qty_by_item()
+		for row in self.doc.required_items:
+			row.db_set("requested_qty", (requested_items.get(row.item_code) or 0.0), update_modified=False)
+
+	def _material_request_pending_qty_by_item(self):
+		mr = frappe.qb.DocType("Material Request")
+		mr_item = frappe.qb.DocType("Material Request Item")
+		query = (
+			frappe.qb.from_(mr)
+			.inner_join(mr_item)
+			.on(mr_item.parent == mr.name)
+			.select(mr_item.item_code, fn.Sum(mr_item.stock_qty - mr_item.ordered_qty).as_("qty"))
+			.where(
+				(mr.docstatus == 1)
+				& (mr.work_order == self.doc.name)
+				& (mr.material_request_type == "Material Transfer")
+				& (mr.status != "Stopped")
+				& (mr_item.stock_qty > mr_item.ordered_qty)
+			)
+			.groupby(mr_item.item_code)
+		)
+		return frappe._dict({d.item_code: flt(d.qty) for d in query.run(as_dict=1)})
+
+	def update_picked_qty_for_required_items(self):
+		"""Refresh per-row qty picked but not yet transferred. Rows of a live material
+		request count as requested_qty instead, until that request stops or cancels."""
+		picked_items = self._pick_list_pending_qty_by_item()
+		for row in self.doc.required_items:
+			row.db_set("picked_qty", (picked_items.get(row.item_code) or 0.0), update_modified=False)
+
+	def _pick_list_pending_qty_by_item(self):
+		pick_list = frappe.qb.DocType("Pick List")
+		pick_list_item = frappe.qb.DocType("Pick List Item")
+		mr = frappe.qb.DocType("Material Request")
+		query = (
+			frappe.qb.from_(pick_list)
+			.inner_join(pick_list_item)
+			.on(pick_list_item.parent == pick_list.name)
+			.left_join(mr)
+			.on(pick_list_item.material_request == mr.name)
+			.select(
+				pick_list_item.item_code,
+				fn.Sum(pick_list_item.picked_qty - pick_list_item.transferred_qty).as_("qty"),
+			)
+			.where(
+				(pick_list.docstatus == 1)
+				& (pick_list.work_order == self.doc.name)
+				& (pick_list_item.picked_qty > pick_list_item.transferred_qty)
+				& (
+					(fn.Coalesce(pick_list_item.material_request_item, "") == "")
+					| (mr.docstatus != 1)
+					| (mr.status == "Stopped")
+				)
+			)
+			.groupby(pick_list_item.item_code)
+		)
+		return frappe._dict({d.item_code: flt(d.qty) for d in query.run(as_dict=1)})
+
 	def _material_transfer_qty_by_item(self, is_return):
 		ste = frappe.qb.DocType("Stock Entry")
 		ste_child = frappe.qb.DocType("Stock Entry Detail")
diff --git a/erpnext/manufacturing/doctype/work_order/test_work_order.py b/erpnext/manufacturing/doctype/work_order/test_work_order.py
index 427a89df811..ec1201d72d4 100644
--- a/erpnext/manufacturing/doctype/work_order/test_work_order.py
+++ b/erpnext/manufacturing/doctype/work_order/test_work_order.py
@@ -1638,6 +1638,359 @@ class TestWorkOrder(ERPNextTestSuite):
 		self.assertEqual(work_order.material_transferred_for_manufacturing, 0.0)
 		self.assertEqual(work_order.status, "In Process")
 
+	def test_material_request_qty_scales_with_requested_qty(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+		required_qty = {row.item_code: flt(row.required_qty) for row in work_order.required_items}
+
+		mr = make_material_request(work_order.name, for_qty=4)
+		self.assertEqual(len(mr.items), len(required_qty))
+		for row in mr.items:
+			self.assertEqual(row.qty, required_qty[row.item_code] * 4 / 10)
+
+		mr = make_material_request(work_order.name)
+		for row in mr.items:
+			self.assertEqual(row.qty, required_qty[row.item_code])
+
+	def test_material_request_qty_capped_at_pending_qty(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+		partially_transferred = work_order.required_items[0]
+		partially_transferred.db_set("transferred_qty", flt(partially_transferred.required_qty) - 1)
+		work_order.reload()
+
+		mr = make_material_request(work_order.name, for_qty=10)
+		requested_qty = {row.item_code: row.qty for row in mr.items}
+		self.assertEqual(requested_qty[partially_transferred.item_code], 1)
+
+	def test_material_request_maps_only_selected_rows(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+		selected = work_order.required_items[0]
+
+		try:
+			frappe.flags.selected_children = {"required_items": [selected.name]}
+			mr = make_material_request(work_order.name, for_qty=4)
+		finally:
+			frappe.flags.selected_children = None
+
+		self.assertEqual([row.item_code for row in mr.items], [selected.item_code])
+		self.assertEqual(mr.items[0].qty, flt(selected.required_qty) * 4 / 10)
+
+	def test_material_request_rejects_nonpositive_qty(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+
+		self.assertRaises(frappe.ValidationError, make_material_request, work_order.name, for_qty=0)
+		self.assertRaises(frappe.ValidationError, make_material_request, work_order.name, for_qty=-1)
+		self.assertRaises(
+			frappe.ValidationError, make_material_request, work_order.name, for_qty=float("inf")
+		)
+		self.assertRaises(
+			frappe.ValidationError, make_material_request, work_order.name, for_qty=float("nan")
+		)
+
+	def test_pick_list_rejects_nonpositive_qty(self):
+		from erpnext.manufacturing.doctype.work_order.mapper import create_pick_list
+
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+
+		self.assertRaises(frappe.ValidationError, create_pick_list, work_order.name, for_qty=0)
+		self.assertRaises(frappe.ValidationError, create_pick_list, work_order.name, for_qty=-1)
+		self.assertRaises(frappe.ValidationError, create_pick_list, work_order.name, for_qty=float("inf"))
+		self.assertRaises(frappe.ValidationError, create_pick_list, work_order.name, for_qty=float("nan"))
+		self.assertRaises(frappe.ValidationError, create_pick_list, work_order.name)
+
+	def submit_material_request(self, work_order_name, for_qty=None):
+		mr = make_material_request(work_order_name, for_qty=for_qty)
+		mr.schedule_date = today()
+		for item in mr.items:
+			item.schedule_date = today()
+		mr.insert()
+		mr.submit()
+		return mr
+
+	def receive_test_fg_raw_materials(self):
+		test_stock_entry.make_stock_entry(
+			item_code="_Test Item", target="Stores - _TC", qty=100, basic_rate=5000.0
+		)
+		test_stock_entry.make_stock_entry(
+			item_code="_Test Item Home Desktop 100", target="Stores - _TC", qty=100, basic_rate=1000.0
+		)
+
+	def test_requested_qty_tracks_open_material_requests(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+
+		mr = self.submit_material_request(work_order.name, for_qty=4)
+		mr_qty = {row.item_code: flt(row.qty) for row in mr.items}
+
+		work_order.reload()
+		for row in work_order.required_items:
+			self.assertEqual(row.requested_qty, mr_qty[row.item_code])
+
+		remainder_mr = make_material_request(work_order.name, for_qty=10)
+		for row in remainder_mr.items:
+			required_row = next(item for item in work_order.required_items if item.item_code == row.item_code)
+			self.assertEqual(row.qty, flt(required_row.required_qty) - mr_qty[row.item_code])
+
+		mr.cancel()
+		work_order.reload()
+		for row in work_order.required_items:
+			self.assertEqual(row.requested_qty, 0)
+
+	def test_requested_qty_moves_to_transferred_qty_on_stock_entry(self):
+		from erpnext.stock.doctype.material_request.mapper import make_stock_entry as mr_to_stock_entry
+
+		self.receive_test_fg_raw_materials()
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+
+		mr = self.submit_material_request(work_order.name, for_qty=4)
+		mr_qty = {row.item_code: flt(row.qty) for row in mr.items}
+
+		stock_entry = frappe.get_doc(mr_to_stock_entry(mr.name))
+		stock_entry.insert()
+		stock_entry.submit()
+
+		work_order.reload()
+		for row in work_order.required_items:
+			self.assertEqual(row.requested_qty, 0)
+			self.assertEqual(row.transferred_qty, mr_qty[row.item_code])
+
+		remainder_mr = make_material_request(work_order.name)
+		for row in remainder_mr.items:
+			required_row = next(item for item in work_order.required_items if item.item_code == row.item_code)
+			self.assertEqual(row.qty, flt(required_row.required_qty) - mr_qty[row.item_code])
+
+	def test_picked_qty_tracks_open_pick_lists(self):
+		from erpnext.manufacturing.doctype.work_order.mapper import create_pick_list
+
+		self.receive_test_fg_raw_materials()
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+
+		pick_list = create_pick_list(work_order.name, for_qty=4)
+		pick_list.insert()
+		pick_list.submit()
+		picked_qty = {row.item_code: flt(row.stock_qty) for row in pick_list.locations}
+
+		work_order.reload()
+		for row in work_order.required_items:
+			self.assertEqual(row.picked_qty, picked_qty[row.item_code])
+
+		remainder_pick_list = create_pick_list(work_order.name, for_qty=10)
+		for row in remainder_pick_list.locations:
+			required_row = next(item for item in work_order.required_items if item.item_code == row.item_code)
+			self.assertEqual(row.qty, flt(required_row.required_qty) - picked_qty[row.item_code])
+
+		remainder_pick_list.insert()
+		remainder_pick_list.submit()
+		self.assertRaises(frappe.ValidationError, create_pick_list, work_order.name, for_qty=10)
+
+	def test_material_request_submit_rejects_exceeding_pending_qty(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+
+		def full_draft():
+			mr = make_material_request(work_order.name)
+			mr.schedule_date = today()
+			for item in mr.items:
+				item.schedule_date = today()
+			mr.insert()
+			return mr
+
+		first, second = full_draft(), full_draft()
+		first.submit()
+		self.assertRaises(frappe.ValidationError, second.submit)
+
+	def test_picked_qty_counts_pick_list_of_stopped_material_request(self):
+		from erpnext.stock.doctype.material_request.mapper import create_pick_list as mr_to_pick_list
+
+		self.receive_test_fg_raw_materials()
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+
+		mr = self.submit_material_request(work_order.name, for_qty=4)
+		mr_qty = {row.item_code: flt(row.qty) for row in mr.items}
+
+		pick_list = mr_to_pick_list(mr.name)
+		pick_list.insert()
+		pick_list.submit()
+
+		work_order.reload()
+		for row in work_order.required_items:
+			self.assertEqual(row.requested_qty, mr_qty[row.item_code])
+			self.assertEqual(row.picked_qty, 0)
+
+		mr.reload()
+		mr.update_status("Stopped")
+
+		work_order.reload()
+		for row in work_order.required_items:
+			self.assertEqual(row.requested_qty, 0)
+			self.assertEqual(row.picked_qty, mr_qty[row.item_code])
+
+	def test_pending_demand_shared_across_duplicate_item_rows(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+		first = work_order.required_items[0]
+		duplicate = work_order.append(
+			"required_items",
+			{
+				"item_code": first.item_code,
+				"required_qty": 5,
+				"stock_uom": first.stock_uom,
+				"source_warehouse": first.source_warehouse,
+				"docstatus": 1,
+			},
+		)
+		duplicate.db_insert()
+		work_order.reload()
+		total_required = flt(first.required_qty) + 5
+
+		mr = self.submit_material_request(work_order.name, for_qty=4)
+		requested = sum(flt(row.qty) for row in mr.items if row.item_code == first.item_code)
+		self.assertAlmostEqual(requested, total_required * 4 / 10, places=6)
+
+		work_order.reload()
+		for row in work_order.required_items:
+			if row.item_code == first.item_code:
+				self.assertAlmostEqual(row.requested_qty, requested, places=6)
+
+		remainder_mr = make_material_request(work_order.name, for_qty=10)
+		remainder = sum(flt(row.qty) for row in remainder_mr.items if row.item_code == first.item_code)
+		self.assertAlmostEqual(remainder, total_required - requested, places=6)
+
+	def test_allocation_splits_by_source_warehouse(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+		first = work_order.required_items[0]
+		duplicate = work_order.append(
+			"required_items",
+			{
+				"item_code": first.item_code,
+				"required_qty": 5,
+				"stock_uom": first.stock_uom,
+				"source_warehouse": "_Test Warehouse 1 - _TC",
+				"docstatus": 1,
+			},
+		)
+		duplicate.db_insert()
+		work_order.reload()
+
+		with self.change_settings("Buying Settings", {"allow_multiple_items": 1}):
+			mr = make_material_request(work_order.name, for_qty=4)
+		rows = {row.from_warehouse: flt(row.qty) for row in mr.items if row.item_code == first.item_code}
+		self.assertEqual(len(rows), 2)
+		self.assertAlmostEqual(rows["Stores - _TC"], flt(first.required_qty) * 4 / 10, places=6)
+		self.assertAlmostEqual(rows["_Test Warehouse 1 - _TC"], 5 * 4 / 10, places=6)
+
+	def test_allocation_collapses_groups_when_multiple_items_disallowed(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+		first = work_order.required_items[0]
+		duplicate = work_order.append(
+			"required_items",
+			{
+				"item_code": first.item_code,
+				"required_qty": 5,
+				"stock_uom": first.stock_uom,
+				"source_warehouse": "_Test Warehouse 1 - _TC",
+				"docstatus": 1,
+			},
+		)
+		duplicate.db_insert()
+		work_order.reload()
+
+		mr = self.submit_material_request(work_order.name, for_qty=4)
+		rows = [row for row in mr.items if row.item_code == first.item_code]
+		self.assertEqual(len(rows), 1)
+		self.assertAlmostEqual(flt(rows[0].qty), (flt(first.required_qty) + 5) * 4 / 10, places=6)
+
+	def test_remainder_allocation_splits_proportionally_across_groups(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+		first = work_order.required_items[0]
+		duplicate = work_order.append(
+			"required_items",
+			{
+				"item_code": first.item_code,
+				"required_qty": 5,
+				"stock_uom": first.stock_uom,
+				"source_warehouse": "_Test Warehouse 1 - _TC",
+				"docstatus": 1,
+			},
+		)
+		duplicate.db_insert()
+		work_order.reload()
+
+		with self.change_settings("Buying Settings", {"allow_multiple_items": 1}):
+			self.submit_material_request(work_order.name, for_qty=4)
+			work_order.reload()
+			remainder = make_material_request(work_order.name, for_qty=10)
+		rows = {
+			row.from_warehouse: flt(row.qty) for row in remainder.items if row.item_code == first.item_code
+		}
+		self.assertAlmostEqual(rows["Stores - _TC"], flt(first.required_qty) * 6 / 10, places=6)
+		self.assertAlmostEqual(rows["_Test Warehouse 1 - _TC"], 5 * 6 / 10, places=6)
+
+	def test_allocation_splits_manual_rows_by_operation_label(self):
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+		first = work_order.required_items[0]
+		for operation in ("_Test Operation A", "_Test Operation B"):
+			row = work_order.append(
+				"required_items",
+				{
+					"item_code": first.item_code,
+					"required_qty": 5,
+					"stock_uom": first.stock_uom,
+					"source_warehouse": first.source_warehouse,
+					"operation": operation,
+					"docstatus": 1,
+				},
+			)
+			row.db_insert()
+		work_order.reload()
+
+		with self.change_settings("Buying Settings", {"allow_multiple_items": 1}):
+			mr = make_material_request(work_order.name, for_qty=4)
+		rows = [flt(row.qty) for row in mr.items if row.item_code == first.item_code]
+		self.assertEqual(len(rows), 3)
+		self.assertAlmostEqual(sum(rows), (flt(first.required_qty) + 10) * 4 / 10, places=6)
+
+	def test_pick_list_rejects_over_pick_against_material_request(self):
+		from erpnext.stock.doctype.material_request.mapper import create_pick_list as mr_to_pick_list
+
+		self.receive_test_fg_raw_materials()
+		work_order = make_wo_order_test_record(
+			planned_start_date=now(), qty=10, source_warehouse="Stores - _TC"
+		)
+
+		mr = self.submit_material_request(work_order.name, for_qty=4)
+		pick_list = mr_to_pick_list(mr.name)
+		pick_list.insert()
+		pick_list.locations[0].picked_qty = flt(pick_list.locations[0].stock_qty) + 1
+
+		self.assertRaises(frappe.ValidationError, pick_list.submit)
+
 	def test_backflushed_batch_raw_materials_based_on_transferred(self):
 		frappe.db.set_single_value(
 			"Manufacturing Settings",
diff --git a/erpnext/manufacturing/doctype/work_order/work_order.js b/erpnext/manufacturing/doctype/work_order/work_order.js
index b540bb7aaa7..079b2831e78 100644
--- a/erpnext/manufacturing/doctype/work_order/work_order.js
+++ b/erpnext/manufacturing/doctype/work_order/work_order.js
@@ -852,7 +852,10 @@ erpnext.work_order = {
 								function () {
 									let purpose = "Material Transfer for Manufacture";
 									erpnext.work_order
-										.show_prompt_for_qty_input(frm, purpose, qty, 1)
+										.show_prompt_for_qty_input(frm, purpose, {
+											qty: qty,
+											additional_transfer_entry: 1,
+										})
 										.then((data) => {
 											return frappe.xcall(
 												"erpnext.manufacturing.doctype.work_order.mapper.make_stock_entry",
@@ -1038,6 +1041,26 @@ erpnext.work_order = {
 		return flt(max, precision("qty"));
 	},
 
+	get_max_requestable_qty: (frm) => {
+		const required = {};
+		const covered = {};
+		(frm.doc.required_items || []).forEach((row) => {
+			required[row.item_code] = (required[row.item_code] || 0) + flt(row.required_qty);
+			if (!(row.item_code in covered)) {
+				covered[row.item_code] =
+					flt(row.transferred_qty) + flt(row.requested_qty) + flt(row.picked_qty);
+			}
+		});
+
+		let max_fraction = 0;
+		Object.keys(required).forEach((item_code) => {
+			if (required[item_code] <= 0) return;
+			const pending = required[item_code] - covered[item_code];
+			max_fraction = Math.max(max_fraction, pending / required[item_code]);
+		});
+		return flt(max_fraction * flt(frm.doc.qty), precision("qty"));
+	},
+
 	show_disassembly_prompt: function (frm) {
 		let max_qty = flt(frm.doc.produced_qty - frm.doc.disassembled_qty);
 
@@ -1092,20 +1115,20 @@ 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;
+	show_prompt_for_qty_input: function (frm, purpose, { qty, additional_transfer_entry, target } = {}) {
+		let max = qty == null ? this.get_max_transferable_qty(frm, purpose) : qty;
 
 		let fields = [
 			{
 				fieldtype: "Float",
-				label: __("Qty for {0}", [__(purpose)]),
+				label: __("Qty for {0}", [target || __(purpose)]),
 				fieldname: "qty",
 				description: __("Max: {0}", [max]),
 				default: max,
 			},
 		];
 
-		if (!additional_transfer_entry) {
+		if (!additional_transfer_entry && !target) {
 			fields.push({
 				fieldtype: "Check",
 				label: __("Consider Process Loss"),
@@ -1127,6 +1150,11 @@ erpnext.work_order = {
 				(data) => {
 					max += (frm.doc.qty * (frm.doc.__onload.overproduction_percentage || 0.0)) / 100;
 
+					if (!data.qty || data.qty <= 0) {
+						frappe.msgprint(__("Quantity must be greater than zero."));
+						reject();
+						return;
+					}
 					if (data.qty > max) {
 						frappe.msgprint(__("Quantity must not be more than {0}", [max]));
 						reject();
@@ -1169,15 +1197,32 @@ erpnext.work_order = {
 		}
 	},
 
-	make_material_request: function (frm) {
-		frappe.model.open_mapped_doc({
-			method: "erpnext.manufacturing.doctype.work_order.mapper.make_material_request",
-			frm,
-		});
+	make_material_request: function (frm, purpose = "Material Transfer for Manufacture") {
+		const max = this.get_max_requestable_qty(frm);
+		if (max <= 0) {
+			frappe.msgprint(__("All required items have already been transferred, requested or picked."));
+			return;
+		}
+
+		const get_material_request = (for_qty) =>
+			frappe.model.open_mapped_doc({
+				method: "erpnext.manufacturing.doctype.work_order.mapper.make_material_request",
+				frm,
+				args: { for_qty: for_qty },
+			});
+
+		this.show_prompt_for_qty_input(frm, purpose, {
+			qty: max,
+			target: __("Material Request"),
+		}).then((data) => get_material_request(data.qty));
 	},
 
 	create_pick_list: function (frm, purpose = "Material Transfer for Manufacture") {
-		const max = this.get_max_transferable_qty(frm, purpose);
+		const max = this.get_max_requestable_qty(frm);
+		if (max <= 0) {
+			frappe.msgprint(__("All required items have already been transferred, requested or picked."));
+			return;
+		}
 
 		const get_pick_list = (for_qty) =>
 			frappe
@@ -1190,11 +1235,10 @@ erpnext.work_order = {
 					frappe.set_route("Form", pick_list.doctype, pick_list.name);
 				});
 
-		if (max <= 0) {
-			get_pick_list(frm.doc.qty);
-		} else {
-			this.show_prompt_for_qty_input(frm, purpose).then((data) => get_pick_list(data.qty));
-		}
+		this.show_prompt_for_qty_input(frm, purpose, {
+			qty: max,
+			target: __("Pick List"),
+		}).then((data) => get_pick_list(data.qty));
 	},
 
 	make_consumption_se: function (frm, backflush_raw_materials_based_on) {
diff --git a/erpnext/manufacturing/doctype/work_order_item/work_order_item.json b/erpnext/manufacturing/doctype/work_order_item/work_order_item.json
index dec4934ea4f..208215b7a5e 100644
--- a/erpnext/manufacturing/doctype/work_order_item/work_order_item.json
+++ b/erpnext/manufacturing/doctype/work_order_item/work_order_item.json
@@ -22,6 +22,8 @@
   "amount",
   "column_break_11",
   "transferred_qty",
+  "requested_qty",
+  "picked_qty",
   "consumed_qty",
   "returned_qty",
   "section_break_idhr",
@@ -93,6 +95,22 @@
    "label": "Transferred Qty",
    "read_only": 1
   },
+  {
+   "depends_on": "eval:!parent.skip_transfer",
+   "fieldname": "requested_qty",
+   "fieldtype": "Float",
+   "label": "Requested Qty",
+   "no_copy": 1,
+   "read_only": 1
+  },
+  {
+   "depends_on": "eval:!parent.skip_transfer",
+   "fieldname": "picked_qty",
+   "fieldtype": "Float",
+   "label": "Picked Qty",
+   "no_copy": 1,
+   "read_only": 1
+  },
   {
    "default": "0",
    "depends_on": "eval:!parent.subcontracting_inward_order",
@@ -209,7 +227,7 @@
  "grid_page_length": 50,
  "istable": 1,
  "links": [],
- "modified": "2026-05-12 12:05:16.687866",
+ "modified": "2026-08-07 10:00:00.000000",
  "modified_by": "Administrator",
  "module": "Manufacturing",
  "name": "Work Order Item",
diff --git a/erpnext/manufacturing/doctype/work_order_item/work_order_item.py b/erpnext/manufacturing/doctype/work_order_item/work_order_item.py
index 4c40e9d688a..c4f2fc4d916 100644
--- a/erpnext/manufacturing/doctype/work_order_item/work_order_item.py
+++ b/erpnext/manufacturing/doctype/work_order_item/work_order_item.py
@@ -31,8 +31,10 @@ class WorkOrderItem(Document):
 		parent: DF.Data
 		parentfield: DF.Data
 		parenttype: DF.Data
+		picked_qty: DF.Float
 		rate: DF.Currency
 		required_qty: DF.Float
+		requested_qty: DF.Float
 		returned_qty: DF.Float
 		source_warehouse: DF.Link | None
 		stock_reserved_qty: DF.Float
diff --git a/erpnext/patches.txt b/erpnext/patches.txt
index f2c2a447817..97cceebe5f7 100644
--- a/erpnext/patches.txt
+++ b/erpnext/patches.txt
@@ -508,3 +508,4 @@ erpnext.patches.v16_0.move_warehouse_defaults_to_company
 erpnext.patches.v16_0.backfill_repost_accounting_ledger_status
 erpnext.patches.v16_0.merge_seeded_item_group_root
 erpnext.patches.v16_0.set_stock_uom_in_job_card
+erpnext.patches.v16_0.set_work_order_requested_and_picked_qty
diff --git a/erpnext/patches/v16_0/set_work_order_requested_and_picked_qty.py b/erpnext/patches/v16_0/set_work_order_requested_and_picked_qty.py
new file mode 100644
index 00000000000..9f30b5142a4
--- /dev/null
+++ b/erpnext/patches/v16_0/set_work_order_requested_and_picked_qty.py
@@ -0,0 +1,38 @@
+import frappe
+
+from erpnext.manufacturing.doctype.work_order.services.required_items import RequiredItemsService
+
+
+def execute():
+	"""Backfill requested_qty and picked_qty for work orders with open demand;
+	fulfilled documents leave the zero default."""
+	work_orders = set(
+		frappe.get_all(
+			"Material Request",
+			filters={
+				"docstatus": 1,
+				"material_request_type": "Material Transfer",
+				"work_order": ("is", "set"),
+				"status": ("!=", "Stopped"),
+				"per_ordered": ("<", 100),
+			},
+			pluck="work_order",
+			distinct=True,
+		)
+	)
+	work_orders.update(
+		frappe.get_all(
+			"Pick List",
+			filters={"docstatus": 1, "work_order": ("is", "set"), "status": ("!=", "Completed")},
+			pluck="work_order",
+			distinct=True,
+		)
+	)
+
+	for name in work_orders:
+		if frappe.db.get_value("Work Order", name, "docstatus") != 1:
+			continue
+
+		service = RequiredItemsService(frappe.get_doc("Work Order", name))
+		service.update_requested_qty_for_required_items()
+		service.update_picked_qty_for_required_items()
diff --git a/erpnext/stock/doctype/material_request/material_request.json b/erpnext/stock/doctype/material_request/material_request.json
index 1c6d7db5296..922b40325c8 100644
--- a/erpnext/stock/doctype/material_request/material_request.json
+++ b/erpnext/stock/doctype/material_request/material_request.json
@@ -315,7 +315,8 @@
    "fieldtype": "Link",
    "label": "Work Order",
    "options": "Work Order",
-   "read_only": 1
+   "read_only": 1,
+   "search_index": 1
   },
   {
    "fieldname": "terms_tab",
@@ -376,7 +377,7 @@
  "idx": 70,
  "is_submittable": 1,
  "links": [],
- "modified": "2026-07-30 11:04:31.517204",
+ "modified": "2026-08-07 10:30:00.000000",
  "modified_by": "Administrator",
  "module": "Stock",
  "name": "Material Request",
diff --git a/erpnext/stock/doctype/material_request/material_request.py b/erpnext/stock/doctype/material_request/material_request.py
index 72760c55972..4350f33c468 100644
--- a/erpnext/stock/doctype/material_request/material_request.py
+++ b/erpnext/stock/doctype/material_request/material_request.py
@@ -273,6 +273,7 @@ class MaterialRequest(BuyingController):
 	def on_submit(self):
 		self.update_requested_qty_in_production_plan()
 		self.update_requested_qty()
+		self.update_requested_qty_in_work_order()
 		if self.material_request_type == "Purchase":
 			self.update_prevdoc_status()
 			if frappe.db.exists("Budget", {"applicable_on_material_request": 1, "docstatus": 1}):
@@ -283,6 +284,20 @@ class MaterialRequest(BuyingController):
 
 	def before_submit(self):
 		self.set_status(update=True)
+		self.validate_pending_qty_in_work_order()
+
+	def validate_pending_qty_in_work_order(self):
+		if not self.work_order or self.material_request_type != "Material Transfer":
+			return
+
+		from erpnext.manufacturing.doctype.work_order.services.required_items import RequiredItemsService
+
+		work_order = frappe.get_doc("Work Order", self.work_order, for_update=True)
+		incoming = {}
+		for row in self.items:
+			incoming[row.item_code] = incoming.get(row.item_code, 0.0) + flt(row.stock_qty)
+
+		RequiredItemsService(work_order).validate_incoming_material_demand(incoming)
 
 	def before_cancel(self):
 		# if MRQ is already closed, no point saving the document
@@ -301,6 +316,7 @@ class MaterialRequest(BuyingController):
 		self.status_can_change(status)
 		self.set_status(update=True, status=status)
 		self.update_requested_qty()
+		self.update_requested_qty_in_work_order()
 
 	def status_can_change(self, status):
 		"""
@@ -330,6 +346,7 @@ class MaterialRequest(BuyingController):
 	def on_cancel(self):
 		self.update_requested_qty_in_production_plan(cancel=True)
 		self.update_requested_qty()
+		self.update_requested_qty_in_work_order()
 		if self.material_request_type == "Purchase":
 			self.update_prevdoc_status()
 
@@ -417,6 +434,19 @@ class MaterialRequest(BuyingController):
 			update_modified,
 		)
 
+		self.update_requested_qty_in_work_order()
+
+	def update_requested_qty_in_work_order(self):
+		"""Refresh both counters: stop and cancel also flip pick list coverage."""
+		if not self.work_order or self.material_request_type != "Material Transfer":
+			return
+
+		from erpnext.manufacturing.doctype.work_order.services.required_items import RequiredItemsService
+
+		service = RequiredItemsService(frappe.get_doc("Work Order", self.work_order))
+		service.update_requested_qty_for_required_items()
+		service.update_picked_qty_for_required_items()
+
 	def update_requested_qty(self, mr_item_rows=None):
 		"""update requested qty (before ordered_qty is updated)"""
 		item_wh_list = []
diff --git a/erpnext/stock/doctype/pick_list/pick_list.json b/erpnext/stock/doctype/pick_list/pick_list.json
index 55e66f74b3c..c0898c7182f 100644
--- a/erpnext/stock/doctype/pick_list/pick_list.json
+++ b/erpnext/stock/doctype/pick_list/pick_list.json
@@ -80,7 +80,8 @@
    "fieldname": "work_order",
    "fieldtype": "Link",
    "label": "Work Order",
-   "options": "Work Order"
+   "options": "Work Order",
+   "search_index": 1
   },
   {
    "fieldname": "locations",
@@ -278,7 +279,7 @@
  ],
  "is_submittable": 1,
  "links": [],
- "modified": "2026-07-01 14:27:50.617011",
+ "modified": "2026-08-07 10:30:00.000000",
  "modified_by": "Administrator",
  "module": "Stock",
  "name": "Pick List",
diff --git a/erpnext/stock/doctype/pick_list/pick_list.py b/erpnext/stock/doctype/pick_list/pick_list.py
index 50a3a0ebfb4..3cf7c25307f 100644
--- a/erpnext/stock/doctype/pick_list/pick_list.py
+++ b/erpnext/stock/doctype/pick_list/pick_list.py
@@ -240,6 +240,45 @@ class PickList(TransactionBase):
 	def before_submit(self):
 		self.validate_sales_order()
 		self.validate_picked_items()
+		self.validate_pending_qty_in_work_order()
+
+	def validate_pending_qty_in_work_order(self):
+		"""Rows covered by a live material request must stay within that request;
+		every other row must fit the work order's pending requirement."""
+		if not self.work_order:
+			return
+
+		from erpnext.manufacturing.doctype.work_order.services.required_items import RequiredItemsService
+
+		work_order = frappe.get_doc("Work Order", self.work_order, for_update=True)
+		live_requests = {}
+		request_pending = {}
+		incoming = {}
+
+		for row in self.locations:
+			if row.material_request not in live_requests:
+				live_requests[row.material_request] = is_live_material_request(row.material_request)
+
+			if not (row.material_request_item and live_requests[row.material_request]):
+				incoming[row.item_code] = incoming.get(row.item_code, 0.0) + flt(row.picked_qty)
+				continue
+
+			if row.material_request_item not in request_pending:
+				stock_qty, ordered_qty = frappe.db.get_value(
+					"Material Request Item", row.material_request_item, ["stock_qty", "ordered_qty"]
+				)
+				request_pending[row.material_request_item] = flt(stock_qty) - flt(ordered_qty)
+
+			if flt(row.picked_qty - request_pending[row.material_request_item], 6) > 0:
+				frappe.throw(
+					_("Row #{0}: picked qty {1} {2} exceeds the pending qty in Material Request {3}.").format(
+						row.idx, row.picked_qty, row.stock_uom, row.material_request
+					),
+					title=_("Exceeds Requested Qty"),
+				)
+			request_pending[row.material_request_item] -= flt(row.picked_qty)
+
+		RequiredItemsService(work_order).validate_incoming_material_demand(incoming)
 
 	def validate_sales_order(self):
 		"""Raises an exception if the `Sales Order` has reserved stock."""
@@ -281,6 +320,7 @@ class PickList(TransactionBase):
 		self.update_bundle_picked_qty()
 		self.update_reference_qty()
 		self.update_sales_order_picking_status()
+		self.update_picked_qty_in_work_order()
 		self.update_prevdoc_status()
 
 	def validate_expired_batches(self):
@@ -358,6 +398,7 @@ class PickList(TransactionBase):
 		self.update_bundle_picked_qty()
 		self.update_reference_qty()
 		self.update_sales_order_picking_status()
+		self.update_picked_qty_in_work_order()
 		self.delink_serial_and_batch_bundle()
 		self.update_prevdoc_status()
 
@@ -494,6 +535,15 @@ class PickList(TransactionBase):
 		for sales_order in sales_orders:
 			frappe.get_doc("Sales Order", sales_order, for_update=True).update_picking_status()
 
+	def update_picked_qty_in_work_order(self):
+		if not self.work_order:
+			return
+
+		from erpnext.manufacturing.doctype.work_order.services.required_items import RequiredItemsService
+
+		work_order = frappe.get_doc("Work Order", self.work_order)
+		RequiredItemsService(work_order).update_picked_qty_for_required_items()
+
 	@frappe.whitelist()
 	def create_stock_reservation_entries(self, notify: bool = True) -> None:
 		"""Creates Stock Reservation Entries for Sales Order Items against Pick List."""
@@ -936,6 +986,15 @@ def update_pick_list_status(pick_list):
 	if pick_list:
 		doc = frappe.get_doc("Pick List", pick_list)
 		doc.run_method("update_status")
+		doc.update_picked_qty_in_work_order()
+
+
+def is_live_material_request(material_request):
+	if not material_request:
+		return False
+
+	docstatus, status = frappe.db.get_value("Material Request", material_request, ["docstatus", "status"])
+	return docstatus == 1 and status != "Stopped"
 
 
 def get_picked_items_qty(items, contains_packed_items=False) -> list[dict]: