Merge pull request #56264 from frappe/mergify/bp/version-15-hotfix/pr-56206

fix(stock): allow partial raw material picking/transfer from work order (backport #56206)

erpnext/manufacturing/doctype/work_order/test_work_order.py

@@ -1461,6 +1461,68 @@ class TestWorkOrder(FrappeTestCase):
 		self.assertEqual(work_order.required_items[0].transferred_qty, 1)
 		self.assertEqual(work_order.required_items[1].transferred_qty, 2)
 
+	def test_material_transferred_min_fraction_on_partial_pick_list(self):
+		"""Pick-list flow (fg_completed_qty = 0): 'Material Transferred for Manufacturing'
+		must reflect the least-transferred required item (the bottleneck), instead of being
+		marked fully transferred prematurely when only some materials are transferred.
+		"""
+		work_order = make_wo_order_test_record(planned_start_date=now(), qty=2)
+		test_stock_entry.make_stock_entry(
+			item_code="_Test Item", target="_Test Warehouse - _TC", qty=10, basic_rate=5000.0
+		)
+		test_stock_entry.make_stock_entry(
+			item_code="_Test Item Home Desktop 100", target="_Test Warehouse - _TC", qty=10, basic_rate=1000.0
+		)
+
+		required_qty = {row.item_code: flt(row.required_qty) for row in work_order.required_items}
+
+		# pick-list transfer: For Quantity = 0
+		transfer_entry = frappe.get_doc(
+			make_stock_entry(work_order.name, "Material Transfer for Manufacture", 0)
+		)
+		self.assertEqual(transfer_entry.fg_completed_qty, 0.0)
+
+		for item in transfer_entry.items:
+			full_qty = required_qty[item.item_code]
+			item.qty = full_qty if item.item_code == "_Test Item" else full_qty / 2
+			item.transfer_qty = item.qty
+		transfer_entry.submit()
+
+		work_order.reload()
+		transferred_qty = {row.item_code: flt(row.transferred_qty) for row in work_order.required_items}
+		self.assertEqual(transferred_qty["_Test Item"], required_qty["_Test Item"])
+		self.assertEqual(
+			transferred_qty["_Test Item Home Desktop 100"],
+			required_qty["_Test Item Home Desktop 100"] / 2,
+		)
+		# bottleneck fraction = 0.5 -> 0.5 * qty(2) = 1.0
+		self.assertEqual(work_order.material_transferred_for_manufacturing, 1.0)
+
+	def test_material_transferred_full_via_pick_list_flow(self):
+		"""Pick-list flow with every required item fully transferred marks the work order
+		as fully transferred (min fraction = 1.0)."""
+		work_order = make_wo_order_test_record(planned_start_date=now(), qty=2)
+		test_stock_entry.make_stock_entry(
+			item_code="_Test Item", target="_Test Warehouse - _TC", qty=10, basic_rate=5000.0
+		)
+		test_stock_entry.make_stock_entry(
+			item_code="_Test Item Home Desktop 100", target="_Test Warehouse - _TC", qty=10, basic_rate=1000.0
+		)
+
+		required_qty = {row.item_code: flt(row.required_qty) for row in work_order.required_items}
+
+		transfer_entry = frappe.get_doc(
+			make_stock_entry(work_order.name, "Material Transfer for Manufacture", 0)
+		)
+		self.assertEqual(transfer_entry.fg_completed_qty, 0.0)
+		for item in transfer_entry.items:
+			item.qty = required_qty[item.item_code]
+			item.transfer_qty = item.qty
+		transfer_entry.submit()
+
+		work_order.reload()
+		self.assertEqual(work_order.material_transferred_for_manufacturing, 2.0)
+
 	def test_backflushed_batch_raw_materials_based_on_transferred(self):
 		frappe.db.set_single_value(
 			"Manufacturing Settings",

erpnext/manufacturing/doctype/work_order/work_order.js

@@ -979,17 +979,24 @@ erpnext.work_order = {
 	},
 
 	create_pick_list: function (frm, purpose = "Material Transfer for Manufacture") {
-		this.show_prompt_for_qty_input(frm, purpose)
-			.then((data) => {
-				return frappe.xcall("erpnext.manufacturing.doctype.work_order.work_order.create_pick_list", {
+		const max = this.get_max_transferable_qty(frm, purpose);
+
+		const get_pick_list = (for_qty) =>
+			frappe
+				.xcall("erpnext.manufacturing.doctype.work_order.work_order.create_pick_list", {
 					source_name: frm.doc.name,
-					for_qty: data.qty,
+					for_qty: for_qty,
+				})
+				.then((pick_list) => {
+					frappe.model.sync(pick_list);
+					frappe.set_route("Form", pick_list.doctype, pick_list.name);
 				});
-			})
-			.then((pick_list) => {
-				frappe.model.sync(pick_list);
-				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));
+		}
 	},
 
 	make_consumption_se: function (frm, backflush_raw_materials_based_on) {

erpnext/manufacturing/doctype/work_order/work_order.py

@@ -1241,6 +1241,36 @@ class WorkOrder(Document):
 				"transferred_qty", (transferred_items.get(row.item_code) or 0.0), update_modified=False
 			)
 
+		self.recompute_material_transferred_for_manufacturing(transferred_items)
+
+	def recompute_material_transferred_for_manufacturing(self, transferred_items):
+		"""Set material_transferred_for_manufacturing based on actual item-level transfers, not fg_completed_qty."""
+		# When fg_completed_qty > 0 (direct stock entries, excess transfer), preserve the
+		# SUM(fg_completed_qty) approach so excess-transfer tracking works correctly.
+		sum_fg_completed_qty = self.get_transferred_or_manufactured_qty("Material Transfer for Manufacture")
+		if sum_fg_completed_qty:
+			self.db_set("material_transferred_for_manufacturing", sum_fg_completed_qty)
+			return
+
+		# Pick list flow sets fg_completed_qty=0; use min-fraction of actual item transfers
+		# so partial availability does not prematurely mark the work order as fully transferred.
+		required_by_item = {}
+		for row in self.required_items:
+			if not row.include_item_in_manufacturing or flt(row.required_qty) <= 0:
+				continue
+			required_by_item[row.item_code] = required_by_item.get(row.item_code, 0.0) + flt(row.required_qty)
+
+		if not required_by_item:
+			return
+
+		min_fraction = min(
+			flt(transferred_items.get(item_code) or 0) / required_qty
+			for item_code, required_qty in required_by_item.items()
+		)
+		min_fraction = min(min_fraction, 1.0)
+		material_transferred = min_fraction * flt(self.qty)
+		self.db_set("material_transferred_for_manufacturing", material_transferred)
+
 	def update_returned_qty(self):
 		ste = frappe.qb.DocType("Stock Entry")
 		ste_child = frappe.qb.DocType("Stock Entry Detail")

erpnext/stock/doctype/pick_list/pick_list.py

@@ -1577,7 +1577,7 @@ def update_stock_entry_based_on_work_order(pick_list, stock_entry):
 	stock_entry.from_bom = 1
 	stock_entry.bom_no = work_order.bom_no
 	stock_entry.use_multi_level_bom = work_order.use_multi_level_bom
-	stock_entry.fg_completed_qty = pick_list.for_qty
+	stock_entry.fg_completed_qty = 0
 	if work_order.bom_no:
 		stock_entry.inspection_required = frappe.db.get_value("BOM", work_order.bom_no, "inspection_required")
 

erpnext/stock/doctype/stock_entry/stock_entry.py

@@ -1146,10 +1146,12 @@ class StockEntry(StockController):
 		if self.purpose not in ["Manufacture", "Material Transfer for Manufacture"]:
 			return
 
-		if not frappe.db.get_single_value("Manufacturing Settings", "validate_components_quantities_per_bom"):
+		if not self.fg_completed_qty:
+			if self.work_order and self.purpose == "Material Transfer for Manufacture":
+				self._validate_no_excess_transfer()
 			return
 
-		if not self.fg_completed_qty:
+		if not frappe.db.get_single_value("Manufacturing Settings", "validate_components_quantities_per_bom"):
 			return
 
 		raw_materials = self.get_bom_raw_materials(self.fg_completed_qty)
@@ -1174,6 +1176,59 @@ class StockEntry(StockController):
 					title=_("Missing Item"),
 				)
 
+	def _validate_no_excess_transfer(self):
+		if self.is_return:
+			return
+
+		if (
+			frappe.db.get_single_value("Manufacturing Settings", "backflush_raw_materials_based_on")
+			== "Material Transferred for Manufacture"
+		):
+			return
+
+		wo = self.pro_doc
+		if not wo:
+			return
+
+		pending_by_item = {}
+		for r in wo.required_items:
+			pending_by_item[r.item_code] = (
+				pending_by_item.get(r.item_code, 0.0) + flt(r.required_qty) - flt(r.transferred_qty)
+			)
+
+		transfer_by_item = {}
+		first_row_by_item = {}
+		for item in self.items:
+			if not item.s_warehouse:
+				continue
+
+			key = (
+				item.item_code if item.item_code in pending_by_item else getattr(item, "original_item", None)
+			)
+			if key not in pending_by_item:
+				continue
+
+			transfer_by_item[key] = transfer_by_item.get(key, 0.0) + flt(item.qty)
+			first_row_by_item.setdefault(key, item)
+
+		for key, transfer_qty in transfer_by_item.items():
+			pending_qty = max(0.0, pending_by_item[key])
+			if transfer_qty > pending_qty:
+				item = first_row_by_item[key]
+				frappe.throw(
+					_(
+						"Row #{0}: Cannot transfer {1} {2} of Item {3}. "
+						"Maximum transferable quantity is {4} {2}."
+					).format(
+						item.idx,
+						transfer_qty,
+						item.uom,
+						frappe.bold(item.item_code),
+						pending_qty,
+					),
+					title=_("Excess Material Transfer"),
+				)
+
 	def validate_same_source_target_warehouse_during_material_transfer(self):
 		"""
 		Validate Material Transfer entries where source and target warehouses are identical.