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fix(manufacturing): prevent excess process loss from inflating plan quantities (#58847)

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This commit is contained in:
Mihir Kandoi
2026-09-08 09:52:02 +05:30
committed by GitHub
parent 1615ecd25e
commit d64e45582a
4 changed files with 153 additions and 13 deletions
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4
erpnext/manufacturing/doctype/job_card/job_card.py
View File

@@ -1080,6 +1080,10 @@ class JobCard(Document):
frappe.db.set_value("Work Order Operation", self.operation_id, "completed_qty", completed_qty)
if self.finished_good and work_order.production_item == self.finished_good:
work_order.db_set("produced_qty", sum(flt(row.manufactured_qty) for row in job_cards))
if work_order.production_plan:
ProductionPlanWorkOrderQuantities(work_order.production_plan).validate_work_order(
work_order, process_loss_qty=work_order.process_loss_qty
)
work_order.db_set("status", work_order.get_status())
def update_corrective_in_work_order(self, wo):

27
erpnext/manufacturing/doctype/production_plan/services/work_order_quantities.py
View File

@@ -29,18 +29,17 @@ class ProductionPlanWorkOrderQuantities:
frappe.db.get_single_value("Manufacturing Settings", "overproduction_percentage_for_work_order")
)
precision = work_order.precision("qty")
maximum_qty = flt(
flt(row.planned_qty) * (1 + allowance / 100) - committed + flt(process_loss_qty), precision
)
if flt(work_order.qty, precision) > maximum_qty:
maximum_qty = flt(flt(row.planned_qty) * (1 + allowance / 100) - committed, precision)
committed_qty = flt(self._get_committed_qty(work_order, process_loss_qty), precision)
if committed_qty > maximum_qty:
frappe.throw(
_(
"Row {0} in {1} {2}: Work Order quantity {3} exceeds the remaining allowed quantity {4}."
"Row {0} in {1} {2}: Work Order quantity after process loss {3} exceeds the remaining allowed quantity {4}."
).format(
row.idx,
_(row.doctype),
get_link_to_form("Production Plan", self.production_plan),
flt(work_order.qty, precision),
committed_qty,
max(0, maximum_qty),
),
OverProductionError,
@@ -111,7 +110,13 @@ class ProductionPlanWorkOrderQuantities:
# Read rows instead of an aggregate so MariaDB uses a current locking read on submit.
work_orders = frappe.qb.get_query(
"Work Order",
fields=["production_plan_item", "production_plan_sub_assembly_item", "qty", "process_loss_qty"],
fields=[
"production_plan_item",
"production_plan_sub_assembly_item",
"qty",
"produced_qty",
"process_loss_qty",
],
filters=filters,
for_update=for_update,
order_by="name",
@@ -127,5 +132,11 @@ class ProductionPlanWorkOrderQuantities:
else "production_plan_item"
)
if work_order.get(field):
quantities[field][work_order[field]] += flt(work_order.qty) - flt(work_order.process_loss_qty)
quantities[field][work_order[field]] += self._get_committed_qty(
work_order, work_order.process_loss_qty
)
return quantities
def _get_committed_qty(self, work_order, process_loss_qty):
# Excess loss in existing records must not erase finished goods already produced.
return max(0, flt(work_order.produced_qty), flt(work_order.qty) - flt(process_loss_qty))

121
erpnext/manufacturing/doctype/production_plan/test_work_order_quantities.py
View File

@@ -7,6 +7,9 @@ from unittest.mock import patch
import frappe
from erpnext.manufacturing.doctype.operation.test_operation import make_operation
from erpnext.manufacturing.doctype.production_plan.services.work_order_quantities import (
ProductionPlanWorkOrderQuantities,
)
from erpnext.manufacturing.doctype.production_plan.test_production_plan import (
create_production_plan,
make_bom,
@@ -14,6 +17,7 @@ from erpnext.manufacturing.doctype.production_plan.test_production_plan import (
from erpnext.manufacturing.doctype.work_order.mapper import make_stock_entry as make_se_from_wo
from erpnext.manufacturing.doctype.work_order.work_order import (
OverProductionError,
StockOverProductionError,
close_work_order,
stop_unstop,
)
@@ -87,6 +91,101 @@ class TestProductionPlanWorkOrderQuantities(ERPNextTestSuite):
first.reload().cancel()
self.assert_pending_qty(plan, field, 100)
def test_cumulative_manufacture_loss_exceeds_work_order(self):
plan = self.make_plan()
for field in (None, *REFERENCE_FIELDS):
with self.subTest(field=field):
first = self.create_work_order(plan, field or "production_plan_item")
if field is None:
first.production_plan = None
first.production_plan_item = None
first.qty = 100
first.submit()
self.manufacture_with_loss(first, loss_qty=99)
second_entry = self.manufacture_with_loss(first, loss_qty=99, submit=False)
self.assert_manufacture_rejected(second_entry, StockOverProductionError)
self.assertEqual(first.reload().produced_qty, 1)
self.assertEqual(first.process_loss_qty, 99)
if field:
self.assert_pending_qty(plan, field, 99)
replacement = self.create_work_order(plan, field)
replacement.submit()
self.assert_pending_qty(plan, field, 0)
def test_cumulative_manufacture_loss_respects_allowance(self):
frappe.db.set_single_value("Manufacturing Settings", "overproduction_percentage_for_work_order", 10)
plan = self.make_plan()
for field in REFERENCE_FIELDS:
with self.subTest(field=field):
first = self.create_work_order(plan, field)
first.submit()
self.manufacture_with_loss(first, qty=50)
self.manufacture_with_loss(first, qty=50)
last_entry = self.manufacture_with_loss(first, qty=10)
self.assertEqual(first.reload().produced_qty, 99)
self.assertEqual(first.process_loss_qty, 11)
self.assert_pending_qty(plan, field, 1)
excess = self.manufacture_with_loss(first, qty=1, submit=False)
self.assert_manufacture_rejected(excess, StockOverProductionError)
excess.delete()
last_entry.cancel()
self.assertEqual(first.reload().produced_qty, 90)
self.assertEqual(first.process_loss_qty, 10)
self.manufacture_with_loss(first, qty=10)
@ERPNextTestSuite.change_settings("System Settings", {"float_precision": 6})
def test_cumulative_fractional_manufacture_loss(self):
plan = self.make_plan(qty=0.3)
for field in REFERENCE_FIELDS:
with self.subTest(field=field):
first = self.create_work_order(plan, field)
first.submit()
self.manufacture_with_loss(first, qty=0.1, loss_qty=0.025)
self.manufacture_with_loss(first, qty=0.2, loss_qty=0.05)
self.assertAlmostEqual(first.reload().produced_qty, 0.225)
self.assertAlmostEqual(first.process_loss_qty, 0.075)
excess = self.manufacture_with_loss(first, qty=0.001, submit=False)
self.assert_manufacture_rejected(excess, StockOverProductionError)
def test_existing_excess_loss_preserves_produced_quantity(self):
for field in REFERENCE_FIELDS:
for loss_qty, produced_qty in ((198, 2), (100, 2), (20, 90), (198, 0)):
with self.subTest(field=field, loss_qty=loss_qty, produced_qty=produced_qty):
plan = self.make_plan()
first = self.create_work_order(plan, field)
first.submit()
# Reproduce records saved before cumulative manufacture validation existed.
first.db_set({"process_loss_qty": loss_qty, "produced_qty": produced_qty})
pending_qty = 100 - produced_qty
self.assert_pending_qty(plan, field, pending_qty)
replacement = self.create_work_order(plan, field)
self.assertEqual(replacement.qty, pending_qty)
self.assert_overproduction(replacement, pending_qty + 1)
replacement.qty = pending_qty
replacement.submit()
self.assert_pending_qty(plan, field, 0)
quantities = ProductionPlanWorkOrderQuantities(plan.name)
quantities.validate_work_order(first, process_loss_qty=loss_qty)
with self.assertRaises(OverProductionError):
quantities.validate_work_order(first, process_loss_qty=0)
def test_more_production_cannot_consume_replacement_allowance(self):
frappe.db.set_single_value("Manufacturing Settings", "overproduction_percentage_for_work_order", 10)
plan = self.make_plan()
for field in REFERENCE_FIELDS:
with self.subTest(field=field):
first = self.create_work_order(plan, field)
first.submit()
self.manufacture_with_loss(first, loss_qty=99)
replacement = self.create_work_order(plan, field)
replacement.qty = 109
replacement.submit()
# This fits the first Work Order's allowance, but exceeds the plan's 110 units.
excess = self.manufacture_with_loss(first, qty=10, loss_qty=9, submit=False)
self.assert_manufacture_rejected(excess, OverProductionError)
self.assertEqual(first.reload().produced_qty, 1)
self.assertEqual(first.process_loss_qty, 99)
def test_loss_reversal_with_draft_replacement(self):
plan = self.make_plan()
for field in REFERENCE_FIELDS:
@@ -337,15 +436,33 @@ class TestProductionPlanWorkOrderQuantities(ERPNextTestSuite):
copy.insert()
return copy
def manufacture_with_loss(self, work_order, qty=None):
def manufacture_with_loss(self, work_order, qty=None, *, loss_qty=None, submit=True):
for item in work_order.required_items:
make_stock_entry(
item_code=item.item_code, target=self.warehouse, qty=item.required_qty, basic_rate=10
)
entry = frappe.get_doc(make_se_from_wo(work_order.name, "Manufacture", qty or work_order.qty))
entry.submit()
if loss_qty is not None:
entry.process_loss_qty = loss_qty
entry.process_loss_percentage = loss_qty / entry.fg_completed_qty * 100
for item in entry.items:
if item.is_finished_item:
item.qty = entry.fg_completed_qty - loss_qty
if submit:
entry.submit()
else:
entry.save()
return entry
def assert_manufacture_rejected(self, entry, exception):
frappe.db.savepoint("excess_manufacture")
try:
with self.assertRaises(exception):
entry.submit()
finally:
frappe.db.rollback(save_point="excess_manufacture")
self.assertEqual(entry.reload().docstatus, 0)
def assert_loss_reversal_blocked(self, document):
work_order = frappe.get_doc("Work Order", document.work_order)
frappe.db.savepoint("loss_reversal")

14
erpnext/manufacturing/doctype/work_order/services/status.py
View File

@@ -216,11 +216,15 @@ class StatusService:
qty = self.get_transferred_or_manufactured_qty(purpose, fieldname)
completed_qty = self.doc.qty + (self._qty_allowance(purpose) / 100 * self.doc.qty)
if qty > completed_qty:
qty_to_validate = qty + flt(self.doc.process_loss_qty) if purpose == "Manufacture" else qty
precision = self.doc.precision(fieldname)
if flt(qty_to_validate, precision) > flt(completed_qty, precision):
frappe.throw(
_("{0} ({1}) cannot be greater than planned quantity ({2}) in Work Order {3}").format(
self.doc.meta.get_translated_label(fieldname),
qty,
_("Manufactured Qty (including Process Loss)")
if purpose == "Manufacture"
else self.doc.meta.get_translated_label(fieldname),
flt(qty_to_validate, precision),
completed_qty,
self.doc.name,
),
@@ -228,6 +232,10 @@ class StatusService:
)
self.doc.db_set(fieldname, qty)
if purpose == "Manufacture" and self.doc.production_plan:
ProductionPlanWorkOrderQuantities(self.doc.production_plan).validate_work_order(
self.doc, process_loss_qty=self.doc.process_loss_qty
)
self._update_produced_qty_in_so()
def _skip_transfer_purpose(self, purpose):