Hello. Hoping someone can help with an issue we have been working around for some time concerning component boxes and kits.

We are currently using Sage 100 Advanced 2022.1 (7.10.1.0) with Production Management

Background:

We sell kits but do not stock the kits, we stock the components that make up the kits. Bom's are setup and working as expected and we explode the kits on sales orders when they are ordered. When shipping assembles the kits, we take all stocked components out of their component boxes and then place those items in a separate kit box. We then reuse those component boxes. Currently we are tracking those component boxes outside of Sage and it has its obvious problems.

Question:

My question is how are some of you managing packing material (boxes) that are reused and tracking that packaging material inventory in Sage? We have tried testing putting the packaging material in the BOMs and also in the kit level components where they explode on the sales order (suppress those lines from sales order and picking sheet reports) to no avail. We tried using negative quantities for those reused boxes on the BOM when it explodes on the order but a lot of times we backorder parts due to them not shipping complete and it does funky things with the negative numbers on the sales order.

There has to be a proper way to track use of boxes and somehow put the reused boxes back in inventory when a kit sales. 

Any ideas of suggestions would be much appreciated. 

Thanks for your time!