Inventory Management: Orphaned Finished Goods Amounts

Solved

I have three issues related to sales orders that were deleted and LOT Value inventory never reallocated, and I have no idea how to troubleshoot them. I'd like to start with this one. It's probably the least goofed up of the three. Thank you in advance for any assistance.

A sales order we placed a week ago was (for unknown reasons), doubling the weight and total cost of a finished good. The person only discovered the values were wrong after accepting it. He contacted me about it. My thoughts: we try removing the item code from the sales order, accepting it, and then tried entering it in again. We did and the same thing happened. 

We created a second sales order as a test to see see if that same item would double the amount and total cost, but this time, it was correct. We figured it was a sales order hiccup and deleted the original,offending sales order. We completed the new one and all was well.

Now I don't think the amount on the original broken sales order was issued back into inventory for the LOT we were pulling from, because when the next two orders were placed for the item on the same day, from the same LOT number (one drum per order), inventory management said we only had one drum, when we should have had 2 drums. the other was showing as sales order committed in the Cost Detail tab. 

As a fix, someone issued in a single drum as a receipt of goods in order to be able to ship to both customers, and now after all invoicing is complete, we have a phantom drum of the product in item maintenance that appears to be sales order committed with no sales order, and Inventory Valuation says we still have that one drum on hand.

There is no sales order showing for this phantom allocation in the Orders tab, and the Cost Detail Tab shows it's SO Committed, but I don't have a Sales Order to connect it to, and I am pretty sure it's the original drum that was orphaned with that original wonky Sales Order.

How do I correct this?

  • +1
    Verified Answer

    Rebuild Sort Files (utility) for the IM Module and SO module.  Click Yes to the prompts.

  • 0 in reply to Kevin M

    KEVIN M I did run Rebuild Sort Files on those two modules. Thanks for that! Is there anything else I should do after that? The committed drum is still showing on the Inventory Valuation Report, and in the item Transactions tab (as the receipt of goods), and the Cost Detail tab. That amount seems tethered to that messed up sales order that we had to delete (just for the particular LOT).

  • 0 in reply to j-fly

    Occasionally there is orphaned data left in one of the tier tables, which interferes with the utilities.  Here is a list of tables to check (which may not be a complete list if you have enhancements).  If you find a record in one of these tables, and the associated header record doesn't exist, remove the orphaned tier row (DFDM) and Rebuild Sort Files after that.

    select * from BM_ProductionTierDistribution;

    select * from BM_DisassemblyTierDistribution;

    select * from IM_TransactionTierDist;

    select * from SO_InvoiceTierDistribution;

    select * from SO_SalesOrderTierDistribution;

    select * from PO_ReceiptTierDistribution;

    select * from PO_ReturnTierDistribution;

    select * from PO_MaterialReqTierDistribution;

    select * from JT_WorkTicketTierDistribution;

    select * from JT_TransactionEntryDist;

    select * from PM_WorkTicketTierDistribution;

    select * from PM_TransactionTierDist;

    There is also a possibility of an orphaned row in IM_DataEntryCostCalcCommit, but that is rare (...only happens with a crashed journal update).

  • 0 in reply to Kevin M

    OK. I found the LOT number I am looking for in a record, and I found the wonky sales order in SO_SalesOrderTierDistribution. They both have the correct quantity of product distributed. The lot number and the sales order are different records, but there is no corresponding header record in SO_SalesOrderHeader. This is starting to coalesce. I copied the live company and am working in the copy.

    When you mention use DFDM to delete an orphaned row, which should I delete? Should the LOT record go, or the sales order. Here are screen shots of both.

    I have only altered data in tables using DFDM, never deleted anything. To delete do you double click the item that shows when you search for a record, effectively opening it up, and then just click Delete?

    I searched the Lot number by KLOTSERIAL and the sales order by KPRIMARY. Are these the same record, and DFDM just allows you to search the records by different criteria?

  • 0 in reply to j-fly

    Remove the extra tier record, which does not align with an open SO.

    Yes, changing the search key is still looking at the same data / records.

  • 0 in reply to Kevin M

    Would that orphan the 480 that is in the Cost Detail for the item? And would that get rid of the 480 for the LOT number on the Inventory Valuation Report? This is really helpful! Thank you. Where some of this data is being governed has been a mystery to me for quite some time. 

  • 0 in reply to j-fly

    Do not delete or edit anything in IM_ItemCost!  Only delete the bad record from the SO Tier table.

    Rebuild Sort Files looks at the data entry tables to recalculate the committed lot quantities.  The orphaned rows are seen by the utility, but are inaccessible through the normal Sage interface.

  • 0 in reply to Kevin M

    If you did a false receipt, to allow the sale to be posted, you need to reverse that false receipt separately (after cleaning up the orphaned row).

  • 0 in reply to Kevin M

    Got it.  I did a little test. I changed the value of the quantity ordered in the tier record. I just made it 479. When I checked Item Maintenance, the 1# was in Other Committed. If i delete the tier record, that should/would put the full 480 into Other Committed, right? Then does rebuild Sort Files clean that up, or does the reverse of the fake receipt do that?

  • 0 in reply to j-fly

    Do not edit anything in DFDM other than removing the orphaned row.  Then run Rebuild Sort Files to do the rest.