Are you always printing your batches from the same workstation and by the same user? We have issues with Sage reports and forms related to Sage not "remembering" report settings as we expect it to. If a user changes to a different machine, or a different user gets on the machine usually printing forms, they might expect that all the settings on the report selection are what they "always" are; but 'always" changes based on who is on what machine. So, the moral is that one has to check each of the many options on the print screen before clicking "Print."

One of the selections that burned us in this regard is the "Include back ordered Lines." The default value is "No", so every time a user gets a new machine they print picks without the back ordered lines until they remember to go change that selection.

You don't say what version you are on. My current experience is with 2017 Premium SQL. There are so many options on that pick print screen now that a number of them could be at the heart of your problem. 

Jim

We are running Sage 100 Advanced ERP 2015 (5.20.2.0) Yes we print from the same computer and login. We have also customized the module by Hiding check boxes such as print orders on hold, credit hold and back orders. Only I have the admin. rights to see those options so I can control how and when they are changed. I have been dealing with this module for a long time and know the majority of the mechanics. In order to lock settings, you have to hit Print, not preview to lock in the settings and that has to be done on the system you plan to print from. We have also learned that the process of un-checking the pick sheet box from the sales order, does not happen until you properly close the pick sheet module window after you print. If you don't shut it down properly, all those pick sheets you just printed will print again. 

I'm confident I have eliminated any user issues that may have directly been causing pick sheet issues on the module itself and I have presented this issue to many sage consultants. None of them can see anything wrong with our current process and setup, however; none of them have seen an issue like this either.  

There is an activity log through Library Master but It does not have any pick sheet logs that I have seen. I came here to see if others were having the same issues and hoped they may have a solution. All of the issues you have explained, I have gone through. You can lock in the default values then customize what certain users can see when they log on to that station. I believe you open the pick sheet window, right click, personalize then customize. At least with our version you can. 

On a temporary basis why not use Role Maintenance and lock out everyone except one person from accessing picking sheet printing. That should help you narrow down the issue and see if it's a user that's causing the problem.