BOMs, Sales orders,and purchase orders

We are a stocking parts distributor and also do equipment repairs. Repairs is a smaller but significant part of the business, and it may be increasing.

We use "Create Purchase Orders from I/C" to create our purchase orders to our vendors, whether the requirement be to maintain stock levels or to order parts required for the repairs we do. We do "stock orders" generally, ordering weekly, rather than do a PO for each sales order, as that would be unmanageable due to volumes.

BOM master items are used for the equipment repair item number, and the required parts are added to the BOM as components.

In order to create a "requirement" for the parts (so that they will be added to a PO during PO creation), and also to track them and what they are required for when they are received, we add all these component parts onto the sales order at no cost, and then delete them when we assemble the master item.

This can lead to a lot of double entry, however, I have been unable to some up with an alternative that will suit our needs as well.

Does anyone have any better ideas and/or perhaps a more streamlined way of getting the BOM components to/from the BOM/Sales order? Export and importing might work, but with all the formatting required, I am not sure it would be much faster than manually typing the items into 2 places. There might be up to 40 components in a repair.