Introduction

Physical Inventories represent a place in time where a user has verified the amount of inventory, by some means outside of inventory control. They enter a physical inventory in the software and regardless of what the inventory's balance is, that entry supersedes it, at the point that it is taken.

We have allowed users in the past to manage inventory "as-of" a specified date, even prior to a physical. What we are finding is that this causes inventory to be lost or infinitely available, because after all of those transactions, the inventory balance will still be the value of the physical at the point it was entered.

To control this, we have added validation to all of our screens that debit or credit inventory balances. If a physical inventory count was taken after the date that we are trying to add, adjust, transfer or relieve inventory then the transaction will not be valid, and will be cancelled. We will either have to change the date of the transaction or delete the physical inventory record.  

Direct Receipts

When a physical inventory exists, Direct Receipts prior to the last physical date (highlighted) of inventory with either a physical by lot or location will not save. Whether it validates by location or by lot determines on whether the user enters a lot on the receipt.

All items on the receiver will not be saved. Any items in violation of the constraint will have to be removed from the receiver, or their physicals rolled back, to continue. 

Purchase Order Receipts

When a physical inventory exists, Purchase Order Receipts prior to the last physical date (highlighted) of inventory with either a physical by lot or location will not save. Whether it validates by location or by lot determines on whether the user enters a lot on the receipt.

All items on the receiver will not be saved. Any items in violation of the constraint will have to be removed from the receiver, or their physicals rolled back, to continue. 

Work Order

When a work order runs to completion, inventories (formula) are created. The work order will fail if the inventories to be created is prior to a physical.

If the work order contains auto formulate premix, the work order process may need to create inventories for the premix.  The same physical check applies to auto formulate premixes.

Adjusting Inventory

Inventory Adjustment 

Inventory Adjustments are not allowed prior to a physical. If the physical was taken by location, then none of the lots on that day can be adjusted.

If a physical was taken by lot, then the lots that were set will not be allowed to be adjusted. 

Transferring Inventory

Inventory Transfer

Inventory transfer out are not allowed prior to a physical.  Transfer out uses the As of Date as the date to transfer out.

Inventory transfer in are also not allowed prior to a physical.  Transfer in  uses the Transfer Date as the date to transfer in.

An error is shown when there is a physical prior to the transfer out/in.

Work Order

Work Order has support for transfer.  If the transfer in is prior to a physical, the transfer process will fail.

Using Inventory

Inventory Usage

Inventory usage are not allowed prior to a physical.  In such a case, the row is highlighted and the Last Physical column is populated with the physical date.

Work Order

As part of the work order process, ingredients are allocated to create the finished good/formula.  If any of the ingredients to be allocated have prior physicals, the work order process will fail.  The same goes for allocating ingredients for auto formulate premixes.

Work order also supports inventory usage.  Once the finished good/formula are created, it possible to use the finished good/formula.  A physical check is also done for the usage.