fix: added process loss in job card (backport #35629)

erpnext/manufacturing/doctype/job_card/job_card.js

@@ -83,7 +83,7 @@ frappe.ui.form.on('Job Card', {
 			// and if stock mvt for WIP is required
 			if (frm.doc.work_order) {
 				frappe.db.get_value('Work Order', frm.doc.work_order, ['skip_transfer', 'status'], (result) => {
-					if (result.skip_transfer === 1 || result.status == 'In Process' || frm.doc.transferred_qty > 0) {
+					if (result.skip_transfer === 1 || result.status == 'In Process' || frm.doc.transferred_qty > 0 || !frm.doc.items.length) {
 						frm.trigger("prepare_timer_buttons");
 					}
 				});
@@ -411,6 +411,16 @@ frappe.ui.form.on('Job Card', {
 			}
 		});
 
+		if (frm.doc.total_completed_qty && frm.doc.for_quantity > frm.doc.total_completed_qty) {
+			let flt_precision = precision('for_quantity', frm.doc);
+			let process_loss_qty = (
+				flt(frm.doc.for_quantity, flt_precision)
+				- flt(frm.doc.total_completed_qty, flt_precision)
+			);
+
+			frm.set_value('process_loss_qty', process_loss_qty);
+		}
+
 		refresh_field("total_completed_qty");
 	}
 });

erpnext/manufacturing/doctype/job_card/job_card.json

@@ -38,6 +38,7 @@
   "time_logs",
   "section_break_13",
   "total_completed_qty",
+  "process_loss_qty",
   "column_break_15",
   "total_time_in_mins",
   "section_break_8",
@@ -435,11 +436,17 @@
    "fieldname": "expected_end_date",
    "fieldtype": "Datetime",
    "label": "Expected End Date"
+  },
+  {
+   "fieldname": "process_loss_qty",
+   "fieldtype": "Float",
+   "label": "Process Loss Qty",
+   "read_only": 1
   }
  ],
  "is_submittable": 1,
  "links": [],
- "modified": "2023-05-23 09:56:43.826602",
+ "modified": "2023-06-09 12:04:55.534264",
  "modified_by": "Administrator",
  "module": "Manufacturing",
  "name": "Job Card",
@@ -497,4 +504,4 @@
  "states": [],
  "title_field": "operation",
  "track_changes": 1
-}
+}

erpnext/manufacturing/doctype/job_card/job_card.py

@@ -161,7 +161,7 @@ def validate_time_logs(self):
 			self.total_completed_qty = flt(self.total_completed_qty, self.precision("total_completed_qty"))
 
 		for row in self.sub_operations:
-			self.total_completed_qty += row.completed_qty
+			self.c += row.completed_qty
 
 	def get_overlap_for(self, args, check_next_available_slot=False):
 		production_capacity = 1
@@ -451,6 +451,9 @@ def get_required_items(self):
 					},
 				)
 
+	def before_save(self):
+		self.set_process_loss()
+
 	def on_submit(self):
 		self.validate_transfer_qty()
 		self.validate_job_card()
@@ -487,19 +490,35 @@ def validate_job_card(self):
 				)
 			)
 
-		if self.for_quantity and self.total_completed_qty != self.for_quantity:
+		precision = self.precision("total_completed_qty")
+		total_completed_qty = flt(
+			flt(self.total_completed_qty, precision) + flt(self.process_loss_qty, precision)
+		)
+
+		if self.for_quantity and flt(total_completed_qty, precision) != flt(
+			self.for_quantity, precision
+		):
 			total_completed_qty = bold(_("Total Completed Qty"))
 			qty_to_manufacture = bold(_("Qty to Manufacture"))
 
 			frappe.throw(
 				_("The {0} ({1}) must be equal to {2} ({3})").format(
 					total_completed_qty,
-					bold(self.total_completed_qty),
+					bold(flt(total_completed_qty, precision)),
 					qty_to_manufacture,
 					bold(self.for_quantity),
 				)
 			)
 
+	def set_process_loss(self):
+		precision = self.precision("total_completed_qty")
+
+		self.process_loss_qty = 0.0
+		if self.total_completed_qty and self.for_quantity > self.total_completed_qty:
+			self.process_loss_qty = flt(self.for_quantity, precision) - flt(
+				self.total_completed_qty, precision
+			)
+
 	def update_work_order(self):
 		if not self.work_order:
 			return
@@ -511,23 +530,24 @@ def update_work_order(self):
 		):
 			return
 
-		for_quantity, time_in_mins = 0, 0
+		for_quantity, time_in_mins, process_loss_qty = 0, 0, 0
 		from_time_list, to_time_list = [], []
 
 		field = "operation_id"
 		data = self.get_current_operation_data()
 		if data and len(data) > 0:
 			for_quantity = flt(data[0].completed_qty)
 			time_in_mins = flt(data[0].time_in_mins)
+			process_loss_qty = flt(data[0].process_loss_qty)
 
 		wo = frappe.get_doc("Work Order", self.work_order)
 
 		if self.is_corrective_job_card:
 			self.update_corrective_in_work_order(wo)
 
 		elif self.operation_id:
-			self.validate_produced_quantity(for_quantity, wo)
-			self.update_work_order_data(for_quantity, time_in_mins, wo)
+			self.validate_produced_quantity(for_quantity, process_loss_qty, wo)
+			self.update_work_order_data(for_quantity, process_loss_qty, time_in_mins, wo)
 
 	def update_corrective_in_work_order(self, wo):
 		wo.corrective_operation_cost = 0.0
@@ -542,11 +562,11 @@ def update_corrective_in_work_order(self, wo):
 		wo.flags.ignore_validate_update_after_submit = True
 		wo.save()
 
-	def validate_produced_quantity(self, for_quantity, wo):
+	def validate_produced_quantity(self, for_quantity, process_loss_qty, wo):
 		if self.docstatus < 2:
 			return
 
-		if wo.produced_qty > for_quantity:
+		if wo.produced_qty > for_quantity + process_loss_qty:
 			first_part_msg = _(
 				"The {0} {1} is used to calculate the valuation cost for the finished good {2}."
 			).format(
@@ -561,7 +581,7 @@ def validate_produced_quantity(self, for_quantity, wo):
 				_("{0} {1}").format(first_part_msg, second_part_msg), JobCardCancelError, title=_("Error")
 			)
 
-	def update_work_order_data(self, for_quantity, time_in_mins, wo):
+	def update_work_order_data(self, for_quantity, process_loss_qty, time_in_mins, wo):
 		workstation_hour_rate = frappe.get_value("Workstation", self.workstation, "hour_rate")
 		jc = frappe.qb.DocType("Job Card")
 		jctl = frappe.qb.DocType("Job Card Time Log")
@@ -582,6 +602,7 @@ def update_work_order_data(self, for_quantity, time_in_mins, wo):
 		for data in wo.operations:
 			if data.get("name") == self.operation_id:
 				data.completed_qty = for_quantity
+				data.process_loss_qty = process_loss_qty
 				data.actual_operation_time = time_in_mins
 				data.actual_start_time = time_data[0].start_time if time_data else None
 				data.actual_end_time = time_data[0].end_time if time_data else None
@@ -599,7 +620,11 @@ def update_work_order_data(self, for_quantity, time_in_mins, wo):
 	def get_current_operation_data(self):
 		return frappe.get_all(
 			"Job Card",
-			fields=["sum(total_time_in_mins) as time_in_mins", "sum(total_completed_qty) as completed_qty"],
+			fields=[
+				"sum(total_time_in_mins) as time_in_mins",
+				"sum(total_completed_qty) as completed_qty",
+				"sum(process_loss_qty) as process_loss_qty",
+			],
 			filters={
 				"docstatus": 1,
 				"work_order": self.work_order,
@@ -777,7 +802,7 @@ def validate_sequence_id(self):
 
 		data = frappe.get_all(
 			"Work Order Operation",
-			fields=["operation", "status", "completed_qty"],
+			fields=["operation", "status", "completed_qty", "sequence_id"],
 			filters={"docstatus": 1, "parent": self.work_order, "sequence_id": ("<", self.sequence_id)},
 			order_by="sequence_id, idx",
 		)
@@ -795,6 +820,16 @@ def validate_sequence_id(self):
 					OperationSequenceError,
 				)
 
+			if row.completed_qty < current_operation_qty:
+				msg = f"""The completed quantity {bold(current_operation_qty)}
+					of an operation {bold(self.operation)} cannot be greater
+					than the completed quantity {bold(row.completed_qty)}
+					of a previous operation
+					{bold(row.operation)}.
+				"""
+
+				frappe.throw(_(msg))
+
 	def validate_work_order(self):
 		if self.is_work_order_closed():
 			frappe.throw(_("You can't make any changes to Job Card since Work Order is closed."))

erpnext/manufacturing/doctype/job_card/test_job_card.py

@@ -5,6 +5,7 @@
 from typing import Literal
 
 import frappe
+from frappe.test_runner import make_test_records
 from frappe.tests.utils import FrappeTestCase, change_settings
 from frappe.utils import random_string
 from frappe.utils.data import add_to_date, now, today
@@ -469,6 +470,119 @@ def test_job_card_material_request_and_bom_details(self):
 		self.assertEqual(ste.from_bom, 1.0)
 		self.assertEqual(ste.bom_no, work_order.bom_no)
 
+	def test_job_card_proccess_qty_and_completed_qty(self):
+		from erpnext.manufacturing.doctype.routing.test_routing import (
+			create_routing,
+			setup_bom,
+			setup_operations,
+		)
+		from erpnext.manufacturing.doctype.work_order.work_order import (
+			make_stock_entry as make_stock_entry_for_wo,
+		)
+		from erpnext.stock.doctype.item.test_item import make_item
+		from erpnext.stock.doctype.warehouse.test_warehouse import create_warehouse
+
+		operations = [
+			{"operation": "Test Operation A1", "workstation": "Test Workstation A", "time_in_mins": 30},
+			{"operation": "Test Operation B1", "workstation": "Test Workstation A", "time_in_mins": 20},
+		]
+
+		make_test_records("UOM")
+
+		warehouse = create_warehouse("Test Warehouse 123 for Job Card")
+
+		setup_operations(operations)
+
+		item_code = "Test Job Card Process Qty Item"
+		for item in [item_code, item_code + "RM 1", item_code + "RM 2"]:
+			if not frappe.db.exists("Item", item):
+				make_item(
+					item,
+					{
+						"item_name": item,
+						"stock_uom": "Nos",
+						"is_stock_item": 1,
+					},
+				)
+
+		routing_doc = create_routing(routing_name="Testing Route", operations=operations)
+		bom_doc = setup_bom(
+			item_code=item_code,
+			routing=routing_doc.name,
+			raw_materials=[item_code + "RM 1", item_code + "RM 2"],
+			source_warehouse=warehouse,
+		)
+
+		for row in bom_doc.items:
+			make_stock_entry(
+				item_code=row.item_code,
+				target=row.source_warehouse,
+				qty=10,
+				basic_rate=100,
+			)
+
+		wo_doc = make_wo_order_test_record(
+			production_item=item_code,
+			bom_no=bom_doc.name,
+			skip_transfer=1,
+			wip_warehouse=warehouse,
+			source_warehouse=warehouse,
+		)
+
+		for row in routing_doc.operations:
+			self.assertEqual(row.sequence_id, row.idx)
+
+		first_job_card = frappe.get_all(
+			"Job Card",
+			filters={"work_order": wo_doc.name, "sequence_id": 1},
+			fields=["name"],
+			order_by="sequence_id",
+			limit=1,
+		)[0].name
+
+		jc = frappe.get_doc("Job Card", first_job_card)
+		jc.time_logs[0].completed_qty = 8
+		jc.save()
+		jc.submit()
+
+		self.assertEqual(jc.process_loss_qty, 2)
+		self.assertEqual(jc.for_quantity, 10)
+
+		second_job_card = frappe.get_all(
+			"Job Card",
+			filters={"work_order": wo_doc.name, "sequence_id": 2},
+			fields=["name"],
+			order_by="sequence_id",
+			limit=1,
+		)[0].name
+
+		jc2 = frappe.get_doc("Job Card", second_job_card)
+		jc2.time_logs[0].completed_qty = 10
+
+		self.assertRaises(frappe.ValidationError, jc2.save)
+
+		jc2.load_from_db()
+		jc2.time_logs[0].completed_qty = 8
+		jc2.save()
+		jc2.submit()
+
+		self.assertEqual(jc2.for_quantity, 10)
+		self.assertEqual(jc2.process_loss_qty, 2)
+
+		s = frappe.get_doc(make_stock_entry_for_wo(wo_doc.name, "Manufacture", 10))
+		s.submit()
+
+		self.assertEqual(s.process_loss_qty, 2)
+
+		wo_doc.reload()
+		for row in wo_doc.operations:
+			self.assertEqual(row.completed_qty, 8)
+			self.assertEqual(row.process_loss_qty, 2)
+
+		self.assertEqual(wo_doc.produced_qty, 8)
+		self.assertEqual(wo_doc.process_loss_qty, 2)
+		self.assertEqual(wo_doc.status, "Completed")
+
 
 def create_bom_with_multiple_operations():
 	"Create a BOM with multiple operations and Material Transfer against Job Card"

erpnext/manufacturing/doctype/routing/test_routing.py

@@ -141,6 +141,7 @@ def setup_bom(**args):
 			routing=args.routing,
 			with_operations=1,
 			currency=args.currency,
+			source_warehouse=args.source_warehouse,
 		)
 	else:
 		bom_doc = frappe.get_doc("BOM", name)

erpnext/manufacturing/doctype/work_order/test_work_order.py

@@ -891,7 +891,7 @@ def test_wo_completion_with_pl_bom(self):
 		self.assertEqual(se.process_loss_qty, 1)
 
 		wo.load_from_db()
-		self.assertEqual(wo.status, "In Process")
+		self.assertEqual(wo.status, "Completed")
 
 	@timeout(seconds=60)
 	def test_job_card_scrap_item(self):