My client is a job shop manufacturer so all production orders are linked to a sales order. They manufacture items that are cut from blank sheets and vary in size. They use an external application to optimize their cuts and limit the amount of scrap because once a blank sheet gets cut it cannot be used again. Sometimes their optimization software tells them to produce more than is needed on the SO. The client deals in delicate material so scrap from breakage is a common occurrence. In each job they need to at least produce the quantity ordered and sometimes this can be absorbed due to the excess produced (based on their optimization software). Sometimes it cannot and they need to manufacture a replacement. For this reason the Include Scrap in Completions is selected in production preferences since it is a more straightforward path. The client would prefer to issue another workorder for the replacement item but this is causing issues with shipping. Materials are not backflushed and in most cases, issued in the first operation.

For example:

Customer ordered 5 items and a production order is created for 5 items.

Prior to releasing the production order, the optimization software suggests manufacturing 6 items

Change the work order quantity to 6

During production, 2 items are lost to breakage so 1 additional item must be manufactured to meet the customer order of 5 items

What is the best way to produce the additional item? Client would like to create a new production order for the additional item for routing purposes however this causes an issue on the sales order side with the original linked order only showing 4 allocated to ship. I tried adding another line to the SO for the single item but it I am unable to ship it.