Full Material Picking for Partial Consumption in Production – D365 F&O

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Posted on by Shubham-007

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Question:
Hi Experts,
I am working on a requirement in Dynamics 365 Finance & Operations related to raw material picking for production orders and need guidance on best practice.
Business Scenario:

Raw material (Glue) is procured in fixed packaging of 5 Liters (CAN)
In production, actual consumption is variable (e.g., 400 ML, 500 ML, etc.)
Physically, warehouse can only issue full container (5L) — partial picking (e.g., 500 ML) is not possible at warehouse level

Current Challenge:
When I release the production order to warehouse, system generates picking workorder based on required quantity (e.g., 500 ML), but business requirement is to always pick full 5L CAN.
Expected Behavior:

System should generate picking for full License Plate (5L container)
Production should consume only required quantity (e.g., 500 ML)
Remaining quantity (e.g., 4.5L) should stay available at production input location for future use or return

Questions:

What is the recommended standard approach in D365 F&O to handle this scenario?

Any guidance, best practices, or real project experience would be very helpful.
Thanks in advance!

Categories:

Dynamics 365 Supply Chain Management

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André Arnaud de Cal... 305,150 Super User 2026 Season 1 on at

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Hi Shubham,

You can use the over-picking feature in case you are using the advanced warehousing with mobile devices. You can read more about this here: Over-pick materials for production and batch orders - Supply Chain Management | Dynamics 365 | Microsoft Learn

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Shubham-007 335 on at

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Hi @André Arnaud de Calavon,

I tested over-picking, but it is not working for my requirement. The reason is that over-picking can only be defined as a percentage at the item level.

For example, if the required consumption is 0.4 ML and I allow 100% over-picking, the system only allows up to 0.8 ML instead of 5000 ML (5 L). This means the system always calculates the over-picking quantity based on the required quantity.

Additionally, I have other items such as fasteners, where it is not feasible to define a fixed over-picking percentage, as the requirement varies and cannot be predicted.

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HardikPatel523 234 on at

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Hi Shubham,
We had a very similar requirement a few years back. I’m not sure if there’s any out-of-the-box solution for this, but I can share our context and what we implemented.
In our case, the items were cables — for example, cable of 5000m. When the required quantity is, say, 200m, it doesn’t really make sense to pick just 200m. Practically, you can’t pick a partial cable.
So our approach was to always pick the full cable and during consumption leftover cable was cut. Since we didn’t find a standard solution for this, we went ahead with a customization. We added a flag at the item level to identify such items (e.g., cable items). For these items, the system creates work for the entire available quantity, regardless of the required quantity. We wrote code for that.
We implemented this customization, and it has been working well for years without any issues.
That said, this is just our approach—others in the community might have handled it differently.

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Venkat 184 on at

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Hi Shubam,

I tested the scenario.

An item A has an inventory of 10 Kg for LP-001.

2 Kg of Item A is required in the Production process. BOM line qnty was set to "2".

Released the production order. Pick work generated for 2 qnty. During the work process through the mibile process, the system suggests to move 10kg as it is the full LP.

2 Kg gets consumed in the order and remaining left over qnty (8kg) will be at Defaut production imput location.

Item A has a setup Material picking in license plate location= Staging in Warehouse tab,

Also, the explaination for staging option is as below

Staging – Whenever possible, the full quantity available at the license plate should be picked. For a worker to be able to pick the full license plate quantity, the license plate must not contain mixed items and must not have mixed dimensions. If the license plate contains mixed dimensions or items, the pick will proceed as if it were set to Order picking.

Regards,

Venkat

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Shubham-007 335 on at

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Hi @Venkat

My pick location is non–license plate tracked, and in the Item Master under the Warehouse tab, the “Staging” option is already selected. Therefore, I am not sure which additional setup you are referring to.

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Venkat 184 on at

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HI @Shubham,

I tested for with LP tracked. I am refering to the below setup.

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Green_oop_North 113 on at

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Hey @Shubham-007

Perhaps you could use replenishment for your scenario?

Create a fixed location in the Production area, assign your item to it.

Create a replenishment template with the relevant criteria relating to the item,

set Min/Max values for replenishment picking

you could create a unique Unit conversion / UOM so any picks will be created for 500L.

You could create picking work automatically on the work template so when you release to warehouse, the picking occurs direct from the fixed location

When the On-hand in the fixed locations reaches the minimum value (say 100L) and as long as you set up a regular batch run from "Replenishments" linked to the replenishment template then I would expect picking work for 500L to be created.

I'm making the assumption you're ok with the setup of location directives, work templates, etc...

Hope it helps

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Shubham-007 335 on at

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Hi @Green_oop_North

Thank you for your suggestion. As you mentioned, this was my Plan B to fulfill the requirement, but I was exploring whether a standard solution is available.

Thanks again.

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