Building Stock from Components
Use this guide when the warehouse needs to build a finished SKU from component stock already held in the warehouse.
When should I use this?
Use Inventory Assemblies when you need to:
- let a client request finished stock to be built from component items
- review and prepare that request into an operational warehouse plan
- print an Assembly Pick Sheet from the saved assembly plan
- track build progress over more than one step
- add the finished stock directly into inventory when the build is completed
This is not the right workflow for supplier deliveries. For incoming stock from outside the warehouse, use Registering and receiving an expected delivery.
Before you start
Check these basics first:
- The finished item is set up as an assembly product.
- The component list is correct.
- The component stock is already in the warehouse, or the warehouse understands the expected shortage.
- The destination warehouse and location are known before the warehouse prepares the assembly.
If you need help setting up the finished SKU, use Items — Product Types And Components.
Client — Request an Assembly
Client users can submit an assembly request for their own client when they need the warehouse to create an assembly. The request tells the warehouse what finished SKU is needed and the requested quantity.
Client workflow:
- Open Inventory Assemblies.
- Create a new assembly request.
- Choose the finished item and requested quantity.
- Add notes for the warehouse if needed.
- Submit the request.
After submission, the request waits for warehouse action. Client users can view progress and can withdraw the request before the warehouse prepares it.
A newly submitted request is not the operational build plan yet. It may have no saved assembly lines, source locations, or destination location. The warehouse must prepare it before build work and pick-sheet printing can start.
Warehouse — Prepare and Build
Warehouse and admin users can create an assembly directly, or review a client-submitted request and turn it into an execution-ready draft.
Warehouse workflow:
- Open the requested assembly.
- Review the client, finished item, requested quantity, and requested notes.
- Click Prepare Assembly.
- Confirm the planned warehouse, planned quantity, destination location, receiving charge settings, and component source locations required by the Prepare Assembly form.
- Save the preparation. This creates the saved assembly plan and component lines.
- Print the Assembly Pick Sheet if the warehouse wants a paper picking guide.
- Use Build to record actual progress.
- Use Build remaining if the rest of the quantity can be finished in one step.
- Use Complete when the assembly is finished, or close it short if the UI asks for a shortfall reason.
The Assembly Pick Sheet is optional and is only available after Prepare Assembly. Preparation selects or confirms the required stock locations and creates the saved assembly plan used by the pick sheet.
Completed, cancelled, and rejected assemblies are not made printable by clicking Prepare Assembly. Use the current status and available actions on the record to decide the next step.
Stock and Buildability
ParcelPilot checks the component stock that is available to build with.
For measured components, the required quantity is shown per finished unit and can use decimal values. The component item's Minimum practical quantity is only a guide for operators; it does not force the BOM quantity to follow a step or multiple rule.
Check Available to Build and any shortage warnings before preparing or recording build progress. Outstanding inbound stock is informational until it has been received into inventory.
The AI Assistant can explain the current assembly status, buildability, and what action is required next.
Locations and Saved Plan
Preparation creates the saved assembly plan, including the planned quantity, destination location, and component source selections. The Assembly Pick Sheet is based on that saved plan.
If the saved destination location no longer belongs to the selected warehouse, or cannot accept the finished SKU because of warehouse or mixed-SKU rules, the assembly may be blocked until the warehouse corrects the location setup.
Partial Builds and Closing Short
An assembly can record progress over more than one build step.
Use Build to record the quantity physically built now. Use Build remaining when all remaining units can be built in one step.
Each successful build execution consumes component stock and adds finished stock for the quantity built in that execution. Recorded build progress is therefore not just a quantity waiting for a later inventory-posting step. Prepare Assembly creates the saved plan without moving stock.
If the full quantity cannot be finished, close short only when the UI offers that option and the operational decision has been approved. Use the reason field shown on Complete so the shortfall is recorded properly.
Completion and Billing
When Build, Build remaining, or Complete successfully builds units:
- component stock is reduced for those units
- finished stock for those units is added to the chosen destination location
- Monthly Operations can include the assembly work and any receiving charge settings attached to that assembly
The assembly moves out of the open-work queue when its planned quantity is fully accounted for by built units and any approved shortfall. Closing an approved shortfall without building more units does not consume or produce stock for that shortfall.
You do not create a separate receipt for the finished goods.
Permissions
Client users can:
- submit an assembly request for their own client
- view progress on that request
- withdraw the request before the warehouse prepares it
Warehouse and admin users can:
- create an assembly directly
- review a client request
- use Prepare Assembly or Reject Request
- choose source and destination locations
- print the Assembly Pick Sheet after preparation
- record build progress
- complete the assembly
Common questions
Can a client user build the stock themselves?
No. Client users can request assembly work, but the warehouse completes the operational build.
Do I need a separate receipt for the finished goods?
No. Completing the assembly creates the finished stock.
Why can't I print the Assembly Pick Sheet?
The Assembly Pick Sheet is generated from the saved assembly plan. A new client request has not been prepared yet, so it does not have that printable saved plan.
Open the request and click Prepare Assembly first. After preparation, an eligible draft assembly with saved lines can have its Assembly Pick Sheet printed.
Completed, cancelled, and rejected assemblies are closed or terminal states. Preparing again is not the fix for those records.
Can we finish short?
Yes, when the UI offers that option. Use the reason field shown on Complete so the shortfall is recorded properly.
Why is Build or Complete unavailable?
Check the record status, component availability, and whether the assembly is still waiting for warehouse preparation.
If the assembly is already in draft, also check whether the saved destination location still belongs to the warehouse and can accept the finished SKU without breaking mixed-SKU rules.
What does ready to complete mean here?
Ready to complete means the saved assembly is in draft state and does not currently show a saved warehouse or destination-location blocker.
It does not guarantee that the full remaining quantity is buildable right now.
If component stock is short, the warehouse may still be able to close the remaining quantity only as an approved shortfall. Final stock, source, destination, and billing validation still runs when Complete is executed.
Things to check if something looks wrong
- Confirm the finished item and component list are correct.
- Check the selected warehouse and destination location.
- Review Available to Build before recording progress.
- If the assembly is still in requested state, open it and click Prepare Assembly to create the saved assembly plan before expecting Build, Complete, or Print Assembly Pick Sheet to appear.
- If the wrong quantity was requested, fix it before build history starts.