this is the issue...First of all, we use special work orders to build items that are not available so a sales order cannot be picked until it’s specific special work order is built. Second, we are using a workaround to ship orders when an item is not physically in a bin but should be, according to the system.
In this scenario where an item should be in a bin according to the system, but is not physically in the bin, we back out of the pick task on the scanner, enter a work order (not a special work order) for the item, and set the order to the side until the work order is built. Once the work order is built it goes into the Order Receiving bin. We then ship the order manually with the item that had to be built shipping from Order Receiving and any other item on the order shipping from shipping stage.
Is it possible that this workaround is causing the issue where a bin has a committed item in it for an order that has potentially already shipped using the new item from Order Receiving?