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Merging is an org setting. To turn it on or off, see Configure inventory merge behavior.

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When merging happens

After you edit an inventory record on the Inventories page, ION checks for matching records. When it finds any, a Merge candidates detected prompt appears and the matching records merge after a short delay. To stop the merge, select Cancel on the prompt before it completes. Several operations leave a record eligible for merge, so editing it afterward can trigger the prompt:
  • Partially kitting a record, which leaves the remaining un-kitted quantity eligible.
  • Unkitting a record.
  • Partially installing or uninstalling inventory.
  • Removing inventory from an issue.
Scanning a barcode on its own doesn’t trigger a merge. Merging can also run through the ION API, so some orgs reconcile inventory in bulk on a schedule, such as an hourly integration. For a walkthrough, see this video on merging inventory.

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Merge criteria

Two inventory records can merge only when they share all of the following:
  • The same part, which must be a part (not a tool) that is untracked or lot tracked. Serial-tracked parts, and any record with an assigned serial number, never merge.
  • The same lot number, or no lot number on either record. This applies whether or not the part is lot tracked.
  • The same location, which must be set and must not have Exclude from Inventory Merge turned on.
  • The same status, which must be Available or Unavailable.
  • The same unit of measure.
  • The same intent, if your org uses intent options.
A record can’t merge while it’s in use elsewhere: installed onto another assembly, holding parts installed on its own aBOM, or tied to a related run or origin run, a related issue, a related kit, a plan reservation, a canceled purchase order line, or a kitted or installed quantity above zero. A record also can’t merge if it’s used to fix an issue on another inventory, or if the part is built on the assembly line (its released mBOM contains made-on-assembly items). Merging won’t occur when the same part appears on different purchase order lines within the same receipt.

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What happens on merge

  • ION creates a new inventory record and deletes the merged records. Merging can’t be undone.
  • Custom attribute values that match across all merged records carry to the new record; comments, file attachments, and labels are combined onto it.
  • The new record links every purchase order line from the merged records and preserves each line’s and receipt’s received quantities, so traceability to purchase orders and receipts holds. It has no transaction history from before the merge.
  • The new record inherits the earliest creation date among the merged records, so FIFO kit picking still selects the oldest stock first.
  • Old barcodes for the merged records point to the new record. You have the option to print a new barcode label, which reflects the new quantity.
When merged records came from purchase orders with different suppliers, the new record’s supplier is cleared, because no single supplier applies. The contributing suppliers stay discoverable through the related purchase order lines.