We have a test system where we are modeling our manufacturing processes. After only modeling a dozen or so manufacturing orders an item allocation was incorrect. It was fixed using an inventory reconciliation but we are concerned for two reasons.
1. The frequency of the problem seems to be very high.
2. The reconciliation process took 40 minutes event though there were very few transactions.
I found a post saying some people run reconciliation on a nightly basis. Why is this necessary? What causes the picklist allocations to be so inaccurate? Does this process usually take so long for other companies?