diff --git a/src/components/DoWorkbench/WorkbenchGoodPickExecutionDetail.tsx b/src/components/DoWorkbench/WorkbenchGoodPickExecutionDetail.tsx
index 0ddae50..2e0e0c3 100644
--- a/src/components/DoWorkbench/WorkbenchGoodPickExecutionDetail.tsx
+++ b/src/components/DoWorkbench/WorkbenchGoodPickExecutionDetail.tsx
@@ -86,19 +86,40 @@ interface Props {
 }
 
 /** 同物料多行时，优先对「有建议批次号」的行做替换，避免误选「无批次/不足」行 */
-function pickExpectedLotForSubstitution(activeSuggestedLots: any[]): any | null {
-  if (!activeSuggestedLots?.length) return null;
-  const withLotNo = activeSuggestedLots.filter(
-    (l) => l.lotNo != null && String(l.lotNo).trim() !== ""
+/** itemId → Set of processed stockOutLineId (allow same physical lot QR for next SOL). */
+type ProcessedStockOutLinesByItemId = Map<number, Set<number>>;
+
+function isLotRowPending(lot: any): boolean {
+  const st = String(lot?.stockOutLineStatus ?? "").toLowerCase();
+  return (
+    st === "pending" ||
+    st === "partially_completed" ||
+    st === "partially_complete" ||
+    st === ""
   );
-  if (withLotNo.length === 1) return withLotNo[0];
-  if (withLotNo.length > 1) {
-    const pending = withLotNo.find(
-      (l) => (l.stockOutLineStatus || "").toLowerCase() === "pending"
-    );
-    return pending || withLotNo[0];
-  }
-  return activeSuggestedLots[0];
+}
+
+function isStockOutLineAlreadyProcessed(
+  processedByItemId: ProcessedStockOutLinesByItemId,
+  itemId: number,
+  stockOutLineId: number | null | undefined,
+): boolean {
+  const solId = Number(stockOutLineId);
+  if (!Number.isFinite(solId) || solId <= 0) return false;
+  return processedByItemId.get(itemId)?.has(solId) ?? false;
+}
+
+function markProcessedStockOutLine(
+  prev: ProcessedStockOutLinesByItemId,
+  itemId: number,
+  stockOutLineId: number | null | undefined,
+): ProcessedStockOutLinesByItemId {
+  const solId = Number(stockOutLineId);
+  if (!Number.isFinite(solId) || solId <= 0) return prev;
+  const newMap = new Map(prev);
+  if (!newMap.has(itemId)) newMap.set(itemId, new Set());
+  newMap.get(itemId)!.add(solId);
+  return newMap;
 }
 
 /** Parse workbench QR / test shortcut into itemId + stockInLineId. */
@@ -150,15 +171,67 @@ function parseWorkbenchScanQrPayload(
   return null;
 }
 
-/** True when another pending/partial SOL still suggests this stockInLineId (same lot across lines). */
-function activeLotsStillNeedStockInLine(
-  activeLotsForItem: any[] | undefined,
+function hasPendingActiveRowForStockInLine(
+  indexes: {
+    byStockInLineId: Map<number, any[]>;
+    activeLotsByItemId: Map<number, any[]>;
+  },
+  itemId: number,
   stockInLineId: number,
+  processedByItemId: ProcessedStockOutLinesByItemId,
 ): boolean {
-  if (!activeLotsForItem?.length) return false;
-  return activeLotsForItem.some(
-    (lot) => Number(lot?.stockInLineId) === Number(stockInLineId),
+  const rows = indexes.byStockInLineId.get(stockInLineId) ?? [];
+  const activeSet = new Set(indexes.activeLotsByItemId.get(itemId) ?? []);
+  return rows.some(
+    (lot) =>
+      lot.itemId === itemId &&
+      activeSet.has(lot) &&
+      isLotRowPending(lot) &&
+      !isStockOutLineAlreadyProcessed(processedByItemId, itemId, lot.stockOutLineId),
+  );
+}
+
+function findExactActiveMatchForStockInLine(
+  stockInLineLots: any[],
+  scannedItemId: number,
+  activeSuggestedLots: any[],
+  processedByItemId: ProcessedStockOutLinesByItemId,
+): any | null {
+  const activeSet = new Set(activeSuggestedLots);
+  const candidates = stockInLineLots.filter(
+    (lot) =>
+      lot.itemId === scannedItemId &&
+      activeSet.has(lot) &&
+      !isStockOutLineAlreadyProcessed(
+        processedByItemId,
+        scannedItemId,
+        lot.stockOutLineId,
+      ),
   );
+  if (candidates.length === 0) return null;
+  return candidates.find((lot) => isLotRowPending(lot)) ?? candidates[0];
+}
+
+function pickExpectedLotForSubstitution(
+  activeSuggestedLots: any[],
+  processedByItemId?: ProcessedStockOutLinesByItemId,
+): any | null {
+  if (!activeSuggestedLots?.length) return null;
+  const itemId = activeSuggestedLots[0]?.itemId;
+  const processed = processedByItemId ?? new Map();
+  const unprocessed = activeSuggestedLots.filter(
+    (l) =>
+      !itemId ||
+      !isStockOutLineAlreadyProcessed(processed, itemId, l.stockOutLineId),
+  );
+  const pool = unprocessed.length > 0 ? unprocessed : activeSuggestedLots;
+  const withLotNo = pool.filter(
+    (l) => l.lotNo != null && String(l.lotNo).trim() !== "",
+  );
+  const searchPool = withLotNo.length > 0 ? withLotNo : pool;
+  if (searchPool.length === 1) return searchPool[0];
+  const pending = searchPool.find((l) => isLotRowPending(l));
+  return pending ?? searchPool[0];
 }
 
 const ManualLotConfirmationModal: React.FC<{
@@ -645,8 +718,9 @@ const [pickOrderSwitching, setPickOrderSwitching] = useState(false);
 
     //  Add these missing state variables after line 352
     const [isManualScanning, setIsManualScanning] = useState<boolean>(false);
-    // Track processed QR codes by itemId+stockInLineId combination for better lot confirmation handling
-    const [processedQrCombinations, setProcessedQrCombinations] = useState<Map<number, Set<number>>>(new Map());
+    // Track processed stock-out lines per item (allow same physical lot QR for next SOL)
+    const [processedQrCombinations, setProcessedQrCombinations] =
+      useState<ProcessedStockOutLinesByItemId>(new Map());
     const [processedQrCodes, setProcessedQrCodes] = useState<Set<string>>(new Set());
     const [lastProcessedQr, setLastProcessedQr] = useState<string>('');
     const [isRefreshingData, setIsRefreshingData] = useState<boolean>(false);
@@ -662,9 +736,10 @@ const [pickOrderSwitching, setPickOrderSwitching] = useState(false);
     const processedQrCodesRef = useRef<Set<string>>(new Set());
     const lastProcessedQrRef = useRef<string>('');
     /** Prevent double-submit while a scan-pick API is in flight (scanner bounce). */
-    const qrProcessInFlightRef = useRef(false);
+    const qrPickInFlightRef = useRef(false);
     /** Latest lot indexes for QR re-scan allow checks outside processOutsideQrCode. */
     const lotDataIndexesRef = useRef<{
+      byStockInLineId: Map<number, any[]>;
       activeLotsByItemId: Map<number, any[]>;
     } | null>(null);
     
@@ -1467,6 +1542,7 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
   }, [combinedLotData.length, combinedLotData]);
 
   lotDataIndexesRef.current = {
+    byStockInLineId: lotDataIndexes.byStockInLineId,
     activeLotsByItemId: lotDataIndexes.activeLotsByItemId,
   };
   
@@ -1474,6 +1550,12 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
   resetScanRef.current = resetScan;
   
   const processOutsideQrCode = useCallback(async (latestQr: string, qrScanCountAtInvoke?: number) => {
+    if (qrPickInFlightRef.current) {
+      console.log("  [SKIP] QR pick already in flight");
+      return;
+    }
+    qrPickInFlightRef.current = true;
+
     const totalStartTime = performance.now();
     console.log(`  [PROCESS OUTSIDE QR START] QR: ${latestQr.substring(0, 50)}...`);
     console.log(`  Start time: ${new Date().toISOString()}`);
@@ -1483,7 +1565,26 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
     const indexes = lotDataIndexes; // Access the memoized indexes
     const indexAccessTime = performance.now() - indexAccessStart;
     console.log(`  [PERF] Index access time: ${indexAccessTime.toFixed(2)}ms`);
-    
+
+    const maybeReleaseQrForNextSol = (
+      itemId: number,
+      stockInLineId: number,
+      processedAfterMark: ProcessedStockOutLinesByItemId,
+    ) => {
+      if (
+        hasPendingActiveRowForStockInLine(
+          indexes,
+          itemId,
+          stockInLineId,
+          processedAfterMark,
+        )
+      ) {
+        lastProcessedQrRef.current = "";
+        processedQrCodesRef.current.delete(latestQr);
+      }
+    };
+
+    try {
     // 1) Parse JSON safely (parse once, reuse)
     const parseStartTime = performance.now();
     let qrData: any = null;
@@ -1516,30 +1617,24 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
   
       const scannedItemId = qrData.itemId;
       const scannedStockInLineId = qrData.stockInLineId;
-      
-      // ✅ Skip only when this lot was already processed AND no other active line still needs it.
-      // Same item + same stockInLineId across different pick-order lines must be re-scannable.
-      const duplicateCheckStartTime = performance.now();
-      const itemProcessedSet = processedQrCombinations.get(scannedItemId);
-      const activeSuggestedLotsEarly =
-        indexes.activeLotsByItemId.get(scannedItemId) || [];
+
       if (
-        itemProcessedSet?.has(scannedStockInLineId) &&
-        !activeLotsStillNeedStockInLine(
-          activeSuggestedLotsEarly,
+        !hasPendingActiveRowForStockInLine(
+          indexes,
+          scannedItemId,
           scannedStockInLineId,
+          processedQrCombinations,
         )
       ) {
-        const duplicateCheckTime = performance.now() - duplicateCheckStartTime;
-        console.log(`  [SKIP] Already processed combination: itemId=${scannedItemId}, stockInLineId=${scannedStockInLineId} (check time: ${duplicateCheckTime.toFixed(2)}ms)`);
+        console.log(
+          `  [SKIP] No pending stock-out line left for itemId=${scannedItemId}, stockInLineId=${scannedStockInLineId}`,
+        );
         return;
       }
-      const duplicateCheckTime = performance.now() - duplicateCheckStartTime;
-      console.log(`  [PERF] Duplicate check time: ${duplicateCheckTime.toFixed(2)}ms`);
       
       // ✅ OPTIMIZATION: Use cached active lots directly (no filtering needed)
       const lookupStartTime = performance.now();
-      const activeSuggestedLots = activeSuggestedLotsEarly;
+      const activeSuggestedLots = indexes.activeLotsByItemId.get(scannedItemId) || [];
       // ✅ Also get all lots for this item (not just active ones) to allow lot switching even when all lots are rejected
       const allLotsForItem = indexes.byItemId.get(scannedItemId) || [];
       const lookupTime = performance.now() - lookupStartTime;
@@ -1547,9 +1642,17 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
       
       // ✅ Check if scanned lot is rejected BEFORE checking activeSuggestedLots
       // This allows users to scan other lots even when all suggested lots are rejected
-      const scannedLot = allLotsForItem.find(
-        (lot: any) => lot.stockInLineId === scannedStockInLineId
-      );
+      const stockInLineRows = indexes.byStockInLineId.get(scannedStockInLineId) ?? [];
+      const scannedLot =
+        findExactActiveMatchForStockInLine(
+          stockInLineRows,
+          scannedItemId,
+          activeSuggestedLots,
+          processedQrCombinations,
+        ) ??
+        allLotsForItem.find(
+          (lot: any) => lot.stockInLineId === scannedStockInLineId,
+        );
       
       if (scannedLot) {
         const isRejected = 
@@ -1566,13 +1669,14 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
               `此批次（${scannedLot.lotNo || scannedStockInLineId}）已被拒绝，无法使用。请扫描其他批次。`
             );
           });
-          // Mark as processed to prevent re-processing
-          setProcessedQrCombinations(prev => {
-            const newMap = new Map(prev);
-            if (!newMap.has(scannedItemId)) newMap.set(scannedItemId, new Set());
-            newMap.get(scannedItemId)!.add(scannedStockInLineId);
-            return newMap;
-          });
+          // Mark this SOL as processed to prevent re-processing
+          setProcessedQrCombinations((prev) =>
+            markProcessedStockOutLine(
+              prev,
+              scannedItemId,
+              scannedLot.stockOutLineId,
+            ),
+          );
           return;
         }
 
@@ -1631,7 +1735,8 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
           pickExpectedLotForSubstitution(
             allLotsForItem.filter(
               (l: any) => l.lotNo != null && String(l.lotNo).trim() !== ""
-            )
+            ),
+            processedQrCombinations,
           ) ||
           allLotsForItem[0];
         
@@ -1759,12 +1864,17 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
           );
         });
 
-        setProcessedQrCombinations((prev) => {
-          const newMap = new Map(prev);
-          if (!newMap.has(scannedItemId)) newMap.set(scannedItemId, new Set());
-          newMap.get(scannedItemId)!.add(scannedStockInLineId);
-          return newMap;
-        });
+        const nextProcessedNoActive = markProcessedStockOutLine(
+          processedQrCombinations,
+          scannedItemId,
+          expectedLot.stockOutLineId,
+        );
+        setProcessedQrCombinations(nextProcessedNoActive);
+        maybeReleaseQrForNextSol(
+          scannedItemId,
+          scannedStockInLineId,
+          nextProcessedNoActive,
+        );
 
         if (workbenchMode) {
           await refreshWorkbenchAfterScanPick();
@@ -1775,16 +1885,13 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
       
       // ✅ OPTIMIZATION: Direct Map lookup for stockInLineId match (O(1))
       const matchStartTime = performance.now();
-      let exactMatch: any = null;
       const stockInLineLots = indexes.byStockInLineId.get(scannedStockInLineId) || [];
-      // Find exact match from stockInLineId index, then verify it's in active lots
-      for (let i = 0; i < stockInLineLots.length; i++) {
-        const lot = stockInLineLots[i];
-        if (lot.itemId === scannedItemId && activeSuggestedLots.includes(lot)) {
-          exactMatch = lot;
-          break;
-        }
-      }
+      const exactMatch = findExactActiveMatchForStockInLine(
+        stockInLineLots,
+        scannedItemId,
+        activeSuggestedLots,
+        processedQrCombinations,
+      );
       const matchTime = performance.now() - matchStartTime;
       console.log(`  [PERF] Find exact match time: ${matchTime.toFixed(2)}ms, found: ${exactMatch ? 'yes' : 'no'}`);
       
@@ -1793,7 +1900,10 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
       // Also handle case where scanned lot is not in allLotsForItem (scannedLot is undefined)
       if (!exactMatch) {
         const expectedLot =
-          pickExpectedLotForSubstitution(activeSuggestedLots) || allLotsForItem[0];
+          pickExpectedLotForSubstitution(
+            activeSuggestedLots,
+            processedQrCombinations,
+          ) || allLotsForItem[0];
         if (expectedLot) {
           const shouldAutoSwitch =
             !scannedLot || (scannedLot.stockInLineId !== expectedLot.stockInLineId);
@@ -1926,12 +2036,17 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
               );
             });
 
-            setProcessedQrCombinations((prev) => {
-              const newMap = new Map(prev);
-              if (!newMap.has(scannedItemId)) newMap.set(scannedItemId, new Set());
-              newMap.get(scannedItemId)!.add(scannedStockInLineId);
-              return newMap;
-            });
+            const nextProcessedAuto = markProcessedStockOutLine(
+              processedQrCombinations,
+              scannedItemId,
+              expectedLot.stockOutLineId,
+            );
+            setProcessedQrCombinations(nextProcessedAuto);
+            maybeReleaseQrForNextSol(
+              scannedItemId,
+              scannedStockInLineId,
+              nextProcessedAuto,
+            );
             if (workbenchMode) {
               await refreshWorkbenchAfterScanPick();
             }
@@ -2022,16 +2137,19 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
             const stateUpdateTime = performance.now() - stateUpdateStartTime;
             console.log(`  [PERF] State update time: ${stateUpdateTime.toFixed(2)}ms`);
             
-            // Mark this combination as processed
+            // Mark this SOL as processed (same physical lot may still be needed by another SOL)
             const markProcessedStartTime = performance.now();
-            setProcessedQrCombinations(prev => {
-              const newMap = new Map(prev);
-              if (!newMap.has(scannedItemId)) {
-                newMap.set(scannedItemId, new Set());
-              }
-              newMap.get(scannedItemId)!.add(scannedStockInLineId);
-              return newMap;
-            });
+            const nextProcessedExact = markProcessedStockOutLine(
+              processedQrCombinations,
+              scannedItemId,
+              exactMatch.stockOutLineId,
+            );
+            setProcessedQrCombinations(nextProcessedExact);
+            maybeReleaseQrForNextSol(
+              scannedItemId,
+              scannedStockInLineId,
+              nextProcessedExact,
+            );
             const markProcessedTime = performance.now() - markProcessedStartTime;
             console.log(`  [PERF] Mark processed time: ${markProcessedTime.toFixed(2)}ms`);
 
@@ -2042,7 +2160,7 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
             const totalTime = performance.now() - totalStartTime;
             console.log(`✅ [PROCESS OUTSIDE QR END] Total time: ${totalTime.toFixed(2)}ms (${(totalTime / 1000).toFixed(3)}s)`);
             console.log(`  End time: ${new Date().toISOString()}`);
-            console.log(`📊 Breakdown: parse=${parseTime.toFixed(2)}ms, validation=${validationTime.toFixed(2)}ms, duplicateCheck=${duplicateCheckTime.toFixed(2)}ms, lookup=${lookupTime.toFixed(2)}ms, match=${matchTime.toFixed(2)}ms, api=${apiTime.toFixed(2)}ms, stateUpdate=${stateUpdateTime.toFixed(2)}ms, markProcessed=${markProcessedTime.toFixed(2)}ms`);
+            console.log(`📊 Breakdown: parse=${parseTime.toFixed(2)}ms, validation=${validationTime.toFixed(2)}ms, lookup=${lookupTime.toFixed(2)}ms, match=${matchTime.toFixed(2)}ms, api=${apiTime.toFixed(2)}ms, stateUpdate=${stateUpdateTime.toFixed(2)}ms, markProcessed=${markProcessedTime.toFixed(2)}ms`);
             console.log(
               workbenchMode
                 ? "✅ Workbench scan-pick: list refreshed from server"
@@ -2085,14 +2203,17 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
       // ✅ Case 2: itemId 匹配但 stockInLineId 不匹配
       // Workbench 策略：不彈窗，直接切換到掃到的批次並提交一次掃描
       const mismatchCheckStartTime = performance.now();
-      const itemProcessedSet2 = processedQrCombinations.get(scannedItemId);
       if (
-        itemProcessedSet2?.has(scannedStockInLineId) &&
-        !activeLotsStillNeedStockInLine(activeSuggestedLots, scannedStockInLineId)
+        !hasPendingActiveRowForStockInLine(
+          indexes,
+          scannedItemId,
+          scannedStockInLineId,
+          processedQrCombinations,
+        )
       ) {
         const mismatchCheckTime = performance.now() - mismatchCheckStartTime;
         console.log(
-          `  [SKIP] Already processed this exact combination (check time: ${mismatchCheckTime.toFixed(2)}ms)`,
+          `  [SKIP] No pending stock-out line left for mismatch path (check time: ${mismatchCheckTime.toFixed(2)}ms)`,
         );
         return;
       }
@@ -2100,7 +2221,10 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
       console.log(`  [PERF] Mismatch check time: ${mismatchCheckTime.toFixed(2)}ms`);
 
       const expectedLotStartTime = performance.now();
-      const expectedLot = pickExpectedLotForSubstitution(activeSuggestedLots);
+      const expectedLot = pickExpectedLotForSubstitution(
+        activeSuggestedLots,
+        processedQrCombinations,
+      );
       if (!expectedLot) {
         console.error("Could not determine expected lot for auto-switch");
         startTransition(() => {
@@ -2239,12 +2363,17 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
           );
         });
 
-        setProcessedQrCombinations((prev) => {
-          const newMap = new Map(prev);
-          if (!newMap.has(scannedItemId)) newMap.set(scannedItemId, new Set());
-          newMap.get(scannedItemId)!.add(scannedStockInLineId);
-          return newMap;
-        });
+        const nextProcessedMismatch = markProcessedStockOutLine(
+          processedQrCombinations,
+          scannedItemId,
+          expectedLot.stockOutLineId,
+        );
+        setProcessedQrCombinations(nextProcessedMismatch);
+        maybeReleaseQrForNextSol(
+          scannedItemId,
+          scannedStockInLineId,
+          nextProcessedMismatch,
+        );
 
         if (workbenchMode) {
           await refreshWorkbenchAfterScanPick();
@@ -2262,7 +2391,7 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
       );
       console.log(`  End time: ${new Date().toISOString()}`);
       console.log(
-        `📊 Breakdown: parse=${parseTime.toFixed(2)}ms, validation=${validationTime.toFixed(2)}ms, duplicateCheck=${duplicateCheckTime.toFixed(2)}ms, lookup=${lookupTime.toFixed(2)}ms, match=${matchTime.toFixed(2)}ms, mismatchCheck=${mismatchCheckTime.toFixed(2)}ms, expectedLot=${expectedLotTime.toFixed(2)}ms`,
+        `📊 Breakdown: parse=${parseTime.toFixed(2)}ms, validation=${validationTime.toFixed(2)}ms, lookup=${lookupTime.toFixed(2)}ms, match=${matchTime.toFixed(2)}ms, mismatchCheck=${mismatchCheckTime.toFixed(2)}ms, expectedLot=${expectedLotTime.toFixed(2)}ms`,
       );
     } catch (error) {
       const totalTime = performance.now() - totalStartTime;
@@ -2274,6 +2403,9 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
       });
       return;
     }
+    } finally {
+      qrPickInFlightRef.current = false;
+    }
   }, [
     lotDataIndexes,
     processedQrCombinations,
@@ -2354,39 +2486,29 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
           
           // ✅ Process immediately (bypass QR scanner delay)
           if (processOutsideQrCodeRef.current) {
-            if (qrProcessInFlightRef.current) {
-              console.log(`  [TEST QR] Skipping — scan-pick already in flight`);
-              return;
-            }
-            qrProcessInFlightRef.current = true;
             processOutsideQrCodeRef.current(simulatedQr, qrValues.length).then(() => {
               const testTime = performance.now() - testStartTime;
               console.log(`  [TEST QR] Total processing time: ${testTime.toFixed(2)}ms (${(testTime / 1000).toFixed(3)}s)`);
               console.log(`  [TEST QR] End time: ${new Date().toISOString()}`);
+              // Release test shortcut string if another SOL still needs this lot
+              if (
+                hasPendingActiveRowForStockInLine(
+                  lotDataIndexes,
+                  itemId,
+                  stockInLineId,
+                  processedQrCombinations,
+                )
+              ) {
+                processedQrCodesRef.current.delete(latestQr);
+                if (lastProcessedQrRef.current === latestQr) {
+                  lastProcessedQrRef.current = "";
+                }
+                setProcessedQrCodes(new Set(processedQrCodesRef.current));
+                setLastProcessedQr("");
+              }
             }).catch((error) => {
               const testTime = performance.now() - testStartTime;
               console.error(`❌ [TEST QR] Error after ${testTime.toFixed(2)}ms:`, error);
-            }).finally(async () => {
-              await new Promise((r) => setTimeout(r, 50));
-              try {
-                const activeForItem =
-                  lotDataIndexesRef.current?.activeLotsByItemId.get(itemId);
-                if (
-                  activeLotsStillNeedStockInLine(activeForItem, stockInLineId)
-                ) {
-                  processedQrCodesRef.current.delete(latestQr);
-                  if (lastProcessedQrRef.current === latestQr) {
-                    lastProcessedQrRef.current = "";
-                  }
-                  setProcessedQrCodes(new Set(processedQrCodesRef.current));
-                  setLastProcessedQr("");
-                  console.log(
-                    `  [TEST QR] Cleared processed test QR so same lot can be scanned for remaining line(s)`,
-                  );
-                }
-              } finally {
-                qrProcessInFlightRef.current = false;
-              }
             });
           }
           
@@ -2423,32 +2545,33 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
     console.log(`  [QR DETECTION] Detection time: ${new Date().toISOString()}`);
     console.log(`  [QR DETECTION] Time since QR scanner set value: ${(qrDetectionStartTime - qrValuesChangeStartTime).toFixed(2)}ms`);
     
-    // Skip if already processed — unless another active line still needs the same lot (cross-POL same lot).
-    const checkProcessedStartTime = performance.now();
-    const alreadySeenQr =
-      processedQrCodesRef.current.has(latestQr) ||
-      lastProcessedQrRef.current === latestQr;
-    if (alreadySeenQr) {
-      const payload = parseWorkbenchScanQrPayload(latestQr);
-      const activeForItem = payload
-        ? lotDataIndexesRef.current?.activeLotsByItemId.get(payload.itemId)
-        : undefined;
-      const allowSameLotRescan =
-        !!payload &&
-        activeLotsStillNeedStockInLine(activeForItem, payload.stockInLineId);
-      if (!allowSameLotRescan) {
-        const checkTime = performance.now() - checkProcessedStartTime;
-        console.log(`  [QR PROCESS] Already processed check time: ${checkTime.toFixed(2)}ms`);
-        return;
-      }
-      console.log(
-        `  [QR PROCESS] Allowing re-scan of same lot QR for remaining active pick line(s)`,
+    const qrPayload = parseWorkbenchScanQrPayload(latestQr);
+    const canRetrySamePhysicalLot =
+      qrPayload != null &&
+      hasPendingActiveRowForStockInLine(
+        lotDataIndexes,
+        qrPayload.itemId,
+        qrPayload.stockInLineId,
+        processedQrCombinations,
       );
-    }
-    if (qrProcessInFlightRef.current) {
-      console.log(`  [QR PROCESS] Skipping — scan-pick already in flight`);
+
+    // Skip if already processed (allow same QR when another pending SOL needs this lot)
+    const checkProcessedStartTime = performance.now();
+    if (
+      (processedQrCodesRef.current.has(latestQr) ||
+        lastProcessedQrRef.current === latestQr) &&
+      !canRetrySamePhysicalLot
+    ) {
+      const checkTime = performance.now() - checkProcessedStartTime;
+      console.log(`  [QR PROCESS] Already processed check time: ${checkTime.toFixed(2)}ms`);
       return;
     }
+    if (canRetrySamePhysicalLot) {
+      processedQrCodesRef.current.delete(latestQr);
+      if (lastProcessedQrRef.current === latestQr) {
+        lastProcessedQrRef.current = "";
+      }
+    }
     const checkTime = performance.now() - checkProcessedStartTime;
     console.log(` [QR PROCESS] Not processed check time: ${checkTime.toFixed(2)}ms`);
     
@@ -2483,8 +2606,7 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
     }
     
     // Process new QR code immediately (background mode - no modal)
-    // Check against refs to avoid state update delays
-    if (latestQr && latestQr !== lastProcessedQrRef.current) {
+    if (latestQr && (latestQr !== lastProcessedQrRef.current || canRetrySamePhysicalLot)) {
       const processingStartTime = performance.now();
       console.log(`  [QR PROCESS] Starting processing at: ${new Date().toISOString()}`);
       console.log(`  [QR PROCESS] Time since detection: ${(processingStartTime - qrDetectionStartTime).toFixed(2)}ms`);
@@ -2516,45 +2638,21 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
       // Use ref to avoid dependency issues
       const processCallStartTime = performance.now();
       if (processOutsideQrCodeRef.current) {
-        qrProcessInFlightRef.current = true;
         processOutsideQrCodeRef.current(latestQr, qrValues.length)
           .then(() => {
             const processCallTime = performance.now() - processCallStartTime;
             const totalProcessingTime = performance.now() - processingStartTime;
             console.log(`  [QR PROCESS] processOutsideQrCode call time: ${processCallTime.toFixed(2)}ms`);
             console.log(`  [QR PROCESS] Total processing time: ${totalProcessingTime.toFixed(2)}ms (${(totalProcessingTime / 1000).toFixed(3)}s)`);
+            // maybeReleaseQrForNextSol may have cleared refs; sync UI state
+            setProcessedQrCodes(new Set(processedQrCodesRef.current));
+            setLastProcessedQr(lastProcessedQrRef.current);
           })
           .catch((error) => {
             const processCallTime = performance.now() - processCallStartTime;
             const totalProcessingTime = performance.now() - processingStartTime;
             console.error(`❌ [QR PROCESS] processOutsideQrCode error after ${processCallTime.toFixed(2)}ms:`, error);
             console.error(`❌ [QR PROCESS] Total processing time before error: ${totalProcessingTime.toFixed(2)}ms`);
-          })
-          .finally(async () => {
-            // Wait a tick so refresh/local status updates commit into lotDataIndexesRef.
-            await new Promise((r) => setTimeout(r, 50));
-            try {
-              const payload = parseWorkbenchScanQrPayload(latestQr);
-              const activeForItem = payload
-                ? lotDataIndexesRef.current?.activeLotsByItemId.get(payload.itemId)
-                : undefined;
-              if (
-                payload &&
-                activeLotsStillNeedStockInLine(activeForItem, payload.stockInLineId)
-              ) {
-                processedQrCodesRef.current.delete(latestQr);
-                if (lastProcessedQrRef.current === latestQr) {
-                  lastProcessedQrRef.current = "";
-                }
-                setProcessedQrCodes(new Set(processedQrCodesRef.current));
-                setLastProcessedQr("");
-                console.log(
-                  `  [QR PROCESS] Cleared processed QR so same lot can be scanned for remaining line(s)`,
-                );
-              }
-            } finally {
-              qrProcessInFlightRef.current = false;
-            }
           });
       }
       
@@ -2577,7 +2675,7 @@ const fetchAllCombinedLotData = useCallback(async (userId?: number, pickOrderIdO
         qrProcessingTimeoutRef.current = null;
       }
     };
-  }, [qrValues, isManualScanning, isRefreshingData, combinedLotData.length, manualLotConfirmationOpen]);
+  }, [qrValues, isManualScanning, isRefreshingData, combinedLotData.length, manualLotConfirmationOpen, lotDataIndexes, processedQrCombinations]);
 const renderCountRef = useRef(0);
 const renderStartTimeRef = useRef<number | null>(null);
 
@@ -3212,7 +3310,7 @@ const handleStartScan = useCallback(() => {
   setProcessedQrCombinations(new Map());
   processedQrCodesRef.current = new Set();
   lastProcessedQrRef.current = '';
-  qrProcessInFlightRef.current = false;
+  qrPickInFlightRef.current = false;
   setQrScanError(false);
   setQrScanSuccess(false);