Shop Orders and Inventory Accuracy

Hi.

I am looking at a situation that I do not have extensive experience in right 
now.  A client has ceased creating and reporting against shop orders.  I have 
searched the archives and found nothing similar.  The client would like to 
have accurate inventory and costs, but I do not see a way to accomplish this 
without using shop orders or reporting production.

Right now they drive the FG inventory negative and the cost of sales should 
then theoretically be accurate.  But they also cut back and don't audit the 
BOMs in BPCS versus their drawing system that generates separate BOMs, routings 
and drawings.  This is being done in a mainly build to order environment.  I 
have considered having the folks here report production using the multi level 
shop order release and have the production backflushed, but I don't know what 
else to attempt.  

Do you have any ideas how to keep inventory accurate without shop orders and 
have accurate costs without BOM and Routing audits?

Thanks.
John Kasper
KASP6281@xxxxxxx