Sage 100

from kb article:

Sort files are automatically maintained when records are added or deleted from the master files. Use the Rebuild Application Sort Files utility for the following reasons:

• The sort files are damaged, resulting in a missing record error (Error 11) or missing information in a report.
• Data files have been rebuilt or reinitialized.
• Balances must be recalculated to resolve a specific issue.

See if they have mucho years of P.O. history involved.  Maybe copy some to history and purge a few years.

Thanks @Lee Graham  Yes, they probably have a lot of history that's never been purged.  I will check that and test removing PO info and re-running the rebuild sort files in a backup company.

See if they have mucho years of P.O. history involved.  Maybe copy some to history and purge a few years.

I looked at the Providex code for purchase order / rebuild sort files. It looks like it recalculates the "on po" quantities in IM_ItemWarehouse. table, and it purges and recalculates the quantities in the table PO_OpenOrderDetailByItem. The program only looks at the PO_PurchaseOrderHeader and PO_PurchaseOrderDetail tables. it does not look at the PO history tables so purging history is not likely to help. @Doug Higgs Do they have a lot of obsolete purchase orders with a lot of detail?  The program looks at every line in the PO_PurchaseOrderDetail table and has to see if there are any un-received quantities 

Thanks @Lee Graham  Yes, they probably have a lot of history that's never been purged.  I will check that and test removing PO info and re-running the rebuild sort files in a backup company.

See if they have mucho years of P.O. history involved.  Maybe copy some to history and purge a few years.

I looked at the Providex code for purchase order / rebuild sort files. It looks like it recalculates the "on po" quantities in IM_ItemWarehouse. table, and it purges and recalculates the quantities in the table PO_OpenOrderDetailByItem. The program only looks at the PO_PurchaseOrderHeader and PO_PurchaseOrderDetail tables. it does not look at the PO history tables so purging history is not likely to help. @Doug Higgs Do they have a lot of obsolete purchase orders with a lot of detail?  The program looks at every line in the PO_PurchaseOrderDetail table and has to see if there are any un-received quantities 

Thanks @Lee Graham  Yes, they probably have a lot of history that's never been purged.  I will check that and test removing PO info and re-running the rebuild sort files in a backup company.

See if they have mucho years of P.O. history involved.  Maybe copy some to history and purge a few years.

@David Overholt  Running the Purge Completed Purchase Orders utility solved it.  Thank you! The Rebuild PO Sort Files now takes 2 minutes.  Do you know what the Rebuild Job Cost Sort Files program does?  This takes 40 minutes or so.  What tables need to be cleaned up?

I looked at the Providex code for purchase order / rebuild sort files. It looks like it recalculates the "on po" quantities in IM_ItemWarehouse. table, and it purges and recalculates the quantities in the table PO_OpenOrderDetailByItem. The program only looks at the PO_PurchaseOrderHeader and PO_PurchaseOrderDetail tables. it does not look at the PO history tables so purging history is not likely to help. @Doug Higgs Do they have a lot of obsolete purchase orders with a lot of detail?  The program looks at every line in the PO_PurchaseOrderDetail table and has to see if there are any un-received quantities 

Thanks @Lee Graham  Yes, they probably have a lot of history that's never been purged.  I will check that and test removing PO info and re-running the rebuild sort files in a backup company.

@David Overholt  Running the Purge Completed Purchase Orders utility solved it.  Thank you! The Rebuild PO Sort Files now takes 2 minutes.  Do you know what the Rebuild Job Cost Sort Files program does?  This takes 40 minutes or so.  What tables need to be cleaned up?

I looked at the Providex code for purchase order / rebuild sort files. It looks like it recalculates the "on po" quantities in IM_ItemWarehouse. table, and it purges and recalculates the quantities in the table PO_OpenOrderDetailByItem. The program only looks at the PO_PurchaseOrderHeader and PO_PurchaseOrderDetail tables. it does not look at the PO history tables so purging history is not likely to help. @Doug Higgs Do they have a lot of obsolete purchase orders with a lot of detail?  The program looks at every line in the PO_PurchaseOrderDetail table and has to see if there are any un-received quantities 

Thanks @Lee Graham  Yes, they probably have a lot of history that's never been purged.  I will check that and test removing PO info and re-running the rebuild sort files in a backup company.

See if they have mucho years of P.O. history involved.  Maybe copy some to history and purge a few years.