diff --git a/src/main/java/com/ffii/fpsms/modules/pickOrder/service/PickOrderService.kt b/src/main/java/com/ffii/fpsms/modules/pickOrder/service/PickOrderService.kt
index 2291c88..9d69786 100644
--- a/src/main/java/com/ffii/fpsms/modules/pickOrder/service/PickOrderService.kt
+++ b/src/main/java/com/ffii/fpsms/modules/pickOrder/service/PickOrderService.kt
@@ -1910,8 +1910,8 @@ open class PickOrderService(
         WHERE spl.pickOrderLineId = :pickOrderLineId
         """.trimIndent()
 
-        println("    Executing SQL: $checkSql")
-        println("    With parameters: pickOrderLineId = $pickOrderLineId")
+        //println("    Executing SQL: $checkSql")
+      //  println("    With parameters: pickOrderLineId = $pickOrderLineId")
 
         val result = jdbcDao.queryForList(checkSql, mapOf("pickOrderLineId" to pickOrderLineId))
 
@@ -4456,9 +4456,25 @@ open fun getAllPickOrderLotsWithDetailsHierarchical(userId: Long): Map<String, A
             }
         
             val oldIll = spl.suggestedLotLine
+        
+            // Load stock out line (if provided) to decide "bind vs split" and compute pickedQty
+            val existingSol = if (req.stockOutLineId != null && req.stockOutLineId > 0) {
+                stockOutLIneRepository.findById(req.stockOutLineId).orElse(null)
+            } else null
+            val pickedQty = existingSol?.qty?.let { numToBigDecimal(it as? Number) } ?: zero
 
             // Allow switch to UNAVAILABLE lot, but do NOT move hold/onHold and do NOT alter SOL status.
             if (targetUnavailable) {
+                // ✅ Release hold from old suggested lot first (prevents stranded holds when user scans unavailable/expired lot).
+                // Release only the remaining qty if some qty has been picked already.
+                val qtyToRelease = qtyToHold.subtract(pickedQty).coerceAtLeast(zero)
+                if (qtyToRelease > zero && oldIll != null && oldIll.id != null && oldIll.id != newIll.id) {
+                    val oldHold = oldIll.holdQty ?: zero
+                    val newOldHold = oldHold.subtract(qtyToRelease).coerceAtLeast(zero)
+                    oldIll.holdQty = newOldHold
+                    inventoryLotLineRepository.save(oldIll)
+                }
+
                 spl.suggestedLotLine = newIll
                 suggestPickLotRepository.saveAndFlush(spl)
 
@@ -4481,12 +4497,7 @@ open fun getAllPickOrderLotsWithDetailsHierarchical(userId: Long): Map<String, A
                     errorPosition = null
                 )
             }
-
-            // Load stock out line (if provided) to decide "bind vs split"
-            val existingSol = if (req.stockOutLineId != null && req.stockOutLineId > 0) {
-                stockOutLIneRepository.findById(req.stockOutLineId).orElse(null)
-            } else null
-            val pickedQty = existingSol?.qty?.let { numToBigDecimal(it as? Number) } ?: zero
+        
 
             // Switch lot rule:
             // - actual pick == 0: replace/bind (no new line)