Zombie POs: The Walking Dead of Manufacturing AP

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Ted McRae
September 18, 2025

The Three Crucial Jobs in AP (and How AI Simplifies Them)

1. Capture & Code Bill Line Items

Here’s the first hurdle: invoices don’t arrive neatly structured. They come as PDFs, emails, and scans—some with dozens or even hundreds of line items. Traditionally, the only way to deal with them has been to type them in by hand. That means hours of tedious data entry, endless opportunities for typos, and a very human temptation to just code the total amount to a single GL account.

But here’s the catch: when you lose line-item detail, you lose margin visibility. If the cost of a single component creeps up, you won’t see it. And before long, you could be selling at a loss without realizing it.

This is where AI shines. Instead of typing, artificial intelligence can extract every line item from every invoice—automatically. It doesn’t just read the total; it captures each component, codes it to the correct job, SKU, class, or cost center, and learns as it goes. Over time, the system gets smarter, requiring less human correction and delivering more accuracy.

The result? Every nut, bolt, and screw is accounted for. No more blind spots. No more hidden cost drift. Just clean data and full visibility into your true costs.

2. Match Bills to POs

Purchase orders are more than paperwork—they’re commitments. They define the prices, quantities, and terms you agreed to. But anyone who’s worked in AP knows invoices rarely match POs line-for-line. Prices change, shipments arrive partially, freight and taxes get tacked on later. And to make it even trickier, one invoice may tie to multiple POs, or one PO may span multiple invoices.

Manually reconciling these is a nightmare. Accounting systems try to help by copying PO lines onto a bill, but someone still has to go line by line fixing mismatches. It’s slow, it’s messy, and it’s error-prone.

AI changes the game. With intelligent PO and invoice reconciliation, AI systems compare bills against open POs line by line—automatically. They handle the many-to-many scenarios without blinking, flagging only the issues that need a human decision. Instead of spending hours reconciling every invoice, your team spends minutes reviewing exceptions.

That means fewer overpayments, no more missed discounts, and much stronger vendor control. Suddenly, three-way matching isn’t a dreaded process—it’s just part of the workflow.

3. Keep POs Accurate & Closed

Now let’s talk about what happens when bills don’t get matched and POs don’t get closed: your Open PO report becomes a graveyard. These “zombie POs” linger long after goods are delivered, cluttering your system, inflating liabilities, and making it appear you owe more than you do.

The real problem? Finance stops trusting the data. When your Open PO report is garbage, cash flow forecasting turns into guesswork. Accruals become unreliable. Vendor negotiations are built on shaky ground.

AI solves this, too. By automatically closing or marking POs as partially fulfilled as invoices are processed, AI keeps your records clean and current. The Open PO report reflects true obligations, which means finance can forecast confidently and operations can plan without second-guessing.

When your PO data is trustworthy, you’re not just managing payables—you’re managing the business with clarity.

The Hidden Costs of Manual AP

It’s easy to think of these problems as annoyances, but they have very real financial consequences.

  • Lost working capital: Companies lose up to 3% of working capital annually due to mismatched POs, invoice errors, and delayed reconciliations. For a $10M manufacturer, that’s roughly $300,000 per year gone.

  • Higher AP costs: Manual reconciliation processes cost about 30% more than automated ones. AP clerks spend hours typing data that could be captured automatically. Exception handling alone consumes massive amounts of staff time.

  • Broken visibility: When Open PO reports are unreliable, cash flow forecasts turn into educated guesses. That leads to poor inventory planning, bad financial decisions, and unnecessary stress for leadership.

  • Damaged vendor relationships: Roughly a quarter of invoice delays are caused by PO mismatches. Late or incorrect payments strain supplier trust, cost you early payment discounts, and can even result in stricter terms.

These aren’t small issues. They’re systemic leaks that quietly drain profit and weaken the very relationships your business relies on.

What “Good” Looks Like with AI

When artificial intelligence takes on these three core jobs, AP stops being a headache and starts becoming a strength. Here’s what good looks like:

  • Clean bill capture at the line-item level, with every cost coded correctly.

  • Seamless PO and invoice reconciliation, even in many-to-many scenarios, with only exceptions flagged for review.

  • Trustworthy PO lifecycle management, where open POs are closed or updated in real time.

  • Aligned finance and operations, because both sides can finally trust the data.

Instead of spending hours on manual tasks, your AP team focuses on analysis, strategy, and strengthening vendor relationships. Finance gains reliable visibility into costs and obligations. Operations can plan with confidence. Vendors get paid on time and correctly, improving trust and collaboration.

And most importantly, margins are protected. Cost drift doesn’t sneak up on you. Cash flow forecasts are based on reality, not gut feel. Your AP function becomes a driver of stability, not uncertainty.

The Role of AI in AP Workflow Automation

Artificial intelligence in AP isn’t about replacing people—it’s about empowering them. AI takes on the repetitive, error-prone tasks so humans can focus on higher-value work. It automates invoice capture, accelerates three-way matching, simplifies approval workflows, and provides continuous visibility into costs.

Think of it like moving from a typewriter to a laptop. The work is the same at its core—you’re still managing invoices, POs, and payments—but the efficiency, accuracy, and scalability are on a completely different level.

For manufacturers, where margins are thin and input costs are volatile, the difference isn’t just convenience. It’s survival.

Introducing MakersHub: AI-Powered AP Automation for Manufacturing

All of this sounds great in theory, but how do you put it into practice? That’s where MakersHub comes in.

MakersHub is built specifically for manufacturers who need to manage complex purchase orders, bill-to-PO line-item matching, and approval workflows at scale. Here’s how it helps:

  • WiseVision AI captures and codes every invoice detail automatically, eliminating manual entry and margin blind spots.

  • Smart PO matching reconciles invoices to POs—even across multiple bills or POs—while flagging only true mismatches for review.

  • Automated PO lifecycle management ensures your Open PO report stays accurate and trustworthy.

  • Custom approval workflows let you enforce the right controls without slowing the process down.

  • Two-way Accounting sync keeps data clean and consistent across platforms.

  • Real-time payment visibility gives finance confidence in obligations, accruals, and cash planning.

With MakersHub, you don’t just automate AP—you transform it into a faster, safer, smarter process that aligns with how manufacturing really works.

Ready to see what faster, safer, and smarter AP looks like? Let’s talk.

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