Just an update:
 
We finally have the one thing we wanted most when we first started using DBA (12 years ago?): accurate inventory information at the touch of a button. As of July 1st, we have deployed a cheap wedge-type bar code scanner and wireless laptop solution to use the HH menu and have closed the inventory loop. We now have complete real time inventory tracking for all our work order, purchase order and sales order activity. Nothing move in out out of stock without being recorded. When DBA says there are 2 in the box, there are 2 in the box. We have a around 2500 active items in a 5000 item inventory and around 300 multi-level BoMs to keep track of, so this is a big step up for us. And once we committed to it, it was much easier than we thought.
 
So don't give up. It can be done and it's worth it.