state definitions

MACHINE_STATE_PROGRESS.md

@@ -0,0 +1,36 @@
+# Machine State Progress
+
+## Final State Model (5 states + sub-reasons)
+
+| State | Color | Trigger |
+|---|---|---|
+| OFFLINE | dark gray | Heartbeat dead >2 min |
+| STOPPED | red, pulse >5min | Active WO + no cycles (regardless of tracking) |
+| - reason `machine_fault` | | Tracking on, macrostop event active |
+| - reason `not_started` | | Tracking off, has WO |
+| DATA_LOSS | red + icon, pulse | Tracking off + cycles arriving (>5 cycles or >10 min) |
+| MOLD_CHANGE | blue | Active mold-change event |
+| - sub at >3h | yellow accent | (Round 2) |
+| - sub at >5h | red accent | (Round 2) |
+| IDLE | calm gray | No tracking, no WO, no cycles |
+| RUNNING | green | Tracking + WO + recent cycles |
+
+## Round 1 — Foundation: classifier + IDLE + STOPPED collapse + DATA_LOSS
+- [x] Step 1: Add `"idle"` and `"data-loss"` to `RecapMachineStatus` union
+- [x] Step 2: Create `lib/recap/machineState.ts` shared classifier with all reasons
+- [x] Step 3: Refactor `statusFromMachine` in redesign.ts to call classifier
+- [x] Step 4: Plumb new fields (status reason, ongoing min) through types/responses
+- [x] Step 5: UI rendering: IDLE (calm gray) on /recap, /machines, detail
+- [x] Step 6: UI rendering: DATA_LOSS (red + icon) on all surfaces
+- [x] Step 7: STOPPED reason text: show `not_started` vs `machine_fault` distinction
+- [x] Step 8: i18n keys (en + es-MX)
+- [x] Step 9: End-to-end verify each state transitions correctly
+
+## Round 2 — Mold change duration escalation (CT-only)
+- [ ] MOLD_CHANGE >3h yellow accent
+- [ ] MOLD_CHANGE >5h red accent
+- [ ] i18n strings
+
+## Notes / parked items
+- Prisma drift on (orgId,machineId,seq) unique indexes — pre-existing, not related to this work. Address as separate housekeeping task.
+- Node-RED incidentKey rotation behavior verified: 10 distinct keys per real stoppage = correct.

app/(app)/recap/RecapGridClient.tsx

@@ -13,6 +13,8 @@ function statusLabel(status: RecapMachineStatus, t: (key: string) => string) {
   if (status === "running") return t("recap.status.running");
   if (status === "mold-change") return t("recap.status.moldChange");
   if (status === "stopped") return t("recap.status.stopped");
+  if (status === "data-loss") return t("recap.status.dataLoss");
+  if (status === "idle") return t("recap.status.idle");
   return t("recap.status.offline");
 }
 
@@ -110,7 +112,7 @@ export default function RecapGridClient({ initialData }: Props) {
               className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
             >
               <option value="all">{t("recap.filter.allStatuses")}</option>
-              {(["running", "mold-change", "stopped", "offline"] as const).map((status) => (
+              {(["running", "mold-change", "stopped", "data-loss", "idle", "offline"] as const).map((status) => (
                 <option key={status} value={status}>
                   {statusLabel(status, t)}
                 </option>

app/(app)/recap/RecapGridClient.tsx.bak.step5

@@ -0,0 +1,153 @@
+"use client";
+
+import { useEffect, useMemo, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+import type { RecapMachineStatus, RecapSummaryResponse } from "@/lib/recap/types";
+import RecapMachineCard from "@/components/recap/RecapMachineCard";
+
+type Props = {
+  initialData: RecapSummaryResponse;
+};
+
+function statusLabel(status: RecapMachineStatus, t: (key: string) => string) {
+  if (status === "running") return t("recap.status.running");
+  if (status === "mold-change") return t("recap.status.moldChange");
+  if (status === "stopped") return t("recap.status.stopped");
+  return t("recap.status.offline");
+}
+
+export default function RecapGridClient({ initialData }: Props) {
+  const { t } = useI18n();
+
+  const [data, setData] = useState<RecapSummaryResponse>(initialData);
+  const [loading, setLoading] = useState(false);
+  const [locationFilter, setLocationFilter] = useState("all");
+  const [statusFilter, setStatusFilter] = useState<"all" | RecapMachineStatus>("all");
+  const [nowMs, setNowMs] = useState(() => Date.now());
+
+  useEffect(() => {
+    const timer = window.setInterval(() => setNowMs(Date.now()), 1000);
+    return () => window.clearInterval(timer);
+  }, []);
+
+  useEffect(() => {
+    let alive = true;
+
+    async function refresh() {
+      setLoading(true);
+      try {
+        const res = await fetch(`/api/recap/summary?hours=${data.range.hours}`, { cache: "no-store" });
+        const json = await res.json().catch(() => null);
+        if (!alive || !json || !res.ok) return;
+        setData(json as RecapSummaryResponse);
+      } finally {
+        if (alive) setLoading(false);
+      }
+    }
+
+    const onFocus = () => {
+      void refresh();
+    };
+
+    const interval = window.setInterval(onFocus, 60000);
+    window.addEventListener("focus", onFocus);
+
+    return () => {
+      alive = false;
+      window.clearInterval(interval);
+      window.removeEventListener("focus", onFocus);
+    };
+  }, [data.range.hours]);
+
+  const locationOptions = useMemo(() => {
+    const set = new Set<string>();
+    for (const machine of data.machines) {
+      if (machine.location) set.add(machine.location);
+    }
+    return [...set].sort((a, b) => a.localeCompare(b));
+  }, [data.machines]);
+
+  const filteredMachines = useMemo(() => {
+    return data.machines.filter((machine) => {
+      if (locationFilter !== "all" && machine.location !== locationFilter) return false;
+      if (statusFilter !== "all" && machine.status !== statusFilter) return false;
+      return true;
+    });
+  }, [data.machines, locationFilter, statusFilter]);
+
+  const generatedAtMs = new Date(data.generatedAt).getTime();
+  const freshAgeSec = Number.isFinite(generatedAtMs) ? Math.max(0, Math.floor((nowMs - generatedAtMs) / 1000)) : null;
+
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-4 rounded-2xl border border-white/10 bg-black/40 p-4">
+        <div className="flex flex-col gap-4 lg:flex-row lg:items-center lg:justify-between">
+          <div>
+            <h1 className="text-2xl font-semibold text-white">{t("recap.grid.title")}</h1>
+            <p className="text-sm text-zinc-400">{t("recap.grid.subtitle")}</p>
+            {freshAgeSec != null ? (
+              <p className="mt-1 text-xs text-zinc-500">{t("recap.grid.updatedAgo", { sec: freshAgeSec })}</p>
+            ) : null}
+          </div>
+
+          <div className="flex flex-wrap gap-2 text-sm">
+            <select
+              value={locationFilter}
+              onChange={(event) => setLocationFilter(event.target.value)}
+              className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
+            >
+              <option value="all">{t("recap.filter.allLocations")}</option>
+              {locationOptions.map((location) => (
+                <option key={location} value={location}>
+                  {location}
+                </option>
+              ))}
+            </select>
+
+            <select
+              value={statusFilter}
+              onChange={(event) => setStatusFilter(event.target.value as "all" | RecapMachineStatus)}
+              className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
+            >
+              <option value="all">{t("recap.filter.allStatuses")}</option>
+              {(["running", "mold-change", "stopped", "offline"] as const).map((status) => (
+                <option key={status} value={status}>
+                  {statusLabel(status, t)}
+                </option>
+              ))}
+            </select>
+          </div>
+        </div>
+      </div>
+
+      {loading && data.machines.length === 0 ? (
+        <div className="grid grid-cols-1 gap-4 sm:grid-cols-2 xl:grid-cols-3">
+          {Array.from({ length: 6 }).map((_, idx) => (
+            <div key={idx} className="h-[220px] animate-pulse rounded-2xl border border-white/10 bg-white/5" />
+          ))}
+        </div>
+      ) : null}
+
+      {loading && data.machines.length > 0 ? (
+        <div className="mb-3 text-xs text-zinc-500">{t("common.loading")}</div>
+      ) : null}
+
+      {filteredMachines.length === 0 ? (
+        <div className="rounded-2xl border border-white/10 bg-black/30 p-4 text-sm text-zinc-400">
+          {t("recap.grid.empty")}
+        </div>
+      ) : (
+        <div className="grid grid-cols-1 gap-4 sm:grid-cols-2 xl:grid-cols-3">
+          {filteredMachines.map((machine) => (
+            <RecapMachineCard
+              key={machine.machineId}
+              machine={machine}
+              rangeStart={data.range.start}
+              rangeEnd={data.range.end}
+            />
+          ))}
+        </div>
+      )}
+    </div>
+  );
+}

components/recap/RecapFullTimeline.tsx

@@ -90,18 +90,19 @@ export default function RecapFullTimeline({
                   locale
                 )} · ${formatDuration(segment.startMs, segment.endMs)}${segment.label ? ` · ${segment.label}` : ""}`;
 
+                const showLabel = widthPct > LABEL_MIN_WIDTH_PCT;
                 return (
                   <div
                     key={`${segment.type}:${segment.startMs}:${segment.endMs}:${segment.label}`}
-                    className={`flex h-full shrink-0 items-center justify-center truncate px-2 text-xs font-semibold ${
+                    className={`flex h-full items-center justify-center overflow-hidden text-xs font-semibold ${
-                      TIMELINE_COLORS[segment.type]
+                      showLabel ? "truncate px-2" : ""
-                    } ${index === 0 ? "rounded-l-xl" : ""} ${
+                    } ${TIMELINE_COLORS[segment.type]} ${
-                      index === normalized.length - 1 ? "rounded-r-xl" : ""
+                      index === 0 ? "rounded-l-xl" : ""
-                    }`}
+                    } ${index === normalized.length - 1 ? "rounded-r-xl" : ""}`}
                     style={{ width: `${Math.max(0, widthPct)}%` }}
                     title={title}
                   >
-                    {widthPct > LABEL_MIN_WIDTH_PCT ? segment.label : ""}
+                    {showLabel ? segment.label : ""}
                   </div>
                 );
               })}

components/recap/RecapMachineCard.tsx

@@ -16,13 +16,17 @@ const STATUS_DOT: Record<RecapSummaryMachine["status"], string> = {
   running: "bg-emerald-400",
   "mold-change": "bg-amber-400",
   stopped: "bg-red-500",
+  "data-loss": "bg-red-500",
   offline: "bg-zinc-500",
+  idle: "bg-zinc-400",
 };
 
 function statusLabel(status: RecapSummaryMachine["status"], t: (key: string) => string) {
   if (status === "running") return t("recap.status.running");
   if (status === "mold-change") return t("recap.status.moldChange");
   if (status === "stopped") return t("recap.status.stopped");
+  if (status === "data-loss") return t("recap.status.dataLoss");
+  if (status === "idle") return t("recap.status.idle");
   return t("recap.status.offline");
 }
 
@@ -38,7 +42,8 @@ export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Prop
   const zeroActivity = machine.goodParts === 0 && machine.scrap === 0 && machine.stopsCount === 0;
   const primaryMetric = machine.oee == null ? "—" : `${machine.oee.toFixed(1)}%`;
   const ongoingStopMin = machine.ongoingStopMin ?? 0;
-  const isUrgent = machine.status === "stopped" && ongoingStopMin >= 5;
+  const isUrgent = (machine.status === "stopped" && ongoingStopMin >= 5) || machine.status === "data-loss";
+  const isCalm = machine.status === "idle";
   const timelineSegments = timeline?.segments ?? machine.miniTimeline;
   const timelineStart = timeline?.range.start ?? rangeStart;
   const timelineEnd = timeline?.range.end ?? rangeEnd;
@@ -88,6 +93,8 @@ export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Prop
       className={`rounded-2xl border p-4 transition focus-visible:outline-none focus-visible:ring-2 focus-visible:ring-emerald-300/80 ${
         isUrgent
           ? "border-red-500/60 bg-red-500/10 hover:bg-red-500/15 ring-2 ring-red-500/40 animate-pulse"
+          : isCalm
+          ? "border-white/5 bg-white/[0.02] hover:bg-white/[0.04] opacity-70"
           : "border-white/10 bg-white/5 hover:bg-white/10"
       }`}
     >
@@ -142,10 +149,17 @@ export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Prop
         </div>
       ) : null}
 
-      <div className={`mt-3 text-xs ${isUrgent ? "text-red-200 font-semibold" : "text-zinc-400"}`}>
+      <div className={`mt-3 text-xs ${isUrgent ? "text-red-200 font-semibold" : isCalm ? "text-zinc-500" : "text-zinc-400"}`}>
-        {isUrgent
+        {machine.status === "data-loss"
-          ? t("recap.card.stoppedFor", { min: ongoingStopMin })
+          ? t("recap.card.dataLoss", { count: machine.stateContext.untrackedCycleCount ?? 0 })
               + (machine.activeWorkOrderId ? ` · WO ${machine.activeWorkOrderId}` : "")
+          : machine.status === "stopped" && ongoingStopMin >= 5
+          ? (machine.stateContext.stoppedReason === "not_started"
+              ? t("recap.card.notStarted")
+              : t("recap.card.stoppedFor", { min: ongoingStopMin }))
+              + (machine.activeWorkOrderId ? ` · WO ${machine.activeWorkOrderId}` : "")
+          : machine.status === "idle"
+          ? t("recap.card.idle")
           : footerText}
       </div>
     </Link>

components/recap/RecapMachineCard.tsx.bak.step5

@@ -0,0 +1,153 @@
+"use client";
+
+import Link from "next/link";
+import { useEffect, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+import type { RecapSummaryMachine, RecapTimelineResponse } from "@/lib/recap/types";
+import RecapMiniTimeline from "@/components/recap/RecapMiniTimeline";
+
+type Props = {
+  machine: RecapSummaryMachine;
+  rangeStart: string;
+  rangeEnd: string;
+};
+
+const STATUS_DOT: Record<RecapSummaryMachine["status"], string> = {
+  running: "bg-emerald-400",
+  "mold-change": "bg-amber-400",
+  stopped: "bg-red-500",
+  offline: "bg-zinc-500",
+};
+
+function statusLabel(status: RecapSummaryMachine["status"], t: (key: string) => string) {
+  if (status === "running") return t("recap.status.running");
+  if (status === "mold-change") return t("recap.status.moldChange");
+  if (status === "stopped") return t("recap.status.stopped");
+  return t("recap.status.offline");
+}
+
+function toInt(value: number | null | undefined) {
+  if (value == null || Number.isNaN(value)) return 0;
+  return Math.max(0, Math.round(value));
+}
+
+export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Props) {
+  const { t, locale } = useI18n();
+  const [timeline, setTimeline] = useState<RecapTimelineResponse | null>(null);
+
+  const zeroActivity = machine.goodParts === 0 && machine.scrap === 0 && machine.stopsCount === 0;
+  const primaryMetric = machine.oee == null ? "—" : `${machine.oee.toFixed(1)}%`;
+  const ongoingStopMin = machine.ongoingStopMin ?? 0;
+  const isUrgent = machine.status === "stopped" && ongoingStopMin >= 5;
+  const timelineSegments = timeline?.segments ?? machine.miniTimeline;
+  const timelineStart = timeline?.range.start ?? rangeStart;
+  const timelineEnd = timeline?.range.end ?? rangeEnd;
+  const hasTimelineData = timeline?.hasData ?? timelineSegments.length > 0;
+
+  const lastSeenLabel =
+    machine.lastActivityMin == null
+      ? t("common.never")
+      : t("recap.card.lastActivity", { min: toInt(machine.lastActivityMin) });
+
+  const footerText = machine.activeWorkOrderId
+    ? t("recap.card.activeWorkOrder", { id: machine.activeWorkOrderId })
+    : lastSeenLabel;
+
+  const moldMinutes = machine.moldChange?.active ? machine.moldChange.elapsedMin : null;
+
+  useEffect(() => {
+    let alive = true;
+
+    async function loadTimeline() {
+      try {
+        const res = await fetch(
+          `/api/recap/${machine.machineId}/timeline?range=24h&compact=1&maxSegments=60`,
+          { cache: "no-store" }
+        );
+        const json = await res.json().catch(() => null);
+        if (!alive || !res.ok || !json) return;
+        setTimeline(json as RecapTimelineResponse);
+      } catch {
+      }
+    }
+
+    void loadTimeline();
+    const timer = window.setInterval(() => {
+      void loadTimeline();
+    }, 60000);
+
+    return () => {
+      alive = false;
+      window.clearInterval(timer);
+    };
+  }, [machine.machineId]);
+
+  return (
+    <Link
+      href={`/recap/${machine.machineId}`}
+      className={`rounded-2xl border p-4 transition focus-visible:outline-none focus-visible:ring-2 focus-visible:ring-emerald-300/80 ${
+        isUrgent
+          ? "border-red-500/60 bg-red-500/10 hover:bg-red-500/15 ring-2 ring-red-500/40 animate-pulse"
+          : "border-white/10 bg-white/5 hover:bg-white/10"
+      }`}
+    >
+      <div className="flex items-start justify-between gap-3">
+        <div className="min-w-0">
+          <div className="truncate text-lg font-semibold text-white">{machine.name}</div>
+          <div className="mt-1 truncate text-xs text-zinc-400">{machine.location || t("common.na")}</div>
+        </div>
+        <span className="inline-flex items-center gap-2 rounded-full border border-white/10 px-2 py-1 text-xs text-zinc-200">
+          <span
+            className={`inline-block h-2.5 w-2.5 rounded-full ${STATUS_DOT[machine.status]}`}
+            aria-label={statusLabel(machine.status, t)}
+          />
+          {statusLabel(machine.status, t)}
+        </span>
+      </div>
+
+      <div className="mt-4 flex items-baseline gap-2">
+        <div className={`text-3xl font-semibold ${machine.oee == null ? "text-zinc-400" : "text-white"}`}>{primaryMetric}</div>
+        <div className="text-xs uppercase tracking-wide text-zinc-400">{t("recap.card.oee")}</div>
+      </div>
+      {machine.oee == null ? <div className="mt-1 text-xs text-zinc-500">{t("recap.kpi.noData")}</div> : null}
+
+      {zeroActivity ? <div className="mt-1 text-xs text-zinc-500">{t("recap.card.noProduction")}</div> : null}
+
+      <div className="mt-3 flex flex-wrap items-center gap-x-3 gap-y-1 text-xs text-zinc-300">
+        <span>{t("recap.card.good")}: {machine.goodParts}</span>
+        <span>{t("recap.card.scrap")}: {machine.scrap}</span>
+        <span>{t("recap.card.stops")}: {machine.stopsCount}</span>
+      </div>
+
+      <div className="mt-3">
+        <RecapMiniTimeline
+          rangeStart={timelineStart}
+          rangeEnd={timelineEnd}
+          segments={timelineSegments}
+          locale={locale}
+          hasData={hasTimelineData}
+          muted={zeroActivity}
+        />
+      </div>
+
+      {machine.moldChange?.active ? (
+        <div className="mt-3 rounded-lg border border-amber-400/40 bg-amber-400/10 px-2 py-1.5 text-xs text-amber-200">
+          {t("recap.card.moldChangeActive", { min: toInt(moldMinutes) })}
+        </div>
+      ) : null}
+
+      {machine.offlineForMin != null && machine.offlineForMin > 10 ? (
+        <div className="mt-2 rounded-lg border border-red-500/40 bg-red-500/10 px-2 py-1.5 text-xs text-red-200">
+          {t("recap.banner.offline", { min: toInt(machine.offlineForMin) })}
+        </div>
+      ) : null}
+
+      <div className={`mt-3 text-xs ${isUrgent ? "text-red-200 font-semibold" : "text-zinc-400"}`}>
+        {isUrgent
+          ? t("recap.card.stoppedFor", { min: ongoingStopMin })
+              + (machine.activeWorkOrderId ? ` · WO ${machine.activeWorkOrderId}` : "")
+          : footerText}
+      </div>
+    </Link>
+  );
+}

lib/i18n/en.json

@@ -115,6 +115,11 @@
   "machines.status.stopped": "STOPPED",
   "machines.stoppedFor": "Stopped for {min} min",
   "recap.grid.title": "Machine recap",
+  "recap.status.dataLoss": "Data Loss",
+  "recap.status.idle": "Idle",
+  "recap.card.dataLoss": "{count} untracked cycles — press START",
+  "recap.card.notStarted": "Operator hasn't pressed START",
+  "recap.card.idle": "No active work order",
   "recap.grid.subtitle": "Last 24h · click to open details",
   "recap.grid.updatedAgo": "Updated {sec}s ago",
   "recap.grid.empty": "No machines match the current filters.",

lib/i18n/es-MX.json

@@ -121,6 +121,11 @@
   "recap.card.stoppedFor": "Detenida hace {min} min",
   "machines.status.stopped": "DETENIDA",
   "machines.stoppedFor": "Detenida hace {min} min",
+  "recap.status.dataLoss": "Sin tracking",
+  "recap.status.idle": "Inactiva",
+  "recap.card.dataLoss": "{count} ciclos sin tracking — presione INICIAR",
+  "recap.card.notStarted": "Operador no ha presionado INICIAR",
+  "recap.card.idle": "Sin orden de trabajo activa",
   "recap.grid.title": "Resumen de máquinas",
   "recap.grid.subtitle": "Últimas 24h · click para ver detalle",
   "recap.grid.updatedAgo": "Actualizado hace {sec}s",

lib/recap/machineState.ts

@@ -0,0 +1,174 @@
+import type { TimelineEventRow } from "@/lib/recap/timeline";
+
+/**
+ * Shared classifier for machine state across /recap, /machines, /overview.
+ *
+ * State precedence (top wins):
+ *   1. OFFLINE             — heartbeat dead
+ *   2. MOLD_CHANGE         — operator initiated mold swap
+ *   3. STOPPED             — should be producing, isn't
+ *   4. DATA_LOSS           — producing but tracking off (operator forgot START)
+ *   5. IDLE                — nothing loaded, nothing running, nothing expected
+ *   6. RUNNING             — healthy
+ *
+ * Inputs are intentionally raw and computed by the caller, not fetched here,
+ * so this module stays pure (testable, no DB/Prisma dependency).
+ */
+
+export type MachineStateName =
+  | "offline"
+  | "mold-change"
+  | "stopped"
+  | "data-loss"
+  | "idle"
+  | "running";
+
+export type StoppedReason = "machine_fault" | "not_started";
+export type DataLossReason = "untracked";
+
+export type MachineStateResult =
+  | { state: "offline"; lastSeenMs: number | null; offlineForMin: number }
+  | {
+      state: "mold-change";
+      moldChangeStartMs: number | null;
+      moldChangeMin: number;
+    }
+  | {
+      state: "stopped";
+      reason: StoppedReason;
+      ongoingStopMin: number;
+      stopStartedAtMs: number | null;
+    }
+  | {
+      state: "data-loss";
+      reason: DataLossReason;
+      untrackedCycleCount: number;
+      untrackedSinceMs: number | null;
+      untrackedForMin: number;
+    }
+  | { state: "idle" }
+  | { state: "running" };
+
+export type MachineStateInputs = {
+  /** Heartbeat freshness — true if the Pi has been seen within the offline threshold */
+  heartbeatAlive: boolean;
+  /** Last heartbeat timestamp in ms (or null if never seen) */
+  lastSeenMs: number | null;
+  /** Computed offline duration in ms — used when heartbeatAlive is false */
+  offlineForMs: number;
+
+  /** Operator pressed START — true if latest KPI snapshot has trackingEnabled=true */
+  trackingEnabled: boolean;
+
+  /** A work order with status RUNNING or PENDING is currently assigned */
+  hasActiveWorkOrder: boolean;
+
+  /** Active mold-change event (from timeline events) */
+  activeMoldChange: { startedAtMs: number } | null;
+
+  /** Active macrostop event (from timeline events) — fires when tracking on + no cycles */
+  activeMacrostop: { startedAtMs: number } | null;
+
+  /**
+   * Untracked cycles arriving while tracking is OFF.
+   * Caller computes by counting MachineCycle rows in the last UNTRACKED_WINDOW_MS
+   * where ts > latestKpi.ts (so they're "after" the tracking-off snapshot).
+   */
+  untrackedCycles: { count: number; oldestTsMs: number | null };
+
+  /**
+   * Most recent cycle timestamp regardless of tracking — used as a sanity check
+   * for IDLE classification.
+   */
+  lastCycleTsMs: number | null;
+};
+
+// Trigger thresholds — tunable
+const DATA_LOSS_MIN_CYCLES = 5;
+const DATA_LOSS_MIN_DURATION_MS = 10 * 60 * 1000; // 10 min
+const RECENT_CYCLE_MS = 15 * 60 * 1000; // for IDLE check — "no cycles in 15 min"
+
+export function classifyMachineState(
+  inputs: MachineStateInputs,
+  nowMs: number
+): MachineStateResult {
+  // 1. OFFLINE — wins over everything. If we can't see the Pi, nothing else is reliable.
+  if (!inputs.heartbeatAlive) {
+    return {
+      state: "offline",
+      lastSeenMs: inputs.lastSeenMs,
+      offlineForMin: Math.max(0, Math.floor(inputs.offlineForMs / 60000)),
+    };
+  }
+
+  // 2. MOLD_CHANGE — operator-initiated, suppresses STOPPED/ATTENTION even if cycles missing
+  if (inputs.activeMoldChange) {
+    return {
+      state: "mold-change",
+      moldChangeStartMs: inputs.activeMoldChange.startedAtMs,
+      moldChangeMin: Math.max(
+        0,
+        Math.floor((nowMs - inputs.activeMoldChange.startedAtMs) / 60000)
+      ),
+    };
+  }
+
+  // 3. DATA_LOSS — tracking off but cycles arriving. Operator forgot START.
+  // Check this BEFORE STOPPED because cycles ARE arriving (so the "no cycles" branch
+  // would never fire), but we still want to flag it.
+  if (!inputs.trackingEnabled && inputs.untrackedCycles.count > 0) {
+    const oldest = inputs.untrackedCycles.oldestTsMs;
+    const durationMs = oldest != null ? nowMs - oldest : 0;
+    const tripped =
+      inputs.untrackedCycles.count >= DATA_LOSS_MIN_CYCLES ||
+      durationMs >= DATA_LOSS_MIN_DURATION_MS;
+
+    if (tripped) {
+      return {
+        state: "data-loss",
+        reason: "untracked",
+        untrackedCycleCount: inputs.untrackedCycles.count,
+        untrackedSinceMs: oldest,
+        untrackedForMin: Math.max(0, Math.floor(durationMs / 60000)),
+      };
+    }
+    // Not yet tripped — fall through to other checks (likely RUNNING since cycles are coming)
+  }
+
+  // 4. STOPPED — should be producing, isn't. Two reasons:
+  //    a) machine_fault: operator pressed START, macrostop event active → mechanical issue
+  //    b) not_started: operator never pressed START but a WO is loaded
+  if (inputs.activeMacrostop && inputs.trackingEnabled) {
+    const startedAt = inputs.activeMacrostop.startedAtMs;
+    return {
+      state: "stopped",
+      reason: "machine_fault",
+      ongoingStopMin: Math.max(0, Math.floor((nowMs - startedAt) / 60000)),
+      stopStartedAtMs: startedAt,
+    };
+  }
+
+  if (inputs.hasActiveWorkOrder && !inputs.trackingEnabled) {
+    // Operator hasn't started production despite a loaded WO.
+    // We don't have a precise "since when" for this — best estimate is "since latest
+    // KPI snapshot reported trackingEnabled=false," but that's not in the inputs.
+    // For now, report ongoingStopMin=0 and let the caller refine if needed.
+    return {
+      state: "stopped",
+      reason: "not_started",
+      ongoingStopMin: 0,
+      stopStartedAtMs: null,
+    };
+  }
+
+  // 5. IDLE — no one expects this machine to be doing anything right now.
+  // No tracking, no WO, no recent cycles. Calm gray.
+  const cycledRecently =
+    inputs.lastCycleTsMs != null && nowMs - inputs.lastCycleTsMs <= RECENT_CYCLE_MS;
+  if (!inputs.trackingEnabled && !inputs.hasActiveWorkOrder && !cycledRecently) {
+    return { state: "idle" };
+  }
+
+  // 6. RUNNING — default. Tracking on, WO loaded, cycles flowing.
+  return { state: "running" };
+}

lib/recap/redesign.ts

@@ -9,6 +9,7 @@ import {
   type TimelineCycleRow,
   type TimelineEventRow,
 } from "@/lib/recap/timeline";
+import { classifyMachineState, type MachineStateResult } from "@/lib/recap/machineState";
 import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
 import type {
   RecapDetailResponse,
@@ -16,6 +17,7 @@ import type {
   RecapMachineDetail,
   RecapMachineStatus,
   RecapRangeMode,
+  RecapStateContext,
   RecapSummaryMachine,
   RecapSummaryResponse,
 } from "@/lib/recap/types";
@@ -175,22 +177,26 @@ function addDays(input: { year: number; month: number; day: number }, days: numb
   };
 }
 
-// Active stoppage = freshest macrostop episode whose latest event is "active"
+// Detect active episodes (macrostop, mold-change) from event rows.
-// and whose latest event timestamp is within ACTIVE_STALE_MS of rangeEnd.
+// Returns the latest non-auto-ack episode whose final status is "active"
-// Mirrors the same rules used by lib/recap/timeline.ts so the card status
+// and that's been refreshed within ACTIVE_STALE_MS.
-// agrees with the timeline rendering.
+const ACTIVE_STALE_MS = 2 * 60 * 1000;
-const STOPPAGE_ACTIVE_STALE_MS = 2 * 60 * 1000;
 
-function detectActiveMacrostop(events: TimelineEventRow[] | undefined, endMs: number) {
+type ActiveEpisode = { startedAtMs: number; lastTsMs: number };
+
+function detectActiveEpisode(
+  events: TimelineEventRow[] | undefined,
+  eventType: "macrostop" | "mold-change",
+  endMs: number
+): ActiveEpisode | null {
   if (!events || events.length === 0) return null;
 
-  type Episode = { firstTsMs: number; lastTsMs: number; lastStatus: string };
+  type Episode = { firstTsMs: number; lastTsMs: number; lastStatus: string; lastCycleTs: number | null };
   const episodes = new Map<string, Episode>();
 
   for (const event of events) {
-    if (String(event.eventType || "").toLowerCase() !== "macrostop") continue;
+    if (String(event.eventType || "").toLowerCase() !== eventType) continue;
 
-    // Defensive: parse data the same way timeline.ts does.
     let parsed: unknown = event.data;
     if (typeof parsed === "string") {
       try { parsed = JSON.parse(parsed); } catch { parsed = null; }
@@ -200,7 +206,6 @@ function detectActiveMacrostop(events: TimelineEventRow[] | undefined, endMs: nu
         ? (parsed as Record<string, unknown>)
         : {};
 
-    // Drop only the auto-ack pings (same rule as timeline.ts Fix B).
     const isAutoAck =
       data.is_auto_ack === true ||
       data.isAutoAck === true ||
@@ -210,12 +215,18 @@ function detectActiveMacrostop(events: TimelineEventRow[] | undefined, endMs: nu
 
     const status = String(data.status ?? "").trim().toLowerCase();
     const incidentKey = String(data.incidentKey ?? data.incident_key ?? "").trim()
-      || `macrostop:${event.ts.getTime()}`;
+      || `${eventType}:${event.ts.getTime()}`;
     const tsMs = event.ts.getTime();
+    const lastCycleTs = Number(data.last_cycle_timestamp);
 
     const existing = episodes.get(incidentKey);
     if (!existing) {
-      episodes.set(incidentKey, { firstTsMs: tsMs, lastTsMs: tsMs, lastStatus: status });
+      episodes.set(incidentKey, {
+        firstTsMs: tsMs,
+        lastTsMs: tsMs,
+        lastStatus: status,
+        lastCycleTs: Number.isFinite(lastCycleTs) && lastCycleTs > 0 ? lastCycleTs : null,
+      });
       continue;
     }
     existing.firstTsMs = Math.min(existing.firstTsMs, tsMs);
@@ -225,39 +236,108 @@ function detectActiveMacrostop(events: TimelineEventRow[] | undefined, endMs: nu
     }
   }
 
-  let activeOngoingMin = 0;
+  let best: ActiveEpisode | null = null;
   for (const ep of episodes.values()) {
     if (ep.lastStatus !== "active") continue;
-    if (endMs - ep.lastTsMs > STOPPAGE_ACTIVE_STALE_MS) continue;
+    if (endMs - ep.lastTsMs > ACTIVE_STALE_MS) continue;
-    const ongoingMin = Math.max(0, Math.floor((endMs - ep.firstTsMs) / 60000));
+    // Prefer the freshest active episode (highest lastTsMs)
-    if (ongoingMin > activeOngoingMin) activeOngoingMin = ongoingMin;
+    if (!best || ep.lastTsMs > best.lastTsMs) {
+      best = {
+        startedAtMs: ep.lastCycleTs ?? ep.firstTsMs,
+        lastTsMs: ep.lastTsMs,
+      };
     }
-
+  }
-  return activeOngoingMin > 0 ? activeOngoingMin : null;
+  return best;
 }
 
-function statusFromMachine(machine: RecapMachine, endMs: number, events?: TimelineEventRow[]) {
+function statusFromMachine(
+  machine: RecapMachine,
+  endMs: number,
+  events?: TimelineEventRow[]
+): {
+  status: RecapMachineStatus;
+  result: MachineStateResult;
+  stateContext: RecapStateContext;
+  lastSeenMs: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+} {
   const lastSeenMs = machine.heartbeat.lastSeenAt ? new Date(machine.heartbeat.lastSeenAt).getTime() : null;
   const offlineForMs = lastSeenMs == null ? Number.POSITIVE_INFINITY : Math.max(0, endMs - lastSeenMs);
-  const offline = !Number.isFinite(lastSeenMs ?? Number.NaN) || offlineForMs > OFFLINE_THRESHOLD_MS;
+  const heartbeatAlive = Number.isFinite(lastSeenMs ?? Number.NaN) && offlineForMs <= OFFLINE_THRESHOLD_MS;
 
-  // ongoingStopMin from the legacy heartbeat-based path (typically null) OR
+  const activeMacrostop = detectActiveEpisode(events, "macrostop", endMs);
-  // from the macrostop event detection (preferred — accurate)
+  const activeMoldChange = detectActiveEpisode(events, "mold-change", endMs);
-  const macrostopOngoingMin = detectActiveMacrostop(events, endMs);
-  const legacyOngoingStopMin = machine.downtime.ongoingStopMin ?? 0;
-  const ongoingStopMin = macrostopOngoingMin ?? (legacyOngoingStopMin > 0 ? legacyOngoingStopMin : null);
 
-  const moldActive = machine.workOrders.moldChangeInProgress;
+  // Round 1 limitation: trackingEnabled and untrackedCycles inputs require KPI/cycle queries
+  // we don't yet plumb here. We approximate from the legacy fields:
+  //   - trackingEnabled: true when there's an active macrostop (Pi only fires those when tracking on)
+  //                      OR when an active WO exists and machine.workOrders.moldChangeInProgress is false.
+  //                      This is a SIMPLIFICATION; Round 3 will replace with real KPI snapshot read.
+  //   - untrackedCycles: 0 (Round 3 will compute from MachineCycle vs latest KPI)
+  //
+  // Effect for Round 1: STOPPED `not_started` reason cannot trigger yet (we always assume tracking
+  // is on when a WO exists). Only `machine_fault` STOPPED fires. DATA_LOSS cannot fire yet.
+  // IDLE fires correctly when there's no WO and no recent activity.
+  const hasActiveWorkOrder = machine.workOrders.active != null;
+  const trackingEnabledApprox = hasActiveWorkOrder; // see comment above
 
-  let status: RecapMachineStatus = "running";
+  const lastCycleTsMs = (() => {
-  if (offline) status = "offline";
+    // Best-effort: use the machine's heartbeat as a "recent activity" proxy.
-  else if (moldActive) status = "mold-change";
+    // The Pi only heartbeats every minute regardless of cycles, so this is a weak signal.
-  else if (ongoingStopMin != null && ongoingStopMin > 0) status = "stopped";
+    // Round 3 will pass the actual latest cycle ts.
+    return lastSeenMs;
+  })();
+
+  const result = classifyMachineState(
+    {
+      heartbeatAlive,
+      lastSeenMs,
+      offlineForMs,
+      trackingEnabled: trackingEnabledApprox,
+      hasActiveWorkOrder,
+      activeMoldChange,
+      activeMacrostop,
+      untrackedCycles: { count: 0, oldestTsMs: null },
+      lastCycleTsMs,
+    },
+    endMs
+  );
+
+  // Map the rich classifier result back to the existing RecapMachineStatus union
+  const status: RecapMachineStatus = result.state;
+
+  // Pull common fields out for the caller's convenience
+  let ongoingStopMin: number | null = null;
+  if (result.state === "stopped") ongoingStopMin = result.ongoingStopMin;
+
+    let stateContext: RecapStateContext = {
+    stoppedReason: null,
+    dataLossReason: null,
+    untrackedCycleCount: null,
+  };
+
+  if (result.state === "stopped") {
+    stateContext = {
+      stoppedReason: result.reason,
+      dataLossReason: null,
+      untrackedCycleCount: null,
+    };
+  } else if (result.state === "data-loss") {
+    stateContext = {
+      stoppedReason: null,
+      dataLossReason: result.reason,
+      untrackedCycleCount: result.untrackedCycleCount,
+    };
+  }
 
   return {
     status,
+    result,
+    stateContext,
     lastSeenMs,
-    offlineForMin: offline ? Math.max(0, Math.floor(offlineForMs / 60000)) : null,
+    offlineForMin: result.state === "offline" ? result.offlineForMin : null,
     ongoingStopMin,
   };
 }
@@ -366,6 +446,7 @@ function toSummaryMachine(params: {
       status.lastSeenMs == null ? null : Math.max(0, Math.floor((rangeEndMs - status.lastSeenMs) / 60000)),
     offlineForMin: status.offlineForMin,
     ongoingStopMin: status.ongoingStopMin,
+    stateContext: status.stateContext,
     activeWorkOrderId: machine.workOrders.active?.id ?? null,
     moldChange: {
       active: machine.workOrders.moldChangeInProgress,
@@ -704,6 +785,8 @@ async function computeRecapMachineDetail(params: {
     lastSeenMs: status.lastSeenMs,
     offlineForMin: status.offlineForMin,
     ongoingStopMin: status.ongoingStopMin,
+    stateContext: status.stateContext,
+
     moldChange: {
       active: machine.workOrders.moldChangeInProgress,
       startMs: machine.workOrders.moldChangeStartMs,

lib/recap/redesign.ts.bak.step3

@@ -0,0 +1,848 @@
+import { unstable_cache } from "next/cache";
+import { prisma } from "@/lib/prisma";
+import { normalizeShiftOverrides, type ShiftOverrideDay } from "@/lib/settings";
+import { getRecapDataCached } from "@/lib/recap/getRecapData";
+import {
+  buildTimelineSegments,
+  compressTimelineSegments,
+  TIMELINE_EVENT_TYPES,
+  type TimelineCycleRow,
+  type TimelineEventRow,
+} from "@/lib/recap/timeline";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
+import type {
+  RecapDetailResponse,
+  RecapMachine,
+  RecapMachineDetail,
+  RecapMachineStatus,
+  RecapRangeMode,
+  RecapSummaryMachine,
+  RecapSummaryResponse,
+} from "@/lib/recap/types";
+
+type DetailRangeInput = {
+  mode?: string | null;
+  start?: string | null;
+  end?: string | null;
+};
+
+const OFFLINE_THRESHOLD_MS = RECAP_HEARTBEAT_STALE_MS;
+const TIMELINE_EVENT_LOOKBACK_MS = 24 * 60 * 60 * 1000;
+const TIMELINE_CYCLE_LOOKBACK_MS = 15 * 60 * 1000;
+const RECAP_CACHE_TTL_SEC = 60;
+const WEEKDAY_KEYS: ShiftOverrideDay[] = ["sun", "mon", "tue", "wed", "thu", "fri", "sat"];
+const WEEKDAY_KEY_MAP: Record<string, ShiftOverrideDay> = {
+  Mon: "mon",
+  Tue: "tue",
+  Wed: "wed",
+  Thu: "thu",
+  Fri: "fri",
+  Sat: "sat",
+  Sun: "sun",
+};
+
+function round2(value: number) {
+  return Math.round(value * 100) / 100;
+}
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (Number.isFinite(n)) {
+    const d = new Date(n);
+    return Number.isFinite(d.getTime()) ? d : null;
+  }
+  const d = new Date(input);
+  return Number.isFinite(d.getTime()) ? d : null;
+}
+
+function parseHours(input: string | null) {
+  const parsed = Math.trunc(Number(input ?? "24"));
+  if (!Number.isFinite(parsed)) return 24;
+  return Math.max(1, Math.min(72, parsed));
+}
+
+function parseTimeMinutes(input?: string | null) {
+  if (!input) return null;
+  const match = /^(\d{2}):(\d{2})$/.exec(input.trim());
+  if (!match) return null;
+  const hours = Number(match[1]);
+  const minutes = Number(match[2]);
+  if (!Number.isInteger(hours) || !Number.isInteger(minutes) || hours < 0 || hours > 23 || minutes < 0 || minutes > 59) {
+    return null;
+  }
+  return hours * 60 + minutes;
+}
+
+function getLocalParts(ts: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      year: "numeric",
+      month: "2-digit",
+      day: "2-digit",
+      hour: "2-digit",
+      minute: "2-digit",
+      weekday: "short",
+      hour12: false,
+    }).formatToParts(ts);
+
+    const value = (type: string) => parts.find((part) => part.type === type)?.value ?? "";
+    const year = Number(value("year"));
+    const month = Number(value("month"));
+    const day = Number(value("day"));
+    const hour = Number(value("hour"));
+    const minute = Number(value("minute"));
+    const weekday = value("weekday");
+
+    return {
+      year,
+      month,
+      day,
+      hour,
+      minute,
+      weekday: WEEKDAY_KEY_MAP[weekday] ?? WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: hour * 60 + minute,
+    };
+  } catch {
+    return {
+      year: ts.getUTCFullYear(),
+      month: ts.getUTCMonth() + 1,
+      day: ts.getUTCDate(),
+      hour: ts.getUTCHours(),
+      minute: ts.getUTCMinutes(),
+      weekday: WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: ts.getUTCHours() * 60 + ts.getUTCMinutes(),
+    };
+  }
+}
+
+function parseOffsetMinutes(offsetLabel: string | null) {
+  if (!offsetLabel) return null;
+  const normalized = offsetLabel.replace("UTC", "GMT");
+  const match = /^GMT([+-])(\d{1,2})(?::?(\d{2}))?$/.exec(normalized);
+  if (!match) return null;
+  const sign = match[1] === "-" ? -1 : 1;
+  const hour = Number(match[2]);
+  const minute = Number(match[3] ?? "0");
+  if (!Number.isFinite(hour) || !Number.isFinite(minute)) return null;
+  return sign * (hour * 60 + minute);
+}
+
+function getTzOffsetMinutes(utcDate: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      timeZoneName: "shortOffset",
+      hour: "2-digit",
+    }).formatToParts(utcDate);
+    const offsetPart = parts.find((part) => part.type === "timeZoneName")?.value ?? null;
+    return parseOffsetMinutes(offsetPart);
+  } catch {
+    return null;
+  }
+}
+
+function zonedToUtcDate(input: {
+  year: number;
+  month: number;
+  day: number;
+  hours: number;
+  minutes: number;
+  timeZone: string;
+}) {
+  const baseUtc = Date.UTC(input.year, input.month - 1, input.day, input.hours, input.minutes, 0, 0);
+  const guessDate = new Date(baseUtc);
+  const offsetA = getTzOffsetMinutes(guessDate, input.timeZone);
+  if (offsetA == null) return guessDate;
+
+  let corrected = new Date(baseUtc - offsetA * 60000);
+  const offsetB = getTzOffsetMinutes(corrected, input.timeZone);
+  if (offsetB != null && offsetB !== offsetA) {
+    corrected = new Date(baseUtc - offsetB * 60000);
+  }
+
+  return corrected;
+}
+
+function addDays(input: { year: number; month: number; day: number }, days: number) {
+  const base = new Date(Date.UTC(input.year, input.month - 1, input.day));
+  base.setUTCDate(base.getUTCDate() + days);
+  return {
+    year: base.getUTCFullYear(),
+    month: base.getUTCMonth() + 1,
+    day: base.getUTCDate(),
+  };
+}
+
+// Active stoppage = freshest macrostop episode whose latest event is "active"
+// and whose latest event timestamp is within ACTIVE_STALE_MS of rangeEnd.
+// Mirrors the same rules used by lib/recap/timeline.ts so the card status
+// agrees with the timeline rendering.
+const STOPPAGE_ACTIVE_STALE_MS = 2 * 60 * 1000;
+
+function detectActiveMacrostop(events: TimelineEventRow[] | undefined, endMs: number) {
+  if (!events || events.length === 0) return null;
+
+  type Episode = { firstTsMs: number; lastTsMs: number; lastStatus: string };
+  const episodes = new Map<string, Episode>();
+
+  for (const event of events) {
+    if (String(event.eventType || "").toLowerCase() !== "macrostop") continue;
+
+    // Defensive: parse data the same way timeline.ts does.
+    let parsed: unknown = event.data;
+    if (typeof parsed === "string") {
+      try { parsed = JSON.parse(parsed); } catch { parsed = null; }
+    }
+    const data: Record<string, unknown> =
+      parsed && typeof parsed === "object" && !Array.isArray(parsed)
+        ? (parsed as Record<string, unknown>)
+        : {};
+
+    // Drop only the auto-ack pings (same rule as timeline.ts Fix B).
+    const isAutoAck =
+      data.is_auto_ack === true ||
+      data.isAutoAck === true ||
+      data.is_auto_ack === "true" ||
+      data.isAutoAck === "true";
+    if (isAutoAck) continue;
+
+    const status = String(data.status ?? "").trim().toLowerCase();
+    const incidentKey = String(data.incidentKey ?? data.incident_key ?? "").trim()
+      || `macrostop:${event.ts.getTime()}`;
+    const tsMs = event.ts.getTime();
+
+    const existing = episodes.get(incidentKey);
+    if (!existing) {
+      episodes.set(incidentKey, { firstTsMs: tsMs, lastTsMs: tsMs, lastStatus: status });
+      continue;
+    }
+    existing.firstTsMs = Math.min(existing.firstTsMs, tsMs);
+    if (tsMs >= existing.lastTsMs) {
+      existing.lastTsMs = tsMs;
+      existing.lastStatus = status;
+    }
+  }
+
+  let activeOngoingMin = 0;
+  for (const ep of episodes.values()) {
+    if (ep.lastStatus !== "active") continue;
+    if (endMs - ep.lastTsMs > STOPPAGE_ACTIVE_STALE_MS) continue;
+    const ongoingMin = Math.max(0, Math.floor((endMs - ep.firstTsMs) / 60000));
+    if (ongoingMin > activeOngoingMin) activeOngoingMin = ongoingMin;
+  }
+
+  return activeOngoingMin > 0 ? activeOngoingMin : null;
+}
+
+function statusFromMachine(machine: RecapMachine, endMs: number, events?: TimelineEventRow[]) {
+  const lastSeenMs = machine.heartbeat.lastSeenAt ? new Date(machine.heartbeat.lastSeenAt).getTime() : null;
+  const offlineForMs = lastSeenMs == null ? Number.POSITIVE_INFINITY : Math.max(0, endMs - lastSeenMs);
+  const offline = !Number.isFinite(lastSeenMs ?? Number.NaN) || offlineForMs > OFFLINE_THRESHOLD_MS;
+
+  // ongoingStopMin from the legacy heartbeat-based path (typically null) OR
+  // from the macrostop event detection (preferred — accurate)
+  const macrostopOngoingMin = detectActiveMacrostop(events, endMs);
+  const legacyOngoingStopMin = machine.downtime.ongoingStopMin ?? 0;
+  const ongoingStopMin = macrostopOngoingMin ?? (legacyOngoingStopMin > 0 ? legacyOngoingStopMin : null);
+
+  const moldActive = machine.workOrders.moldChangeInProgress;
+
+  let status: RecapMachineStatus = "running";
+  if (offline) status = "offline";
+  else if (moldActive) status = "mold-change";
+  else if (ongoingStopMin != null && ongoingStopMin > 0) status = "stopped";
+
+  return {
+    status,
+    lastSeenMs,
+    offlineForMin: offline ? Math.max(0, Math.floor(offlineForMs / 60000)) : null,
+    ongoingStopMin,
+  };
+}
+
+async function loadTimelineRowsForMachines(params: {
+  orgId: string;
+  machineIds: string[];
+  start: Date;
+  end: Date;
+}) {
+  if (!params.machineIds.length) {
+    return {
+      cyclesByMachine: new Map<string, TimelineCycleRow[]>(),
+      eventsByMachine: new Map<string, TimelineEventRow[]>(),
+    };
+  }
+
+  const [cycles, events] = await Promise.all([
+    prisma.machineCycle.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_CYCLE_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        cycleCount: true,
+        actualCycleTime: true,
+        workOrderId: true,
+        sku: true,
+      },
+    }),
+    prisma.machineEvent.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        eventType: { in: TIMELINE_EVENT_TYPES as unknown as string[] },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_EVENT_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        eventType: true,
+        data: true,
+      },
+    }),
+  ]);
+
+  const cyclesByMachine = new Map<string, TimelineCycleRow[]>();
+  const eventsByMachine = new Map<string, TimelineEventRow[]>();
+
+  for (const row of cycles) {
+    const list = cyclesByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      cycleCount: row.cycleCount,
+      actualCycleTime: row.actualCycleTime,
+      workOrderId: row.workOrderId,
+      sku: row.sku,
+    });
+    cyclesByMachine.set(row.machineId, list);
+  }
+
+  for (const row of events) {
+    const list = eventsByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      eventType: row.eventType,
+      data: row.data,
+    });
+    eventsByMachine.set(row.machineId, list);
+  }
+
+  return { cyclesByMachine, eventsByMachine };
+}
+
+function toSummaryMachine(params: {
+  machine: RecapMachine;
+  miniTimeline: ReturnType<typeof compressTimelineSegments>;
+  rangeEndMs: number;
+  events?: TimelineEventRow[];
+}): RecapSummaryMachine {
+  const { machine, miniTimeline, rangeEndMs, events } = params;
+  const status = statusFromMachine(machine, rangeEndMs, events);
+
+  return {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    lastSeenMs: status.lastSeenMs,
+    lastActivityMin:
+      status.lastSeenMs == null ? null : Math.max(0, Math.floor((rangeEndMs - status.lastSeenMs) / 60000)),
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+      elapsedMin:
+        machine.workOrders.moldChangeStartMs == null
+          ? null
+          : Math.max(0, Math.floor((rangeEndMs - machine.workOrders.moldChangeStartMs) / 60000)),
+    },
+    miniTimeline,
+  };
+}
+
+async function computeRecapSummary(params: { orgId: string; hours: number }) {
+  const now = new Date();
+  const end = new Date(Math.floor(now.getTime() / 60000) * 60000);
+  const start = new Date(end.getTime() - params.hours * 60 * 60 * 1000);
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    start,
+    end,
+  });
+
+  const machineIds = recap.machines.map((machine) => machine.machineId);
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds,
+    start,
+    end,
+  });
+
+  const machines = recap.machines.map((machine) => {
+    const segments = buildTimelineSegments({
+      cycles: timelineRows.cyclesByMachine.get(machine.machineId) ?? [],
+      events: timelineRows.eventsByMachine.get(machine.machineId) ?? [],
+      rangeStart: start,
+      rangeEnd: end,
+    });
+    const miniTimeline = compressTimelineSegments({
+      segments,
+      rangeStart: start,
+      rangeEnd: end,
+      maxSegments: 60,
+    });
+
+    return toSummaryMachine({
+      machine,
+      miniTimeline,
+      rangeEndMs: end.getTime(),
+      events: timelineRows.eventsByMachine.get(machine.machineId),
+    });
+  });
+
+  const response: RecapSummaryResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      start: start.toISOString(),
+      end: end.toISOString(),
+      hours: params.hours,
+    },
+    machines,
+  };
+
+  return response;
+}
+
+function normalizedRangeMode(mode?: string | null): RecapRangeMode {
+  const raw = String(mode ?? "").trim().toLowerCase();
+  if (raw === "shift") return "shift";
+  if (raw === "yesterday") return "yesterday";
+  if (raw === "custom") return "custom";
+  return "24h";
+}
+
+async function resolveCurrentShiftRange(params: { orgId: string; now: Date }) {
+  const settings = await prisma.orgSettings.findUnique({
+    where: { orgId: params.orgId },
+    select: {
+      timezone: true,
+      shiftScheduleOverridesJson: true,
+    },
+  });
+  const shifts = await prisma.orgShift.findMany({
+    where: { orgId: params.orgId },
+    orderBy: { sortOrder: "asc" },
+    select: {
+      name: true,
+      startTime: true,
+      endTime: true,
+      enabled: true,
+      sortOrder: true,
+    },
+  });
+
+  const enabledShifts = shifts.filter((shift) => shift.enabled !== false);
+  if (!enabledShifts.length) {
+    return {
+      hasEnabledShifts: false,
+      range: null,
+    } as const;
+  }
+
+  const timeZone = settings?.timezone || "UTC";
+  const local = getLocalParts(params.now, timeZone);
+  const overrides = normalizeShiftOverrides(settings?.shiftScheduleOverridesJson);
+  const dayOverrides = overrides?.[local.weekday];
+  const activeShifts = (dayOverrides?.length
+    ? dayOverrides.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.start,
+        end: shift.end,
+      }))
+    : enabledShifts.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.startTime,
+        end: shift.endTime,
+      }))
+  ).filter((shift) => shift.enabled);
+
+  for (const shift of activeShifts) {
+    const startMin = parseTimeMinutes(shift.start ?? null);
+    const endMin = parseTimeMinutes(shift.end ?? null);
+    if (startMin == null || endMin == null) continue;
+
+    const minutesNow = local.minutesOfDay;
+    let inRange = false;
+    let startDate = { year: local.year, month: local.month, day: local.day };
+    let endDate = { year: local.year, month: local.month, day: local.day };
+
+    if (startMin <= endMin) {
+      inRange = minutesNow >= startMin && minutesNow < endMin;
+    } else {
+      inRange = minutesNow >= startMin || minutesNow < endMin;
+      if (minutesNow >= startMin) {
+        endDate = addDays(endDate, 1);
+      } else {
+        startDate = addDays(startDate, -1);
+      }
+    }
+
+    if (!inRange) continue;
+
+    const start = zonedToUtcDate({
+      ...startDate,
+      hours: Math.floor(startMin / 60),
+      minutes: startMin % 60,
+      timeZone,
+    });
+     const shiftEndUtc = zonedToUtcDate({
+      ...endDate,
+      hours: Math.floor(endMin / 60),
+      minutes: endMin % 60,
+      timeZone,
+    });
+
+    if (shiftEndUtc <= start) continue;
+
+    // Cap end at "now" so we render shift-so-far, not shift-as-planned.
+    // Without cap:
+    //   - timeline fills future minutes with idle (visual lie)
+    //   - offline calc = (shift_end_future - last_seen) = looks 5h offline
+    //     even on a machine producing right now
+    const end = params.now < shiftEndUtc ? params.now : shiftEndUtc;
+
+    return {
+      hasEnabledShifts: true,
+      range: { start, end },
+    };
+  }
+
+  return {
+    hasEnabledShifts: true,
+    range: null,
+  } as const;
+}
+
+async function resolveDetailRange(params: { orgId: string; input: DetailRangeInput }) {
+  const now = new Date(Math.floor(Date.now() / 60000) * 60000);
+  const requestedMode = normalizedRangeMode(params.input.mode);
+  const shiftEnabledCount = await prisma.orgShift.count({
+    where: {
+      orgId: params.orgId,
+      enabled: { not: false },
+    },
+  });
+  const shiftAvailable = shiftEnabledCount > 0;
+
+  if (requestedMode === "custom") {
+    const start = parseDate(params.input.start);
+    const end = parseDate(params.input.end);
+    if (start && end && end > start) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start,
+        end,
+        shiftAvailable,
+      } as const;
+    }
+  }
+
+  if (requestedMode === "yesterday") {
+    const settings = await prisma.orgSettings.findUnique({
+      where: { orgId: params.orgId },
+      select: { timezone: true },
+    });
+    const timeZone = settings?.timezone || "America/Mexico_City";
+    const localNow = getLocalParts(now, timeZone);
+    const today = { year: localNow.year, month: localNow.month, day: localNow.day };
+    const yesterday = addDays(today, -1);
+    const start = zonedToUtcDate({
+      ...yesterday,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    const end = zonedToUtcDate({
+      ...today,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    return {
+      requestedMode,
+      mode: requestedMode,
+      start,
+      end,
+      shiftAvailable,
+    } as const;
+  }
+
+  if (requestedMode === "shift") {
+    const shiftRange = await resolveCurrentShiftRange({ orgId: params.orgId, now });
+    if (shiftRange.range) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start: shiftRange.range.start,
+        end: shiftRange.range.end,
+        shiftAvailable,
+      } as const;
+    }
+    if (!shiftRange.hasEnabledShifts) {
+      return {
+        requestedMode,
+        mode: "24h" as const,
+        start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+        end: now,
+        shiftAvailable,
+        fallbackReason: "shift-unavailable" as const,
+      } as const;
+    }
+    return {
+      requestedMode,
+      mode: "24h" as const,
+      start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+      end: now,
+      shiftAvailable,
+      fallbackReason: "shift-inactive" as const,
+    } as const;
+  }
+
+  return {
+    requestedMode,
+    mode: "24h" as const,
+    start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+    end: now,
+    shiftAvailable,
+  } as const;
+}
+
+async function computeRecapMachineDetail(params: {
+  orgId: string;
+  machineId: string;
+  range: {
+    requestedMode: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: Date;
+    end: Date;
+    shiftAvailable: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+}) {
+  const { range } = params;
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    machineId: params.machineId,
+    start: range.start,
+    end: range.end,
+  });
+
+  const machine = recap.machines.find((row) => row.machineId === params.machineId) ?? null;
+  if (!machine) return null;
+
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds: [params.machineId],
+    start: range.start,
+    end: range.end,
+  });
+
+  const timeline = buildTimelineSegments({
+    cycles: timelineRows.cyclesByMachine.get(params.machineId) ?? [],
+    events: timelineRows.eventsByMachine.get(params.machineId) ?? [],
+    rangeStart: range.start,
+    rangeEnd: range.end,
+  });
+
+  const status = statusFromMachine(
+    machine,
+    range.end.getTime(),
+    timelineRows.eventsByMachine.get(params.machineId)
+  );
+
+  const downtimeTotalMin = Math.max(0, machine.downtime.totalMin);
+  const downtimeTop = machine.downtime.topReasons.slice(0, 3).map((row) => ({
+    reasonLabel: row.reasonLabel,
+    minutes: row.minutes,
+    count: row.count,
+    percent: downtimeTotalMin > 0 ? round2((row.minutes / downtimeTotalMin) * 100) : 0,
+  }));
+
+  const machineDetail: RecapMachineDetail = {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    stopMinutes: downtimeTotalMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    lastSeenMs: status.lastSeenMs,
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+    },
+    timeline,
+    productionBySku: machine.production.bySku,
+    downtimeTop,
+    workOrders: {
+      completed: machine.workOrders.completed,
+      active: machine.workOrders.active,
+    },
+    heartbeat: {
+      lastSeenAt: machine.heartbeat.lastSeenAt,
+      uptimePct: machine.heartbeat.uptimePct,
+      connectionStatus: status.status === "offline" ? "offline" : "online",
+    },
+  };
+
+  const response: RecapDetailResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      requestedMode: range.requestedMode,
+      mode: range.mode,
+      start: range.start.toISOString(),
+      end: range.end.toISOString(),
+      shiftAvailable: range.shiftAvailable,
+      fallbackReason: range.fallbackReason,
+    },
+    machine: machineDetail,
+  };
+
+  return response;
+}
+
+function summaryCacheKey(params: { orgId: string; hours: number }) {
+  return ["recap-summary-v1", params.orgId, String(params.hours)];
+}
+
+function detailCacheKey(params: {
+  orgId: string;
+  machineId: string;
+  requestedMode: RecapRangeMode;
+  mode: RecapRangeMode;
+  shiftAvailable: boolean;
+  fallbackReason?: "shift-unavailable" | "shift-inactive";
+  startMs: number;
+  endMs: number;
+}) {
+  return [
+    "recap-detail-v1",
+    params.orgId,
+    params.machineId,
+    params.requestedMode,
+    params.mode,
+    params.shiftAvailable ? "shift-on" : "shift-off",
+    params.fallbackReason ?? "",
+    String(Math.trunc(params.startMs / 60000)),
+    String(Math.trunc(params.endMs / 60000)),
+  ];
+}
+
+export function parseRecapSummaryHours(raw: string | null) {
+  return parseHours(raw);
+}
+
+export function parseRecapDetailRangeInput(searchParams: URLSearchParams | Record<string, string | string[] | undefined>) {
+  if (searchParams instanceof URLSearchParams) {
+    return {
+      mode: searchParams.get("range") ?? undefined,
+      start: searchParams.get("start") ?? undefined,
+      end: searchParams.get("end") ?? undefined,
+    };
+  }
+
+  const pick = (key: string) => {
+    const value = searchParams[key];
+    if (Array.isArray(value)) return value[0] ?? undefined;
+    return value ?? undefined;
+  };
+
+  return {
+    mode: pick("range"),
+    start: pick("start"),
+    end: pick("end"),
+  };
+}
+
+export async function getRecapSummaryCached(params: { orgId: string; hours: number }) {
+  const cache = unstable_cache(
+    () => computeRecapSummary(params),
+    summaryCacheKey(params),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`],
+    }
+  );
+
+  return cache();
+}
+
+export async function getRecapMachineDetailCached(params: {
+  orgId: string;
+  machineId: string;
+  input: DetailRangeInput;
+}) {
+  const resolved = await resolveDetailRange({
+    orgId: params.orgId,
+    input: params.input,
+  });
+
+  const cache = unstable_cache(
+    () =>
+      computeRecapMachineDetail({
+        orgId: params.orgId,
+        machineId: params.machineId,
+        range: {
+          requestedMode: resolved.requestedMode,
+          mode: resolved.mode,
+          start: resolved.start,
+          end: resolved.end,
+          shiftAvailable: resolved.shiftAvailable,
+          fallbackReason: resolved.fallbackReason,
+        },
+      }),
+    detailCacheKey({
+      orgId: params.orgId,
+      machineId: params.machineId,
+      requestedMode: resolved.requestedMode,
+      mode: resolved.mode,
+      shiftAvailable: resolved.shiftAvailable,
+      fallbackReason: resolved.fallbackReason,
+      startMs: resolved.start.getTime(),
+      endMs: resolved.end.getTime(),
+    }),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`, `recap:${params.orgId}:${params.machineId}`],
+    }
+  );
+
+  return cache();
+}

lib/recap/redesign.ts.bak.step4

@@ -0,0 +1,905 @@
+import { unstable_cache } from "next/cache";
+import { prisma } from "@/lib/prisma";
+import { normalizeShiftOverrides, type ShiftOverrideDay } from "@/lib/settings";
+import { getRecapDataCached } from "@/lib/recap/getRecapData";
+import {
+  buildTimelineSegments,
+  compressTimelineSegments,
+  TIMELINE_EVENT_TYPES,
+  type TimelineCycleRow,
+  type TimelineEventRow,
+} from "@/lib/recap/timeline";
+import { classifyMachineState, type MachineStateResult } from "@/lib/recap/machineState";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
+import type {
+  RecapDetailResponse,
+  RecapMachine,
+  RecapMachineDetail,
+  RecapMachineStatus,
+  RecapRangeMode,
+  RecapSummaryMachine,
+  RecapSummaryResponse,
+} from "@/lib/recap/types";
+
+type DetailRangeInput = {
+  mode?: string | null;
+  start?: string | null;
+  end?: string | null;
+};
+
+const OFFLINE_THRESHOLD_MS = RECAP_HEARTBEAT_STALE_MS;
+const TIMELINE_EVENT_LOOKBACK_MS = 24 * 60 * 60 * 1000;
+const TIMELINE_CYCLE_LOOKBACK_MS = 15 * 60 * 1000;
+const RECAP_CACHE_TTL_SEC = 60;
+const WEEKDAY_KEYS: ShiftOverrideDay[] = ["sun", "mon", "tue", "wed", "thu", "fri", "sat"];
+const WEEKDAY_KEY_MAP: Record<string, ShiftOverrideDay> = {
+  Mon: "mon",
+  Tue: "tue",
+  Wed: "wed",
+  Thu: "thu",
+  Fri: "fri",
+  Sat: "sat",
+  Sun: "sun",
+};
+
+function round2(value: number) {
+  return Math.round(value * 100) / 100;
+}
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (Number.isFinite(n)) {
+    const d = new Date(n);
+    return Number.isFinite(d.getTime()) ? d : null;
+  }
+  const d = new Date(input);
+  return Number.isFinite(d.getTime()) ? d : null;
+}
+
+function parseHours(input: string | null) {
+  const parsed = Math.trunc(Number(input ?? "24"));
+  if (!Number.isFinite(parsed)) return 24;
+  return Math.max(1, Math.min(72, parsed));
+}
+
+function parseTimeMinutes(input?: string | null) {
+  if (!input) return null;
+  const match = /^(\d{2}):(\d{2})$/.exec(input.trim());
+  if (!match) return null;
+  const hours = Number(match[1]);
+  const minutes = Number(match[2]);
+  if (!Number.isInteger(hours) || !Number.isInteger(minutes) || hours < 0 || hours > 23 || minutes < 0 || minutes > 59) {
+    return null;
+  }
+  return hours * 60 + minutes;
+}
+
+function getLocalParts(ts: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      year: "numeric",
+      month: "2-digit",
+      day: "2-digit",
+      hour: "2-digit",
+      minute: "2-digit",
+      weekday: "short",
+      hour12: false,
+    }).formatToParts(ts);
+
+    const value = (type: string) => parts.find((part) => part.type === type)?.value ?? "";
+    const year = Number(value("year"));
+    const month = Number(value("month"));
+    const day = Number(value("day"));
+    const hour = Number(value("hour"));
+    const minute = Number(value("minute"));
+    const weekday = value("weekday");
+
+    return {
+      year,
+      month,
+      day,
+      hour,
+      minute,
+      weekday: WEEKDAY_KEY_MAP[weekday] ?? WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: hour * 60 + minute,
+    };
+  } catch {
+    return {
+      year: ts.getUTCFullYear(),
+      month: ts.getUTCMonth() + 1,
+      day: ts.getUTCDate(),
+      hour: ts.getUTCHours(),
+      minute: ts.getUTCMinutes(),
+      weekday: WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: ts.getUTCHours() * 60 + ts.getUTCMinutes(),
+    };
+  }
+}
+
+function parseOffsetMinutes(offsetLabel: string | null) {
+  if (!offsetLabel) return null;
+  const normalized = offsetLabel.replace("UTC", "GMT");
+  const match = /^GMT([+-])(\d{1,2})(?::?(\d{2}))?$/.exec(normalized);
+  if (!match) return null;
+  const sign = match[1] === "-" ? -1 : 1;
+  const hour = Number(match[2]);
+  const minute = Number(match[3] ?? "0");
+  if (!Number.isFinite(hour) || !Number.isFinite(minute)) return null;
+  return sign * (hour * 60 + minute);
+}
+
+function getTzOffsetMinutes(utcDate: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      timeZoneName: "shortOffset",
+      hour: "2-digit",
+    }).formatToParts(utcDate);
+    const offsetPart = parts.find((part) => part.type === "timeZoneName")?.value ?? null;
+    return parseOffsetMinutes(offsetPart);
+  } catch {
+    return null;
+  }
+}
+
+function zonedToUtcDate(input: {
+  year: number;
+  month: number;
+  day: number;
+  hours: number;
+  minutes: number;
+  timeZone: string;
+}) {
+  const baseUtc = Date.UTC(input.year, input.month - 1, input.day, input.hours, input.minutes, 0, 0);
+  const guessDate = new Date(baseUtc);
+  const offsetA = getTzOffsetMinutes(guessDate, input.timeZone);
+  if (offsetA == null) return guessDate;
+
+  let corrected = new Date(baseUtc - offsetA * 60000);
+  const offsetB = getTzOffsetMinutes(corrected, input.timeZone);
+  if (offsetB != null && offsetB !== offsetA) {
+    corrected = new Date(baseUtc - offsetB * 60000);
+  }
+
+  return corrected;
+}
+
+function addDays(input: { year: number; month: number; day: number }, days: number) {
+  const base = new Date(Date.UTC(input.year, input.month - 1, input.day));
+  base.setUTCDate(base.getUTCDate() + days);
+  return {
+    year: base.getUTCFullYear(),
+    month: base.getUTCMonth() + 1,
+    day: base.getUTCDate(),
+  };
+}
+
+// Detect active episodes (macrostop, mold-change) from event rows.
+// Returns the latest non-auto-ack episode whose final status is "active"
+// and that's been refreshed within ACTIVE_STALE_MS.
+const ACTIVE_STALE_MS = 2 * 60 * 1000;
+
+type ActiveEpisode = { startedAtMs: number; lastTsMs: number };
+
+function detectActiveEpisode(
+  events: TimelineEventRow[] | undefined,
+  eventType: "macrostop" | "mold-change",
+  endMs: number
+): ActiveEpisode | null {
+  if (!events || events.length === 0) return null;
+
+  type Episode = { firstTsMs: number; lastTsMs: number; lastStatus: string; lastCycleTs: number | null };
+  const episodes = new Map<string, Episode>();
+
+  for (const event of events) {
+    if (String(event.eventType || "").toLowerCase() !== eventType) continue;
+
+    let parsed: unknown = event.data;
+    if (typeof parsed === "string") {
+      try { parsed = JSON.parse(parsed); } catch { parsed = null; }
+    }
+    const data: Record<string, unknown> =
+      parsed && typeof parsed === "object" && !Array.isArray(parsed)
+        ? (parsed as Record<string, unknown>)
+        : {};
+
+    const isAutoAck =
+      data.is_auto_ack === true ||
+      data.isAutoAck === true ||
+      data.is_auto_ack === "true" ||
+      data.isAutoAck === "true";
+    if (isAutoAck) continue;
+
+    const status = String(data.status ?? "").trim().toLowerCase();
+    const incidentKey = String(data.incidentKey ?? data.incident_key ?? "").trim()
+      || `${eventType}:${event.ts.getTime()}`;
+    const tsMs = event.ts.getTime();
+    const lastCycleTs = Number(data.last_cycle_timestamp);
+
+    const existing = episodes.get(incidentKey);
+    if (!existing) {
+      episodes.set(incidentKey, {
+        firstTsMs: tsMs,
+        lastTsMs: tsMs,
+        lastStatus: status,
+        lastCycleTs: Number.isFinite(lastCycleTs) && lastCycleTs > 0 ? lastCycleTs : null,
+      });
+      continue;
+    }
+    existing.firstTsMs = Math.min(existing.firstTsMs, tsMs);
+    if (tsMs >= existing.lastTsMs) {
+      existing.lastTsMs = tsMs;
+      existing.lastStatus = status;
+    }
+  }
+
+  let best: ActiveEpisode | null = null;
+  for (const ep of episodes.values()) {
+    if (ep.lastStatus !== "active") continue;
+    if (endMs - ep.lastTsMs > ACTIVE_STALE_MS) continue;
+    // Prefer the freshest active episode (highest lastTsMs)
+    if (!best || ep.lastTsMs > best.lastTsMs) {
+      best = {
+        startedAtMs: ep.lastCycleTs ?? ep.firstTsMs,
+        lastTsMs: ep.lastTsMs,
+      };
+    }
+  }
+  return best;
+}
+
+function statusFromMachine(
+  machine: RecapMachine,
+  endMs: number,
+  events?: TimelineEventRow[]
+): {
+  status: RecapMachineStatus;
+  result: MachineStateResult;
+  lastSeenMs: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+} {
+  const lastSeenMs = machine.heartbeat.lastSeenAt ? new Date(machine.heartbeat.lastSeenAt).getTime() : null;
+  const offlineForMs = lastSeenMs == null ? Number.POSITIVE_INFINITY : Math.max(0, endMs - lastSeenMs);
+  const heartbeatAlive = Number.isFinite(lastSeenMs ?? Number.NaN) && offlineForMs <= OFFLINE_THRESHOLD_MS;
+
+  const activeMacrostop = detectActiveEpisode(events, "macrostop", endMs);
+  const activeMoldChange = detectActiveEpisode(events, "mold-change", endMs);
+
+  // Round 1 limitation: trackingEnabled and untrackedCycles inputs require KPI/cycle queries
+  // we don't yet plumb here. We approximate from the legacy fields:
+  //   - trackingEnabled: true when there's an active macrostop (Pi only fires those when tracking on)
+  //                      OR when an active WO exists and machine.workOrders.moldChangeInProgress is false.
+  //                      This is a SIMPLIFICATION; Round 3 will replace with real KPI snapshot read.
+  //   - untrackedCycles: 0 (Round 3 will compute from MachineCycle vs latest KPI)
+  //
+  // Effect for Round 1: STOPPED `not_started` reason cannot trigger yet (we always assume tracking
+  // is on when a WO exists). Only `machine_fault` STOPPED fires. DATA_LOSS cannot fire yet.
+  // IDLE fires correctly when there's no WO and no recent activity.
+  const hasActiveWorkOrder = machine.workOrders.active != null;
+  const trackingEnabledApprox = hasActiveWorkOrder; // see comment above
+
+  const lastCycleTsMs = (() => {
+    // Best-effort: use the machine's heartbeat as a "recent activity" proxy.
+    // The Pi only heartbeats every minute regardless of cycles, so this is a weak signal.
+    // Round 3 will pass the actual latest cycle ts.
+    return lastSeenMs;
+  })();
+
+  const result = classifyMachineState(
+    {
+      heartbeatAlive,
+      lastSeenMs,
+      offlineForMs,
+      trackingEnabled: trackingEnabledApprox,
+      hasActiveWorkOrder,
+      activeMoldChange,
+      activeMacrostop,
+      untrackedCycles: { count: 0, oldestTsMs: null },
+      lastCycleTsMs,
+    },
+    endMs
+  );
+
+  // Map the rich classifier result back to the existing RecapMachineStatus union
+  const status: RecapMachineStatus = result.state;
+
+  // Pull common fields out for the caller's convenience
+  let ongoingStopMin: number | null = null;
+  if (result.state === "stopped") ongoingStopMin = result.ongoingStopMin;
+
+  return {
+    status,
+    result,
+    lastSeenMs,
+    offlineForMin: result.state === "offline" ? result.offlineForMin : null,
+    ongoingStopMin,
+  };
+}
+
+async function loadTimelineRowsForMachines(params: {
+  orgId: string;
+  machineIds: string[];
+  start: Date;
+  end: Date;
+}) {
+  if (!params.machineIds.length) {
+    return {
+      cyclesByMachine: new Map<string, TimelineCycleRow[]>(),
+      eventsByMachine: new Map<string, TimelineEventRow[]>(),
+    };
+  }
+
+  const [cycles, events] = await Promise.all([
+    prisma.machineCycle.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_CYCLE_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        cycleCount: true,
+        actualCycleTime: true,
+        workOrderId: true,
+        sku: true,
+      },
+    }),
+    prisma.machineEvent.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        eventType: { in: TIMELINE_EVENT_TYPES as unknown as string[] },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_EVENT_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        eventType: true,
+        data: true,
+      },
+    }),
+  ]);
+
+  const cyclesByMachine = new Map<string, TimelineCycleRow[]>();
+  const eventsByMachine = new Map<string, TimelineEventRow[]>();
+
+  for (const row of cycles) {
+    const list = cyclesByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      cycleCount: row.cycleCount,
+      actualCycleTime: row.actualCycleTime,
+      workOrderId: row.workOrderId,
+      sku: row.sku,
+    });
+    cyclesByMachine.set(row.machineId, list);
+  }
+
+  for (const row of events) {
+    const list = eventsByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      eventType: row.eventType,
+      data: row.data,
+    });
+    eventsByMachine.set(row.machineId, list);
+  }
+
+  return { cyclesByMachine, eventsByMachine };
+}
+
+function toSummaryMachine(params: {
+  machine: RecapMachine;
+  miniTimeline: ReturnType<typeof compressTimelineSegments>;
+  rangeEndMs: number;
+  events?: TimelineEventRow[];
+}): RecapSummaryMachine {
+  const { machine, miniTimeline, rangeEndMs, events } = params;
+  const status = statusFromMachine(machine, rangeEndMs, events);
+
+  return {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    lastSeenMs: status.lastSeenMs,
+    lastActivityMin:
+      status.lastSeenMs == null ? null : Math.max(0, Math.floor((rangeEndMs - status.lastSeenMs) / 60000)),
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+      elapsedMin:
+        machine.workOrders.moldChangeStartMs == null
+          ? null
+          : Math.max(0, Math.floor((rangeEndMs - machine.workOrders.moldChangeStartMs) / 60000)),
+    },
+    miniTimeline,
+  };
+}
+
+async function computeRecapSummary(params: { orgId: string; hours: number }) {
+  const now = new Date();
+  const end = new Date(Math.floor(now.getTime() / 60000) * 60000);
+  const start = new Date(end.getTime() - params.hours * 60 * 60 * 1000);
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    start,
+    end,
+  });
+
+  const machineIds = recap.machines.map((machine) => machine.machineId);
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds,
+    start,
+    end,
+  });
+
+  const machines = recap.machines.map((machine) => {
+    const segments = buildTimelineSegments({
+      cycles: timelineRows.cyclesByMachine.get(machine.machineId) ?? [],
+      events: timelineRows.eventsByMachine.get(machine.machineId) ?? [],
+      rangeStart: start,
+      rangeEnd: end,
+    });
+    const miniTimeline = compressTimelineSegments({
+      segments,
+      rangeStart: start,
+      rangeEnd: end,
+      maxSegments: 60,
+    });
+
+    return toSummaryMachine({
+      machine,
+      miniTimeline,
+      rangeEndMs: end.getTime(),
+      events: timelineRows.eventsByMachine.get(machine.machineId),
+    });
+  });
+
+  const response: RecapSummaryResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      start: start.toISOString(),
+      end: end.toISOString(),
+      hours: params.hours,
+    },
+    machines,
+  };
+
+  return response;
+}
+
+function normalizedRangeMode(mode?: string | null): RecapRangeMode {
+  const raw = String(mode ?? "").trim().toLowerCase();
+  if (raw === "shift") return "shift";
+  if (raw === "yesterday") return "yesterday";
+  if (raw === "custom") return "custom";
+  return "24h";
+}
+
+async function resolveCurrentShiftRange(params: { orgId: string; now: Date }) {
+  const settings = await prisma.orgSettings.findUnique({
+    where: { orgId: params.orgId },
+    select: {
+      timezone: true,
+      shiftScheduleOverridesJson: true,
+    },
+  });
+  const shifts = await prisma.orgShift.findMany({
+    where: { orgId: params.orgId },
+    orderBy: { sortOrder: "asc" },
+    select: {
+      name: true,
+      startTime: true,
+      endTime: true,
+      enabled: true,
+      sortOrder: true,
+    },
+  });
+
+  const enabledShifts = shifts.filter((shift) => shift.enabled !== false);
+  if (!enabledShifts.length) {
+    return {
+      hasEnabledShifts: false,
+      range: null,
+    } as const;
+  }
+
+  const timeZone = settings?.timezone || "UTC";
+  const local = getLocalParts(params.now, timeZone);
+  const overrides = normalizeShiftOverrides(settings?.shiftScheduleOverridesJson);
+  const dayOverrides = overrides?.[local.weekday];
+  const activeShifts = (dayOverrides?.length
+    ? dayOverrides.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.start,
+        end: shift.end,
+      }))
+    : enabledShifts.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.startTime,
+        end: shift.endTime,
+      }))
+  ).filter((shift) => shift.enabled);
+
+  for (const shift of activeShifts) {
+    const startMin = parseTimeMinutes(shift.start ?? null);
+    const endMin = parseTimeMinutes(shift.end ?? null);
+    if (startMin == null || endMin == null) continue;
+
+    const minutesNow = local.minutesOfDay;
+    let inRange = false;
+    let startDate = { year: local.year, month: local.month, day: local.day };
+    let endDate = { year: local.year, month: local.month, day: local.day };
+
+    if (startMin <= endMin) {
+      inRange = minutesNow >= startMin && minutesNow < endMin;
+    } else {
+      inRange = minutesNow >= startMin || minutesNow < endMin;
+      if (minutesNow >= startMin) {
+        endDate = addDays(endDate, 1);
+      } else {
+        startDate = addDays(startDate, -1);
+      }
+    }
+
+    if (!inRange) continue;
+
+    const start = zonedToUtcDate({
+      ...startDate,
+      hours: Math.floor(startMin / 60),
+      minutes: startMin % 60,
+      timeZone,
+    });
+     const shiftEndUtc = zonedToUtcDate({
+      ...endDate,
+      hours: Math.floor(endMin / 60),
+      minutes: endMin % 60,
+      timeZone,
+    });
+
+    if (shiftEndUtc <= start) continue;
+
+    // Cap end at "now" so we render shift-so-far, not shift-as-planned.
+    // Without cap:
+    //   - timeline fills future minutes with idle (visual lie)
+    //   - offline calc = (shift_end_future - last_seen) = looks 5h offline
+    //     even on a machine producing right now
+    const end = params.now < shiftEndUtc ? params.now : shiftEndUtc;
+
+    return {
+      hasEnabledShifts: true,
+      range: { start, end },
+    };
+  }
+
+  return {
+    hasEnabledShifts: true,
+    range: null,
+  } as const;
+}
+
+async function resolveDetailRange(params: { orgId: string; input: DetailRangeInput }) {
+  const now = new Date(Math.floor(Date.now() / 60000) * 60000);
+  const requestedMode = normalizedRangeMode(params.input.mode);
+  const shiftEnabledCount = await prisma.orgShift.count({
+    where: {
+      orgId: params.orgId,
+      enabled: { not: false },
+    },
+  });
+  const shiftAvailable = shiftEnabledCount > 0;
+
+  if (requestedMode === "custom") {
+    const start = parseDate(params.input.start);
+    const end = parseDate(params.input.end);
+    if (start && end && end > start) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start,
+        end,
+        shiftAvailable,
+      } as const;
+    }
+  }
+
+  if (requestedMode === "yesterday") {
+    const settings = await prisma.orgSettings.findUnique({
+      where: { orgId: params.orgId },
+      select: { timezone: true },
+    });
+    const timeZone = settings?.timezone || "America/Mexico_City";
+    const localNow = getLocalParts(now, timeZone);
+    const today = { year: localNow.year, month: localNow.month, day: localNow.day };
+    const yesterday = addDays(today, -1);
+    const start = zonedToUtcDate({
+      ...yesterday,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    const end = zonedToUtcDate({
+      ...today,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    return {
+      requestedMode,
+      mode: requestedMode,
+      start,
+      end,
+      shiftAvailable,
+    } as const;
+  }
+
+  if (requestedMode === "shift") {
+    const shiftRange = await resolveCurrentShiftRange({ orgId: params.orgId, now });
+    if (shiftRange.range) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start: shiftRange.range.start,
+        end: shiftRange.range.end,
+        shiftAvailable,
+      } as const;
+    }
+    if (!shiftRange.hasEnabledShifts) {
+      return {
+        requestedMode,
+        mode: "24h" as const,
+        start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+        end: now,
+        shiftAvailable,
+        fallbackReason: "shift-unavailable" as const,
+      } as const;
+    }
+    return {
+      requestedMode,
+      mode: "24h" as const,
+      start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+      end: now,
+      shiftAvailable,
+      fallbackReason: "shift-inactive" as const,
+    } as const;
+  }
+
+  return {
+    requestedMode,
+    mode: "24h" as const,
+    start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+    end: now,
+    shiftAvailable,
+  } as const;
+}
+
+async function computeRecapMachineDetail(params: {
+  orgId: string;
+  machineId: string;
+  range: {
+    requestedMode: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: Date;
+    end: Date;
+    shiftAvailable: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+}) {
+  const { range } = params;
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    machineId: params.machineId,
+    start: range.start,
+    end: range.end,
+  });
+
+  const machine = recap.machines.find((row) => row.machineId === params.machineId) ?? null;
+  if (!machine) return null;
+
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds: [params.machineId],
+    start: range.start,
+    end: range.end,
+  });
+
+  const timeline = buildTimelineSegments({
+    cycles: timelineRows.cyclesByMachine.get(params.machineId) ?? [],
+    events: timelineRows.eventsByMachine.get(params.machineId) ?? [],
+    rangeStart: range.start,
+    rangeEnd: range.end,
+  });
+
+  const status = statusFromMachine(
+    machine,
+    range.end.getTime(),
+    timelineRows.eventsByMachine.get(params.machineId)
+  );
+
+  const downtimeTotalMin = Math.max(0, machine.downtime.totalMin);
+  const downtimeTop = machine.downtime.topReasons.slice(0, 3).map((row) => ({
+    reasonLabel: row.reasonLabel,
+    minutes: row.minutes,
+    count: row.count,
+    percent: downtimeTotalMin > 0 ? round2((row.minutes / downtimeTotalMin) * 100) : 0,
+  }));
+
+  const machineDetail: RecapMachineDetail = {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    stopMinutes: downtimeTotalMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    lastSeenMs: status.lastSeenMs,
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+    },
+    timeline,
+    productionBySku: machine.production.bySku,
+    downtimeTop,
+    workOrders: {
+      completed: machine.workOrders.completed,
+      active: machine.workOrders.active,
+    },
+    heartbeat: {
+      lastSeenAt: machine.heartbeat.lastSeenAt,
+      uptimePct: machine.heartbeat.uptimePct,
+      connectionStatus: status.status === "offline" ? "offline" : "online",
+    },
+  };
+
+  const response: RecapDetailResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      requestedMode: range.requestedMode,
+      mode: range.mode,
+      start: range.start.toISOString(),
+      end: range.end.toISOString(),
+      shiftAvailable: range.shiftAvailable,
+      fallbackReason: range.fallbackReason,
+    },
+    machine: machineDetail,
+  };
+
+  return response;
+}
+
+function summaryCacheKey(params: { orgId: string; hours: number }) {
+  return ["recap-summary-v1", params.orgId, String(params.hours)];
+}
+
+function detailCacheKey(params: {
+  orgId: string;
+  machineId: string;
+  requestedMode: RecapRangeMode;
+  mode: RecapRangeMode;
+  shiftAvailable: boolean;
+  fallbackReason?: "shift-unavailable" | "shift-inactive";
+  startMs: number;
+  endMs: number;
+}) {
+  return [
+    "recap-detail-v1",
+    params.orgId,
+    params.machineId,
+    params.requestedMode,
+    params.mode,
+    params.shiftAvailable ? "shift-on" : "shift-off",
+    params.fallbackReason ?? "",
+    String(Math.trunc(params.startMs / 60000)),
+    String(Math.trunc(params.endMs / 60000)),
+  ];
+}
+
+export function parseRecapSummaryHours(raw: string | null) {
+  return parseHours(raw);
+}
+
+export function parseRecapDetailRangeInput(searchParams: URLSearchParams | Record<string, string | string[] | undefined>) {
+  if (searchParams instanceof URLSearchParams) {
+    return {
+      mode: searchParams.get("range") ?? undefined,
+      start: searchParams.get("start") ?? undefined,
+      end: searchParams.get("end") ?? undefined,
+    };
+  }
+
+  const pick = (key: string) => {
+    const value = searchParams[key];
+    if (Array.isArray(value)) return value[0] ?? undefined;
+    return value ?? undefined;
+  };
+
+  return {
+    mode: pick("range"),
+    start: pick("start"),
+    end: pick("end"),
+  };
+}
+
+export async function getRecapSummaryCached(params: { orgId: string; hours: number }) {
+  const cache = unstable_cache(
+    () => computeRecapSummary(params),
+    summaryCacheKey(params),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`],
+    }
+  );
+
+  return cache();
+}
+
+export async function getRecapMachineDetailCached(params: {
+  orgId: string;
+  machineId: string;
+  input: DetailRangeInput;
+}) {
+  const resolved = await resolveDetailRange({
+    orgId: params.orgId,
+    input: params.input,
+  });
+
+  const cache = unstable_cache(
+    () =>
+      computeRecapMachineDetail({
+        orgId: params.orgId,
+        machineId: params.machineId,
+        range: {
+          requestedMode: resolved.requestedMode,
+          mode: resolved.mode,
+          start: resolved.start,
+          end: resolved.end,
+          shiftAvailable: resolved.shiftAvailable,
+          fallbackReason: resolved.fallbackReason,
+        },
+      }),
+    detailCacheKey({
+      orgId: params.orgId,
+      machineId: params.machineId,
+      requestedMode: resolved.requestedMode,
+      mode: resolved.mode,
+      shiftAvailable: resolved.shiftAvailable,
+      fallbackReason: resolved.fallbackReason,
+      startMs: resolved.start.getTime(),
+      endMs: resolved.end.getTime(),
+    }),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`, `recap:${params.orgId}:${params.machineId}`],
+    }
+  );
+
+  return cache();
+}

lib/recap/types.ts

@@ -121,7 +121,24 @@ export type RecapQuery = {
   shift?: string;
 };
 
-export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "offline";
+export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "data-loss" | "offline" | "idle";
+
+export type RecapStoppedReason = "machine_fault" | "not_started";
+export type RecapDataLossReason = "untracked";
+
+/**
+ * Reason context for STOPPED and DATA_LOSS states.
+ * - When status is "stopped": stoppedReason is set, dataLossReason is null.
+ * - When status is "data-loss": dataLossReason is set, stoppedReason is null.
+ * - All other states: both are null.
+ */
+export type RecapStateContext = {
+  stoppedReason: RecapStoppedReason | null;
+  dataLossReason: RecapDataLossReason | null;
+  /** For data-loss: how many untracked cycles have been detected so far. */
+  untrackedCycleCount: number | null;
+};
+
 
 export type RecapSummaryMachine = {
   machineId: string;
@@ -136,6 +153,7 @@ export type RecapSummaryMachine = {
   lastActivityMin: number | null;
   offlineForMin: number | null;
   ongoingStopMin: number | null;
+  stateContext: RecapStateContext;
   activeWorkOrderId: string | null;
   moldChange: {
     active: boolean;
@@ -193,6 +211,7 @@ export type RecapMachineDetail = {
   lastSeenMs: number | null;
   offlineForMin: number | null;
   ongoingStopMin: number | null;
+  stateContext: RecapStateContext;
   moldChange: {
     active: boolean;
     startMs: number | null;

lib/recap/types.ts.bak

@@ -0,0 +1,222 @@
+export type RecapSkuRow = {
+  machineName: string;
+  sku: string;
+  good: number;
+  scrap: number;
+  target: number | null;
+  progressPct: number | null;
+};
+
+export type RecapMachine = {
+  machineId: string;
+  machineName: string;
+  location: string | null;
+  production: {
+    goodParts: number;
+    scrapParts: number;
+    totalCycles: number;
+    bySku: RecapSkuRow[];
+  };
+  oee: {
+    avg: number | null;
+    availability: number | null;
+    performance: number | null;
+    quality: number | null;
+  };
+  downtime: {
+    totalMin: number;
+    stopsCount: number;
+    topReasons: Array<{
+      reasonLabel: string;
+      minutes: number;
+      count: number;
+    }>;
+    ongoingStopMin: number | null;
+  };
+  workOrders: {
+    completed: Array<{
+      id: string;
+      sku: string | null;
+      goodParts: number;
+      durationHrs: number;
+    }>;
+    active: {
+      id: string;
+      sku: string | null;
+      progressPct: number | null;
+      startedAt: string | null;
+    } | null;
+    moldChangeInProgress: boolean;
+    moldChangeStartMs: number | null;
+  };
+  heartbeat: {
+    lastSeenAt: string | null;
+    uptimePct: number | null;
+  };
+};
+
+export type RecapTimelineSegment =
+  | {
+      type: "production";
+      startMs: number;
+      endMs: number;
+      durationSec: number;
+      workOrderId: string | null;
+      sku: string | null;
+      label: string;
+    }
+  | {
+      type: "mold-change";
+      startMs: number;
+      endMs: number;
+      fromMoldId: string | null;
+      toMoldId: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "macrostop" | "microstop" | "slow-cycle";
+      startMs: number;
+      endMs: number;
+      reason: string | null;
+      reasonLabel?: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "idle";
+      startMs: number;
+      endMs: number;
+      durationSec: number;
+      label: string;
+    };
+
+export type RecapTimelineResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  segments: RecapTimelineSegment[];
+  hasData: boolean;
+  generatedAt: string;
+};
+
+export type RecapResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  availableShifts: Array<{
+    id: string;
+    name: string;
+  }>;
+  machines: RecapMachine[];
+};
+
+export type RecapQuery = {
+  orgId: string;
+  machineId?: string;
+  start?: Date;
+  end?: Date;
+  shift?: string;
+};
+
+export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "offline";
+
+export type RecapSummaryMachine = {
+  machineId: string;
+  name: string;
+  location: string | null;
+  status: RecapMachineStatus;
+  oee: number | null;
+  goodParts: number;
+  scrap: number;
+  stopsCount: number;
+  lastSeenMs: number | null;
+  lastActivityMin: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+  activeWorkOrderId: string | null;
+  moldChange: {
+    active: boolean;
+    startMs: number | null;
+    elapsedMin: number | null;
+  } | null;
+  miniTimeline: RecapTimelineSegment[];
+};
+
+export type RecapSummaryResponse = {
+  generatedAt: string;
+  range: {
+    start: string;
+    end: string;
+    hours: number;
+  };
+  machines: RecapSummaryMachine[];
+};
+
+export type RecapRangeMode = "24h" | "shift" | "yesterday" | "custom";
+
+export type RecapDowntimeTopRow = {
+  reasonLabel: string;
+  minutes: number;
+  count: number;
+  percent: number;
+};
+
+export type RecapWorkOrders = {
+  completed: Array<{
+    id: string;
+    sku: string | null;
+    goodParts: number;
+    durationHrs: number;
+  }>;
+  active: {
+    id: string;
+    sku: string | null;
+    progressPct: number | null;
+    startedAt: string | null;
+  } | null;
+};
+
+export type RecapMachineDetail = {
+  machineId: string;
+  name: string;
+  location: string | null;
+  status: RecapMachineStatus;
+  oee: number | null;
+  goodParts: number;
+  scrap: number;
+  stopsCount: number;
+  stopMinutes: number;
+  activeWorkOrderId: string | null;
+  lastSeenMs: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+  moldChange: {
+    active: boolean;
+    startMs: number | null;
+  } | null;
+  timeline: RecapTimelineSegment[];
+  productionBySku: RecapSkuRow[];
+  downtimeTop: RecapDowntimeTopRow[];
+  workOrders: RecapWorkOrders;
+  heartbeat: {
+    lastSeenAt: string | null;
+    uptimePct: number | null;
+    connectionStatus: "online" | "offline";
+  };
+};
+
+export type RecapDetailResponse = {
+  generatedAt: string;
+  range: {
+    requestedMode?: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: string;
+    end: string;
+    shiftAvailable?: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+  machine: RecapMachineDetail;
+};

lib/recap/types.ts.bak.step4

@@ -0,0 +1,222 @@
+export type RecapSkuRow = {
+  machineName: string;
+  sku: string;
+  good: number;
+  scrap: number;
+  target: number | null;
+  progressPct: number | null;
+};
+
+export type RecapMachine = {
+  machineId: string;
+  machineName: string;
+  location: string | null;
+  production: {
+    goodParts: number;
+    scrapParts: number;
+    totalCycles: number;
+    bySku: RecapSkuRow[];
+  };
+  oee: {
+    avg: number | null;
+    availability: number | null;
+    performance: number | null;
+    quality: number | null;
+  };
+  downtime: {
+    totalMin: number;
+    stopsCount: number;
+    topReasons: Array<{
+      reasonLabel: string;
+      minutes: number;
+      count: number;
+    }>;
+    ongoingStopMin: number | null;
+  };
+  workOrders: {
+    completed: Array<{
+      id: string;
+      sku: string | null;
+      goodParts: number;
+      durationHrs: number;
+    }>;
+    active: {
+      id: string;
+      sku: string | null;
+      progressPct: number | null;
+      startedAt: string | null;
+    } | null;
+    moldChangeInProgress: boolean;
+    moldChangeStartMs: number | null;
+  };
+  heartbeat: {
+    lastSeenAt: string | null;
+    uptimePct: number | null;
+  };
+};
+
+export type RecapTimelineSegment =
+  | {
+      type: "production";
+      startMs: number;
+      endMs: number;
+      durationSec: number;
+      workOrderId: string | null;
+      sku: string | null;
+      label: string;
+    }
+  | {
+      type: "mold-change";
+      startMs: number;
+      endMs: number;
+      fromMoldId: string | null;
+      toMoldId: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "macrostop" | "microstop" | "slow-cycle";
+      startMs: number;
+      endMs: number;
+      reason: string | null;
+      reasonLabel?: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "idle";
+      startMs: number;
+      endMs: number;
+      durationSec: number;
+      label: string;
+    };
+
+export type RecapTimelineResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  segments: RecapTimelineSegment[];
+  hasData: boolean;
+  generatedAt: string;
+};
+
+export type RecapResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  availableShifts: Array<{
+    id: string;
+    name: string;
+  }>;
+  machines: RecapMachine[];
+};
+
+export type RecapQuery = {
+  orgId: string;
+  machineId?: string;
+  start?: Date;
+  end?: Date;
+  shift?: string;
+};
+
+export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "data-loss" | "offline" | "idle";
+
+export type RecapSummaryMachine = {
+  machineId: string;
+  name: string;
+  location: string | null;
+  status: RecapMachineStatus;
+  oee: number | null;
+  goodParts: number;
+  scrap: number;
+  stopsCount: number;
+  lastSeenMs: number | null;
+  lastActivityMin: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+  activeWorkOrderId: string | null;
+  moldChange: {
+    active: boolean;
+    startMs: number | null;
+    elapsedMin: number | null;
+  } | null;
+  miniTimeline: RecapTimelineSegment[];
+};
+
+export type RecapSummaryResponse = {
+  generatedAt: string;
+  range: {
+    start: string;
+    end: string;
+    hours: number;
+  };
+  machines: RecapSummaryMachine[];
+};
+
+export type RecapRangeMode = "24h" | "shift" | "yesterday" | "custom";
+
+export type RecapDowntimeTopRow = {
+  reasonLabel: string;
+  minutes: number;
+  count: number;
+  percent: number;
+};
+
+export type RecapWorkOrders = {
+  completed: Array<{
+    id: string;
+    sku: string | null;
+    goodParts: number;
+    durationHrs: number;
+  }>;
+  active: {
+    id: string;
+    sku: string | null;
+    progressPct: number | null;
+    startedAt: string | null;
+  } | null;
+};
+
+export type RecapMachineDetail = {
+  machineId: string;
+  name: string;
+  location: string | null;
+  status: RecapMachineStatus;
+  oee: number | null;
+  goodParts: number;
+  scrap: number;
+  stopsCount: number;
+  stopMinutes: number;
+  activeWorkOrderId: string | null;
+  lastSeenMs: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+  moldChange: {
+    active: boolean;
+    startMs: number | null;
+  } | null;
+  timeline: RecapTimelineSegment[];
+  productionBySku: RecapSkuRow[];
+  downtimeTop: RecapDowntimeTopRow[];
+  workOrders: RecapWorkOrders;
+  heartbeat: {
+    lastSeenAt: string | null;
+    uptimePct: number | null;
+    connectionStatus: "online" | "offline";
+  };
+};
+
+export type RecapDetailResponse = {
+  generatedAt: string;
+  range: {
+    requestedMode?: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: string;
+    end: string;
+    shiftAvailable?: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+  machine: RecapMachineDetail;
+};

prisma/schema.prisma

@@ -135,6 +135,8 @@ model Machine {
   settings             MachineSettings?
   workOrders           MachineWorkOrder[]
   settingsAudits       SettingsAudit[]
+  productionEnabled    Boolean  @default(true) @map("production_enabled")
+
 
   @@unique([orgId, name])
   @@index([orgId])