recent

app/(app)/recap/RecapClient.tsx

@@ -2,12 +2,13 @@
 
 import { useEffect, useMemo, useState } from "react";
 import { useI18n } from "@/lib/i18n/useI18n";
-import type { RecapMachine, RecapResponse } from "@/lib/recap/types";
+import type { RecapMachine, RecapResponse, RecapTimelineResponse } from "@/lib/recap/types";
 import RecapKpiRow from "@/components/recap/RecapKpiRow";
 import RecapProductionBySku from "@/components/recap/RecapProductionBySku";
 import RecapDowntimeTop from "@/components/recap/RecapDowntimeTop";
 import RecapWorkOrderStatus from "@/components/recap/RecapWorkOrderStatus";
 import RecapMachineStatus from "@/components/recap/RecapMachineStatus";
+import RecapTimeline from "@/components/recap/RecapTimeline";
 
 type Props = {
   initialData: RecapResponse;
@@ -46,6 +47,25 @@ export default function RecapClient({ initialData, initialFilters }: Props) {
     return "24h";
   });
   const [loading, setLoading] = useState(false);
+  const [timeline, setTimeline] = useState<RecapTimelineResponse | null>(null);
+
+  const shiftOptions = useMemo(
+    () =>
+      data.availableShifts?.length
+        ? data.availableShifts
+        : [
+            { id: "shift1", name: t("recap.shift.1") },
+            { id: "shift2", name: t("recap.shift.2") },
+            { id: "shift3", name: t("recap.shift.3") },
+          ],
+    [data.availableShifts, t]
+  );
+
+  useEffect(() => {
+    if (mode !== "shift") return;
+    if (shiftOptions.some((option) => option.id === shift)) return;
+    setShift(shiftOptions[0]?.id ?? "shift1");
+  }, [mode, shift, shiftOptions]);
 
   useEffect(() => {
     let alive = true;
@@ -108,6 +128,41 @@ export default function RecapClient({ initialData, initialFilters }: Props) {
     return data.machines.find((m) => m.machineId === machineId) ?? data.machines[0];
   }, [data.machines, machineId]);
 
+  useEffect(() => {
+    let alive = true;
+
+    async function loadTimeline() {
+      if (mode !== "24h") {
+        if (alive) setTimeline(null);
+        return;
+      }
+      if (!selectedMachine?.machineId) {
+        if (alive) setTimeline(null);
+        return;
+      }
+
+      const qs = new URLSearchParams({
+        machineId: selectedMachine.machineId,
+        hours: "24",
+        start: data.range.start,
+        end: data.range.end,
+      });
+      const res = await fetch(`/api/recap/timeline?${qs.toString()}`, { cache: "no-cache" });
+      const json = await res.json().catch(() => null);
+      if (!alive) return;
+      if (res.ok && json && json.segments) {
+        setTimeline(json as RecapTimelineResponse);
+      } else {
+        setTimeline(null);
+      }
+    }
+
+    void loadTimeline();
+    return () => {
+      alive = false;
+    };
+  }, [mode, selectedMachine?.machineId, data.range.start, data.range.end]);
+
   const fleet = useMemo(() => {
     let good = 0;
     let scrap = 0;
@@ -132,6 +187,11 @@ export default function RecapClient({ initialData, initialFilters }: Props) {
   }, [data.machines]);
 
   const bannerMold = selectedMachine?.workOrders.moldChangeInProgress;
+  const moldStartMs = selectedMachine?.workOrders.moldChangeStartMs ?? null;
+  const moldStartLabel = moldStartMs
+    ? new Date(moldStartMs).toLocaleTimeString(locale, { hour: "2-digit", minute: "2-digit" })
+    : "--:--";
+  const moldElapsedMin = moldStartMs ? Math.max(0, Math.floor((Date.now() - moldStartMs) / 60000)) : null;
   const bannerStop = (selectedMachine?.downtime.ongoingStopMin ?? 0) > 0;
 
   return (
@@ -174,9 +234,11 @@ export default function RecapClient({ initialData, initialFilters }: Props) {
                 onChange={(event) => setShift(event.target.value)}
                 className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
               >
-                <option value="shift1">{t("recap.shift.1")}</option>
+                {shiftOptions.map((option) => (
-                <option value="shift2">{t("recap.shift.2")}</option>
+                  <option key={option.id} value={option.id}>
-                <option value="shift3">{t("recap.shift.3")}</option>
+                    {option.name}
+                  </option>
+                ))}
               </select>
             ) : null}
 
@@ -202,7 +264,8 @@ export default function RecapClient({ initialData, initialFilters }: Props) {
 
       {bannerMold ? (
         <div className="mb-3 rounded-2xl border border-amber-500/40 bg-amber-500/10 p-3 text-sm text-amber-300">
-          {t("recap.banner.mold")} {selectedMachine?.workOrders.active?.startedAt ? new Date(selectedMachine.workOrders.active.startedAt).toLocaleTimeString(locale, { hour: "2-digit", minute: "2-digit" }) : "--:--"}
+          {t("recap.banner.mold")} {moldStartLabel}
+          {moldElapsedMin != null ? ` · ${moldElapsedMin} min` : ""}
         </div>
       ) : null}
       {bannerStop ? (
@@ -213,6 +276,15 @@ export default function RecapClient({ initialData, initialFilters }: Props) {
 
       {loading ? <div className="mb-3 text-sm text-zinc-400">{t("common.loading")}</div> : null}
 
+      {timeline ? (
+        <RecapTimeline
+          rangeStart={timeline.range.start}
+          rangeEnd={timeline.range.end}
+          segments={timeline.segments}
+          locale={locale}
+        />
+      ) : null}
+
       <RecapKpiRow oeeAvg={fleet.oeeAvg} goodParts={fleet.good} totalStops={fleet.stops} scrapParts={fleet.scrap} />
 
       <div className="mt-4 grid grid-cols-1 gap-4 xl:grid-cols-2">
@@ -227,6 +299,7 @@ export default function RecapClient({ initialData, initialFilters }: Props) {
               completed: [],
               active: null,
               moldChangeInProgress: false,
+              moldChangeStartMs: null,
             }
           }
         />

app/api/analytics/downtime-events/route.ts

@@ -2,6 +2,7 @@ import { NextResponse } from "next/server";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
 import { coerceDowntimeRange, rangeToStart } from "@/lib/analytics/downtimeRange";
+import type { Prisma } from "@prisma/client";
 
 const bad = (status: number, error: string) =>
   NextResponse.json({ ok: false, error }, { status });
@@ -24,6 +25,7 @@ export async function GET(req: Request) {
 
   const machineId = url.searchParams.get("machineId"); // optional
   const reasonCode = url.searchParams.get("reasonCode"); // optional
+  const includeMoldChange = url.searchParams.get("includeMoldChange") === "true";
 
   const limitRaw = url.searchParams.get("limit");
   const limit = Math.min(Math.max(Number(limitRaw || 200), 1), 500);
@@ -44,10 +46,11 @@ export async function GET(req: Request) {
 
   // ✅ Query ReasonEntry as the "episode" table for downtime
   // We only return rows that have an episodeId (true downtime episodes)
-  const where: any = {
+  const where: Prisma.ReasonEntryWhereInput = {
     orgId,
     kind: "downtime",
     episodeId: { not: null },
+    ...(includeMoldChange ? {} : { reasonCode: { not: "MOLD_CHANGE" } }),
     capturedAt: {
       gte: start,
       ...(beforeDate ? { lt: beforeDate } : {}),
@@ -122,6 +125,7 @@ export async function GET(req: Request) {
     start,
     machineId: machineId ?? null,
     reasonCode: reasonCode ?? null,
+    includeMoldChange,
     limit,
     before: before ?? null,
     nextBefore, // pass this back for pagination

app/api/analytics/pareto/route.ts

@@ -20,9 +20,10 @@ export async function GET(req: Request) {
 
   const machineId = url.searchParams.get("machineId"); // optional
   const kind = (url.searchParams.get("kind") || "downtime").toLowerCase();
+  const includeMoldChange = url.searchParams.get("includeMoldChange") === "true";
 
-  if (kind !== "downtime" && kind !== "scrap") {
+  if (kind !== "downtime" && kind !== "scrap" && kind !== "planned-downtime") {
-    return bad(400, "Invalid kind (downtime|scrap)");
+    return bad(400, "Invalid kind (downtime|scrap|planned-downtime)");
   }
 
   // ✅ If machineId provided, verify it belongs to this org
@@ -40,7 +41,9 @@ export async function GET(req: Request) {
     where: {
       orgId,
       ...(machineId ? { machineId } : {}),
-      kind,
+      kind: kind === "planned-downtime" ? "downtime" : kind,
+      ...(kind === "downtime" && !includeMoldChange ? { reasonCode: { not: "MOLD_CHANGE" } } : {}),
+      ...(kind === "planned-downtime" ? { reasonCode: "MOLD_CHANGE" } : {}),
       capturedAt: { gte: start },
     },
     _sum: {
@@ -53,7 +56,7 @@ export async function GET(req: Request) {
   const itemsRaw = grouped
     .map((g) => {
       const value =
-        kind === "downtime"
+        kind === "downtime" || kind === "planned-downtime"
           ? Math.round(((g._sum.durationSeconds ?? 0) / 60) * 10) / 10 // minutes, 1 decimal
           : g._sum.scrapQty ?? 0;
 
@@ -64,7 +67,9 @@ export async function GET(req: Request) {
         count: g._count._all,
       };
     })
-    .filter((x) => (kind === "downtime" ? x.value > 0 || x.count > 0 : x.value > 0));
+    .filter((x) =>
+      kind === "downtime" || kind === "planned-downtime" ? x.value > 0 || x.count > 0 : x.value > 0
+    );
 
   itemsRaw.sort((a, b) => b.value - a.value);
 
@@ -83,7 +88,7 @@ export async function GET(req: Request) {
     return {
       reasonCode: x.reasonCode,
       reasonLabel: x.reasonLabel,
-      minutesLost: kind === "downtime" ? x.value : undefined,
+      minutesLost: kind === "downtime" || kind === "planned-downtime" ? x.value : undefined,
       scrapQty: kind === "scrap" ? x.value : undefined,
       pctOfTotal,
       cumulativePct,
@@ -106,9 +111,10 @@ export async function GET(req: Request) {
     orgId,
     machineId: machineId ?? null,
     kind,
+    includeMoldChange,
     range,       // ✅ now defined correctly
     start,       // ✅ now defined correctly
-    totalMinutesLost: kind === "downtime" ? total : undefined,
+    totalMinutesLost: kind === "downtime" || kind === "planned-downtime" ? total : undefined,
     totalScrap: kind === "scrap" ? total : undefined,
     rows,
     top3,

app/api/ingest/cycle/route.ts

@@ -68,7 +68,8 @@ function normalizeCycleInput(raw: unknown): Record<string, unknown> | null {
     cycle_count: fromRowOrData(["cycle_count", "cycleCount"]),
     work_order_id: fromRowOrData(["work_order_id", "workOrderId"]),
     good_delta: fromRowOrData(["good_delta", "goodDelta"]),
-    scrap_delta: fromRowOrData(["scrap_delta", "scrapDelta", "scrap_total"]),
+    // `scrap_total` is cumulative and should not be persisted as per-cycle delta.
+    scrap_delta: fromRowOrData(["scrap_delta", "scrapDelta"]),
     timestamp: fromRowOrData(["timestamp", "tsMs"]),
     ts: fromRowOrData(["ts", "tsMs"]),
     event_timestamp: fromRowOrData(["event_timestamp", "eventTimestamp"]),

app/api/ingest/event/route.ts

@@ -40,6 +40,7 @@ const CANON_TYPE: Record<string, string> = {
   "down": "stop",
   "downtime-acknowledged": "downtime-acknowledged",
   "scrap-manual-entry": "scrap-manual-entry",
+  "mold-change": "mold-change",
 };
 
 const ALLOWED_TYPES = new Set([
@@ -54,6 +55,7 @@ const ALLOWED_TYPES = new Set([
   "predictive-oee-decline",
   "downtime-acknowledged",
   "scrap-manual-entry",
+  "mold-change",
 ]);
 
 const machineIdSchema = z.string().uuid();
@@ -441,9 +443,26 @@ export async function POST(req: Request) {
     // If it doesn't, still create an "UNCLASSIFIED" downtime ReasonEntry for stop events so the dashboard can show coverage.
     if (evRecord.is_update || evRecord.is_auto_ack || dataObj.is_update || dataObj.is_auto_ack){
   // skip duplicate reasonEntry for refresh/ack 
-    } else if (evReason || finalType === "microstop" || finalType === "macrostop" || finalType === "downtime-acknowledged"){
+    } else if (evReason || finalType === "microstop" || finalType === "macrostop" || finalType === "downtime-acknowledged" || finalType === "mold-change"){
+      const moldIncidentKey =
+        clampText(evData.incidentKey ?? dataObj.incidentKey, 128) ??
+        (numberFrom(evData.start_ms ?? dataObj.start_ms) != null
+          ? `mold-change:${Math.trunc(numberFrom(evData.start_ms ?? dataObj.start_ms) as number)}`
+          : null);
       const reasonRaw: Record<string, unknown> =
         evReason ??
+        (finalType === "mold-change"
+          ? ({
+              type: "downtime",
+              categoryId: "cambio-molde",
+              detailId: "cambio-molde",
+              categoryLabel: "Cambio molde",
+              detailLabel: "Cambio molde",
+              reasonCode: "MOLD_CHANGE",
+              reasonText: "Cambio molde",
+              incidentKey: moldIncidentKey ?? row.id,
+            } as Record<string, unknown>)
+          :
         ({
           type: "downtime",
           categoryId: "unclassified",
@@ -453,7 +472,7 @@ export async function POST(req: Request) {
           reasonCode: "UNCLASSIFIED",
           reasonText: "Unclassified",
           incidentKey: row.id,
-        } as Record<string, unknown>);
+        } as Record<string, unknown>));
 
       const inferredKind: ReasonCatalogKind =
         String(reasonRaw.type ?? "").toLowerCase() === "scrap" || finalType === "scrap-manual-entry"
@@ -506,11 +525,13 @@ export async function POST(req: Request) {
           const incidentKey = clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id;
           const durationSeconds =
             numberFrom(evDowntime?.durationSeconds) ??
+            numberFrom(evData.duration_sec) ??
             numberFrom(evData.stoppage_duration_seconds) ??
             numberFrom(evData.stop_duration_seconds) ??
             (stopSecForReason != null ? stopSecForReason : null) ??
             null;
           const episodeEndTsMs =
+            numberFrom(evData.end_ms) ??
             numberFrom(evDowntime?.episodeEndTsMs) ??
             numberFrom(evDowntime?.acknowledgedAtMs) ??
             null;

app/api/recap/timeline/route.ts

@@ -0,0 +1,461 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { prisma } from "@/lib/prisma";
+import type { RecapTimelineResponse, RecapTimelineSegment } from "@/lib/recap/types";
+
+type RawSegment =
+  | {
+      type: "production";
+      startMs: number;
+      endMs: number;
+      priority: number;
+      workOrderId: string | null;
+      sku: string | null;
+      label: string;
+    }
+  | {
+      type: "mold-change";
+      startMs: number;
+      endMs: number;
+      priority: number;
+      fromMoldId: string | null;
+      toMoldId: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "macrostop" | "microstop" | "slow-cycle";
+      startMs: number;
+      endMs: number;
+      priority: number;
+      reason: string | null;
+      durationSec: number;
+      label: string;
+    };
+
+const EVENT_TYPES = ["mold-change", "macrostop", "microstop", "slow-cycle"] as const;
+type TimelineEventType = (typeof EVENT_TYPES)[number];
+const ACTIVE_STALE_MS = 2 * 60 * 1000;
+const PRIORITY: Record<string, number> = {
+  idle: 0,
+  production: 1,
+  microstop: 2,
+  "slow-cycle": 2,
+  macrostop: 3,
+  "mold-change": 4,
+};
+
+function bad(status: number, error: string) {
+  return NextResponse.json({ ok: false, error }, { status });
+}
+
+function safeNum(value: unknown) {
+  if (typeof value === "number" && Number.isFinite(value)) return value;
+  if (typeof value === "string" && value.trim()) {
+    const parsed = Number(value);
+    if (Number.isFinite(parsed)) return parsed;
+  }
+  return null;
+}
+
+function normalizeToken(value: unknown) {
+  return String(value ?? "").trim();
+}
+
+function dedupeByKey<T>(rows: T[], keyFn: (row: T) => string) {
+  const seen = new Set<string>();
+  const out: T[] = [];
+  for (const row of rows) {
+    const key = keyFn(row);
+    if (seen.has(key)) continue;
+    seen.add(key);
+    out.push(row);
+  }
+  return out;
+}
+
+function parseHours(raw: string | null) {
+  const value = Math.trunc(Number(raw || "24"));
+  if (!Number.isFinite(value)) return 24;
+  return Math.max(1, Math.min(72, value));
+}
+
+function parseDateInput(raw: string | null) {
+  if (!raw) return null;
+  const asNum = Number(raw);
+  if (Number.isFinite(asNum)) {
+    const d = new Date(asNum);
+    return Number.isFinite(d.getTime()) ? d : null;
+  }
+  const d = new Date(raw);
+  return Number.isFinite(d.getTime()) ? d : null;
+}
+
+function extractData(value: unknown) {
+  let parsed: unknown = value;
+  if (typeof value === "string") {
+    try {
+      parsed = JSON.parse(value);
+    } catch {
+      parsed = null;
+    }
+  }
+  const record = typeof parsed === "object" && parsed && !Array.isArray(parsed) ? (parsed as Record<string, unknown>) : {};
+  const nested = record.data;
+  if (typeof nested === "object" && nested && !Array.isArray(nested)) return nested as Record<string, unknown>;
+  return record;
+}
+
+function clampToRange(startMs: number, endMs: number, rangeStartMs: number, rangeEndMs: number) {
+  const clampedStart = Math.max(rangeStartMs, Math.min(rangeEndMs, startMs));
+  const clampedEnd = Math.max(rangeStartMs, Math.min(rangeEndMs, endMs));
+  if (clampedEnd <= clampedStart) return null;
+  return { startMs: clampedStart, endMs: clampedEnd };
+}
+
+function eventIncidentKey(eventType: string, data: Record<string, unknown>, fallbackTsMs: number) {
+  const key = String(data.incidentKey ?? data.incident_key ?? "").trim();
+  if (key) return key;
+  const alertId = String(data.alert_id ?? data.alertId ?? "").trim();
+  if (alertId) return `${eventType}:${alertId}`;
+  const startMs = safeNum(data.start_ms) ?? safeNum(data.startMs);
+  if (startMs != null) return `${eventType}:${Math.trunc(startMs)}`;
+  return `${eventType}:${fallbackTsMs}`;
+}
+
+function reasonLabelFromData(data: Record<string, unknown>) {
+  const direct =
+    String(data.reasonText ?? data.reason_label ?? data.reasonLabel ?? "").trim() || null;
+  if (direct) return direct;
+
+  const reason = data.reason;
+  if (typeof reason === "string") {
+    const text = reason.trim();
+    return text || null;
+  }
+  if (reason && typeof reason === "object" && !Array.isArray(reason)) {
+    const rec = reason as Record<string, unknown>;
+    const reasonText =
+      String(rec.reasonText ?? rec.reason_label ?? rec.reasonLabel ?? "").trim() || null;
+    if (reasonText) return reasonText;
+    const detail =
+      String(rec.detailLabel ?? rec.detail_label ?? rec.detailId ?? rec.detail_id ?? "").trim() || null;
+    const category =
+      String(rec.categoryLabel ?? rec.category_label ?? rec.categoryId ?? rec.category_id ?? "").trim() || null;
+    if (category && detail) return `${category} > ${detail}`;
+    if (detail) return detail;
+    if (category) return category;
+  }
+  return null;
+}
+
+function labelForStop(type: "macrostop" | "microstop" | "slow-cycle", reason: string | null) {
+  if (type === "macrostop") return reason ? `Paro: ${reason}` : "Paro";
+  if (type === "microstop") return reason ? `Microparo: ${reason}` : "Microparo";
+  return "Ciclo lento";
+}
+
+function isEquivalent(a: RecapTimelineSegment, b: RecapTimelineSegment) {
+  if (a.type !== b.type) return false;
+  if (a.type === "idle" && b.type === "idle") return true;
+  if (a.type === "production" && b.type === "production") {
+    return a.workOrderId === b.workOrderId && a.sku === b.sku && a.label === b.label;
+  }
+  if (a.type === "mold-change" && b.type === "mold-change") {
+    return a.fromMoldId === b.fromMoldId && a.toMoldId === b.toMoldId;
+  }
+  if (
+    (a.type === "macrostop" || a.type === "microstop" || a.type === "slow-cycle") &&
+    (b.type === "macrostop" || b.type === "microstop" || b.type === "slow-cycle")
+  ) {
+    return a.type === b.type && a.reason === b.reason;
+  }
+  return false;
+}
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return bad(401, "Unauthorized");
+
+  const url = new URL(req.url);
+  const machineId = url.searchParams.get("machineId");
+  if (!machineId) return bad(400, "machineId is required");
+  const hours = parseHours(url.searchParams.get("hours"));
+  const startParam = parseDateInput(url.searchParams.get("start"));
+  const endParam = parseDateInput(url.searchParams.get("end"));
+
+  const machine = await prisma.machine.findFirst({
+    where: { id: machineId, orgId: session.orgId },
+    select: { id: true },
+  });
+  if (!machine) return bad(404, "Machine not found");
+
+  const end = endParam ?? new Date();
+  const start = startParam && startParam < end ? startParam : new Date(end.getTime() - hours * 60 * 60 * 1000);
+  const rangeStartMs = start.getTime();
+  const rangeEndMs = end.getTime();
+
+  const [cycles, events] = await Promise.all([
+    prisma.machineCycle.findMany({
+      where: {
+        orgId: session.orgId,
+        machineId,
+        ts: { gte: start, lte: end },
+      },
+      orderBy: { ts: "asc" },
+      select: {
+        ts: true,
+        cycleCount: true,
+        actualCycleTime: true,
+        workOrderId: true,
+        sku: true,
+      },
+    }),
+    prisma.machineEvent.findMany({
+      where: {
+        orgId: session.orgId,
+        machineId,
+        eventType: { in: EVENT_TYPES as unknown as string[] },
+        ts: { gte: new Date(start.getTime() - 24 * 60 * 60 * 1000), lte: end },
+      },
+      orderBy: { ts: "asc" },
+      select: {
+        ts: true,
+        eventType: true,
+        data: true,
+      },
+    }),
+  ]);
+
+  const dedupedCycles = dedupeByKey(
+    cycles,
+    (cycle) =>
+      `${cycle.ts.getTime()}:${safeNum(cycle.cycleCount) ?? "na"}:${normalizeToken(cycle.workOrderId).toUpperCase()}:${normalizeToken(cycle.sku).toUpperCase()}:${safeNum(cycle.actualCycleTime) ?? "na"}`
+  );
+
+  const rawSegments: RawSegment[] = [];
+
+  let currentProduction: RawSegment | null = null;
+  for (const cycle of dedupedCycles) {
+    if (!cycle.workOrderId) continue;
+    const cycleStartMs = cycle.ts.getTime();
+    const cycleDurationMs = Math.max(1000, Math.min(600000, Math.trunc((safeNum(cycle.actualCycleTime) ?? 1) * 1000)));
+    const cycleEndMs = cycleStartMs + cycleDurationMs;
+
+    if (
+      currentProduction &&
+      currentProduction.type === "production" &&
+      currentProduction.workOrderId === cycle.workOrderId &&
+      currentProduction.sku === cycle.sku &&
+      cycleStartMs <= currentProduction.endMs + 5 * 60 * 1000
+    ) {
+      currentProduction.endMs = Math.max(currentProduction.endMs, cycleEndMs);
+      continue;
+    }
+
+    if (currentProduction) rawSegments.push(currentProduction);
+    currentProduction = {
+      type: "production",
+      startMs: cycleStartMs,
+      endMs: cycleEndMs,
+      priority: PRIORITY.production,
+      workOrderId: cycle.workOrderId,
+      sku: cycle.sku,
+      label: cycle.workOrderId,
+    };
+  }
+  if (currentProduction) rawSegments.push(currentProduction);
+
+  const eventEpisodes = new Map<
+    string,
+    {
+      type: "mold-change" | "macrostop" | "microstop" | "slow-cycle";
+      firstTsMs: number;
+      lastTsMs: number;
+      startMs: number | null;
+      endMs: number | null;
+      durationSec: number | null;
+      statusActive: boolean;
+      statusResolved: boolean;
+      reason: string | null;
+      fromMoldId: string | null;
+      toMoldId: string | null;
+    }
+  >();
+
+  for (const event of events) {
+    const eventType = String(event.eventType || "").toLowerCase() as TimelineEventType;
+    if (!EVENT_TYPES.includes(eventType)) continue;
+
+    const data = extractData(event.data);
+    const tsMs = event.ts.getTime();
+    const key = eventIncidentKey(eventType, data, tsMs);
+    const status = String(data.status ?? "").trim().toLowerCase();
+
+    const episode = eventEpisodes.get(key) ?? {
+      type: eventType,
+      firstTsMs: tsMs,
+      lastTsMs: tsMs,
+      startMs: null,
+      endMs: null,
+      durationSec: null,
+      statusActive: false,
+      statusResolved: false,
+      reason: null,
+      fromMoldId: null,
+      toMoldId: null,
+    };
+    episode.firstTsMs = Math.min(episode.firstTsMs, tsMs);
+    episode.lastTsMs = Math.max(episode.lastTsMs, tsMs);
+
+    const startMs = safeNum(data.start_ms) ?? safeNum(data.startMs);
+    const endMs = safeNum(data.end_ms) ?? safeNum(data.endMs);
+    const durationSec =
+      safeNum(data.duration_sec) ??
+      safeNum(data.stoppage_duration_seconds) ??
+      safeNum(data.stop_duration_seconds) ??
+      safeNum(data.duration_seconds);
+
+    if (startMs != null) episode.startMs = episode.startMs == null ? startMs : Math.min(episode.startMs, startMs);
+    if (endMs != null) episode.endMs = episode.endMs == null ? endMs : Math.max(episode.endMs, endMs);
+    if (durationSec != null) episode.durationSec = Math.max(0, Math.trunc(durationSec));
+
+    if (status === "active") episode.statusActive = true;
+    if (status === "resolved") episode.statusResolved = true;
+
+    const reason = reasonLabelFromData(data);
+    if (reason) episode.reason = reason;
+    const fromMoldId = String(data.from_mold_id ?? data.fromMoldId ?? "").trim() || null;
+    const toMoldId = String(data.to_mold_id ?? data.toMoldId ?? "").trim() || null;
+    if (fromMoldId) episode.fromMoldId = fromMoldId;
+    if (toMoldId) episode.toMoldId = toMoldId;
+
+    eventEpisodes.set(key, episode);
+  }
+
+  for (const episode of eventEpisodes.values()) {
+    const startMs = Math.trunc(episode.startMs ?? episode.firstTsMs);
+    let endMs = Math.trunc(episode.endMs ?? episode.lastTsMs);
+    if (episode.statusActive && !episode.statusResolved) {
+      const isFreshActive = rangeEndMs - episode.lastTsMs <= ACTIVE_STALE_MS;
+      endMs = isFreshActive ? rangeEndMs : episode.lastTsMs;
+    } else if (endMs <= startMs && episode.durationSec != null && episode.durationSec > 0) {
+      endMs = startMs + episode.durationSec * 1000;
+    }
+    if (endMs <= startMs) continue;
+
+    if (episode.type === "mold-change") {
+      rawSegments.push({
+        type: "mold-change",
+        startMs,
+        endMs,
+        priority: PRIORITY["mold-change"],
+        fromMoldId: episode.fromMoldId,
+        toMoldId: episode.toMoldId,
+        durationSec: Math.max(0, Math.trunc((endMs - startMs) / 1000)),
+        label: episode.toMoldId ? `Cambio molde ${episode.toMoldId}` : "Cambio molde",
+      });
+      continue;
+    }
+
+    const stopType = episode.type;
+    rawSegments.push({
+      type: stopType,
+      startMs,
+      endMs,
+      priority: PRIORITY[stopType],
+      reason: episode.reason,
+      durationSec: Math.max(0, Math.trunc((endMs - startMs) / 1000)),
+      label: labelForStop(stopType, episode.reason),
+    });
+  }
+
+  const clipped = rawSegments
+    .map((segment) => {
+      const range = clampToRange(segment.startMs, segment.endMs, rangeStartMs, rangeEndMs);
+      return range ? { ...segment, ...range } : null;
+    })
+    .filter((segment): segment is RawSegment => !!segment);
+
+  const boundaries = new Set<number>([rangeStartMs, rangeEndMs]);
+  for (const segment of clipped) {
+    boundaries.add(segment.startMs);
+    boundaries.add(segment.endMs);
+  }
+  const orderedBoundaries = Array.from(boundaries).sort((a, b) => a - b);
+
+  const timeline: RecapTimelineSegment[] = [];
+  for (let i = 0; i < orderedBoundaries.length - 1; i += 1) {
+    const intervalStart = orderedBoundaries[i];
+    const intervalEnd = orderedBoundaries[i + 1];
+    if (intervalEnd <= intervalStart) continue;
+
+    const covering = clipped
+      .filter((segment) => segment.startMs < intervalEnd && segment.endMs > intervalStart)
+      .sort((a, b) => b.priority - a.priority || b.startMs - a.startMs);
+
+    const winner = covering[0];
+    if (!winner) {
+      timeline.push({ type: "idle", startMs: intervalStart, endMs: intervalEnd, label: "Idle" });
+      continue;
+    }
+
+    if (winner.type === "production") {
+      timeline.push({
+        type: "production",
+        startMs: intervalStart,
+        endMs: intervalEnd,
+        workOrderId: winner.workOrderId,
+        sku: winner.sku,
+        label: winner.label,
+      });
+      continue;
+    }
+    if (winner.type === "mold-change") {
+      timeline.push({
+        type: "mold-change",
+        startMs: intervalStart,
+        endMs: intervalEnd,
+        fromMoldId: winner.fromMoldId,
+        toMoldId: winner.toMoldId,
+        durationSec: Math.max(0, Math.trunc((intervalEnd - intervalStart) / 1000)),
+        label: winner.label,
+      });
+      continue;
+    }
+
+    timeline.push({
+      type: winner.type,
+      startMs: intervalStart,
+      endMs: intervalEnd,
+      reason: winner.reason,
+      durationSec: Math.max(0, Math.trunc((intervalEnd - intervalStart) / 1000)),
+      label: winner.label,
+    });
+  }
+
+  const merged: RecapTimelineSegment[] = [];
+  for (const segment of timeline) {
+    const prev = merged[merged.length - 1];
+    if (!prev || !isEquivalent(prev, segment) || prev.endMs !== segment.startMs) {
+      merged.push(segment);
+      continue;
+    }
+    prev.endMs = segment.endMs;
+    if (prev.type === "mold-change") prev.durationSec = Math.max(0, Math.trunc((prev.endMs - prev.startMs) / 1000));
+    if (prev.type === "macrostop" || prev.type === "microstop" || prev.type === "slow-cycle") {
+      prev.durationSec = Math.max(0, Math.trunc((prev.endMs - prev.startMs) / 1000));
+    }
+  }
+
+  const response: RecapTimelineResponse = {
+    range: {
+      start: start.toISOString(),
+      end: end.toISOString(),
+    },
+    segments: merged,
+  };
+
+  return NextResponse.json(response);
+}

app/page.tsx

@@ -1,5 +1,5 @@
 import { redirect } from "next/navigation";
 
 export default function Home() {
-  redirect("/machines");
+  redirect("/recap");
 }

components/layout/Sidebar.tsx

@@ -30,13 +30,13 @@ type NavItem = {
 };
 
 const items: NavItem[] = [
+  { href: "/recap", labelKey: "nav.recap", icon: Sunrise },
   { href: "/overview", labelKey: "nav.overview", icon: LayoutGrid },
   { href: "/machines", labelKey: "nav.machines", icon: Wrench },
   { href: "/reports", labelKey: "nav.reports", icon: BarChart3 },
   { href: "/alerts", labelKey: "nav.alerts", icon: Bell },
   { href: "/financial", labelKey: "nav.financial", icon: DollarSign, ownerOnly: true },
   { href: "/downtime", labelKey: "nav.downtime", icon: BarChart3 },
-  { href: "/recap", labelKey: "nav.recap", icon: Sunrise },
 ];
 const settingsItem: NavItem = { href: "/settings", labelKey: "nav.settings", icon: Settings };
 

components/recap/RecapProductionBySku.tsx

@@ -17,7 +17,8 @@ export default function RecapProductionBySku({ rows }: Props) {
         <div className="text-sm text-zinc-400">{t("recap.empty.production")}</div>
       ) : (
         <div className="space-y-2">
-          <div className="grid grid-cols-5 gap-2 border-b border-white/10 pb-2 text-xs uppercase tracking-wide text-zinc-400">
+          <div className="grid grid-cols-6 gap-2 border-b border-white/10 pb-2 text-xs uppercase tracking-wide text-zinc-400">
+            <div>Maquina</div>
             <div>SKU</div>
             <div>{t("recap.production.good")}</div>
             <div>{t("recap.production.scrap")}</div>
@@ -27,7 +28,8 @@ export default function RecapProductionBySku({ rows }: Props) {
           {rows.slice(0, 8).map((row) => {
             const pct = row.progressPct == null ? "--" : `${Math.round(row.progressPct)}%`;
             return (
-              <div key={row.sku} className="grid grid-cols-5 gap-2 text-sm text-zinc-200">
+              <div key={`${row.machineName}:${row.sku}`} className="grid grid-cols-6 gap-2 text-sm text-zinc-200">
+                <div className="truncate text-zinc-400">{row.machineName}</div>
                 <div className="truncate">{row.sku}</div>
                 <div>{row.good}</div>
                 <div className={row.scrap > 0 ? "text-red-400" : "text-zinc-200"}>{row.scrap}</div>

components/recap/RecapTimeline.tsx

@@ -0,0 +1,84 @@
+"use client";
+
+import type { RecapTimelineSegment } from "@/lib/recap/types";
+
+type Props = {
+  rangeStart: string;
+  rangeEnd: string;
+  segments: RecapTimelineSegment[];
+  locale: string;
+};
+
+const COLORS: Record<RecapTimelineSegment["type"], string> = {
+  production: "bg-emerald-500 text-emerald-50",
+  "mold-change": "bg-blue-400 text-blue-950",
+  macrostop: "bg-red-500 text-red-50",
+  microstop: "bg-orange-500 text-orange-50",
+  "slow-cycle": "bg-amber-500 text-amber-950",
+  idle: "bg-zinc-600 text-zinc-100",
+};
+
+function fmtTime(valueMs: number, locale: string) {
+  return new Date(valueMs).toLocaleTimeString(locale, { hour: "2-digit", minute: "2-digit" });
+}
+
+function fmtDuration(startMs: number, endMs: number) {
+  const totalMin = Math.max(0, Math.round((endMs - startMs) / 60000));
+  if (totalMin < 60) return `${totalMin}m`;
+  const h = Math.floor(totalMin / 60);
+  const m = totalMin % 60;
+  return `${h}h ${m}m`;
+}
+
+export default function RecapTimeline({ rangeStart, rangeEnd, segments, locale }: Props) {
+  const startMs = new Date(rangeStart).getTime();
+  const endMs = new Date(rangeEnd).getTime();
+  const totalMs = Math.max(1, endMs - startMs);
+
+  const bars: RecapTimelineSegment[] = [];
+  const dots: Array<{ leftPct: number; segment: RecapTimelineSegment }> = [];
+
+  for (const segment of segments) {
+    const widthPct = ((segment.endMs - segment.startMs) / totalMs) * 100;
+    const leftPct = ((segment.startMs - startMs) / totalMs) * 100;
+    if (widthPct < 1) {
+      if (segment.type !== "idle" && leftPct > 0.5 && leftPct < 99.5) {
+        dots.push({ leftPct, segment });
+      }
+    } else {
+      bars.push(segment);
+    }
+  }
+
+  return (
+    <div className="mb-4 rounded-2xl border border-white/10 bg-black/40 p-3">
+      <div className="mb-2 text-xs uppercase tracking-wide text-zinc-400">Timeline 24h</div>
+      <div className="relative">
+        <div className="flex h-12 w-full overflow-hidden rounded-xl border border-white/10">
+          {bars.map((segment) => {
+            const widthPct = ((segment.endMs - segment.startMs) / totalMs) * 100;
+            const title = `${segment.type} · ${fmtTime(segment.startMs, locale)}-${fmtTime(segment.endMs, locale)} · ${fmtDuration(segment.startMs, segment.endMs)}${segment.label ? ` · ${segment.label}` : ""}`;
+            return (
+              <div
+                key={`${segment.type}:${segment.startMs}:${segment.endMs}:${segment.label}`}
+                className={`flex items-center justify-center truncate px-1 text-xs font-medium ${COLORS[segment.type]}`}
+                style={{ width: `${widthPct}%` }}
+                title={title}
+              >
+                {widthPct >= 6 ? segment.label : ""}
+              </div>
+            );
+          })}
+        </div>
+        {dots.map(({ leftPct, segment }) => (
+          <div
+            key={`dot:${segment.type}:${segment.startMs}:${segment.endMs}`}
+            className={`absolute top-1/2 h-2 w-2 -translate-x-1/2 -translate-y-1/2 rounded-full border border-black/30 ${COLORS[segment.type].split(" ")[0]}`}
+            style={{ left: `${Math.max(0.3, Math.min(99.7, leftPct))}%` }}
+            title={`${segment.type} · ${fmtTime(segment.startMs, locale)}-${fmtTime(segment.endMs, locale)} · ${fmtDuration(segment.startMs, segment.endMs)}`}
+          />
+        ))}
+      </div>
+    </div>
+  );
+}

lib/financial/impact.ts

@@ -244,6 +244,7 @@ export async function computeFinancialImpact(params: FinancialImpactParams): Pro
 
   for (const ev of events) {
     const eventType = String(ev.eventType ?? "").toLowerCase();
+    if (eventType === "mold-change") continue;
     const { blob, inner } = parseBlob(ev.data);
     const status = String(blob?.status ?? inner?.status ?? "").toLowerCase();
     const severity = String(ev.severity ?? "").toLowerCase();

lib/recap/getRecapData.ts

@@ -26,7 +26,7 @@ const WEEKDAY_KEY_MAP: Record<string, ShiftOverrideDay> = {
 const STOP_TYPES = new Set(["microstop", "macrostop"]);
 const STOP_STATUS = new Set(["STOP", "DOWN", "OFFLINE"]);
 const CACHE_TTL_SEC = 180;
-const MOLD_IDLE_MIN = 10;
+const MOLD_LOOKBACK_MS = 14 * 24 * 60 * 60 * 1000;
 
 function safeNum(value: unknown) {
   if (typeof value === "number" && Number.isFinite(value)) return value;
@@ -37,6 +37,32 @@ function safeNum(value: unknown) {
   return null;
 }
 
+function normalizeToken(value: unknown) {
+  return String(value ?? "").trim();
+}
+
+function workOrderKey(value: unknown) {
+  const token = normalizeToken(value);
+  return token ? token.toUpperCase() : "";
+}
+
+function skuKey(value: unknown) {
+  const token = normalizeToken(value);
+  return token ? token.toUpperCase() : "";
+}
+
+function dedupeByKey<T>(rows: T[], keyFn: (row: T) => string) {
+  const seen = new Set<string>();
+  const out: T[] = [];
+  for (const row of rows) {
+    const key = keyFn(row);
+    if (seen.has(key)) continue;
+    seen.add(key);
+    out.push(row);
+  }
+  return out;
+}
+
 function toIso(value?: Date | null) {
   return value ? value.toISOString() : null;
 }
@@ -134,6 +160,18 @@ function normalizeShiftAlias(shift?: string | null) {
 }
 
 function eventDurationSec(data: unknown) {
+  const inner = extractEventData(data);
+  return (
+    safeNum(inner.stoppage_duration_seconds) ??
+    safeNum(inner.stop_duration_seconds) ??
+    safeNum(inner.duration_seconds) ??
+    safeNum(inner.duration_sec) ??
+    safeNum(inner.durationSeconds) ??
+    0
+  );
+}
+
+function extractEventData(data: unknown) {
   let blob = data;
   if (typeof blob === "string") {
     try {
@@ -148,14 +186,26 @@ function eventDurationSec(data: unknown) {
     typeof innerCandidate === "object" && innerCandidate !== null
       ? (innerCandidate as Record<string, unknown>)
       : {};
+  return inner;
+}
 
-  return (
+function eventStatus(data: unknown) {
-    safeNum(inner.stoppage_duration_seconds) ??
+  const inner = extractEventData(data);
-    safeNum(inner.stop_duration_seconds) ??
+  return String(inner.status ?? "").trim().toLowerCase();
-    safeNum(inner.duration_seconds) ??
+}
-    safeNum(record?.durationSeconds) ??
+
-    0
+function eventIncidentKey(data: unknown, eventType: string, ts: Date) {
-  );
+  const inner = extractEventData(data);
+  const direct = String(inner.incidentKey ?? inner.incident_key ?? "").trim();
+  if (direct) return direct;
+  const startMs = safeNum(inner.start_ms) ?? safeNum(inner.startMs);
+  if (startMs != null) return `${eventType}:${Math.trunc(startMs)}`;
+  return `${eventType}:${ts.getTime()}`;
+}
+
+function moldStartMs(data: unknown, fallbackTs: Date) {
+  const inner = extractEventData(data);
+  return Math.trunc(safeNum(inner.start_ms) ?? safeNum(inner.startMs) ?? fallbackTs.getTime());
 }
 
 function avg(sum: number, count: number) {
@@ -193,12 +243,14 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
   if (!machines.length) {
     return {
       range: { start: params.start.toISOString(), end: params.end.toISOString() },
+      availableShifts: [],
       machines: [],
     };
   }
 
   const machineIds = machines.map((m) => m.id);
-  const [settings, shifts, cyclesRaw, kpisRaw, eventsRaw, reasonsRaw, workOrdersRaw, hbRangeRaw, hbLatestRaw] =
+  const moldStartLookback = new Date(params.end.getTime() - MOLD_LOOKBACK_MS);
+  const [settings, shifts, cyclesRaw, kpisRaw, eventsRaw, reasonsRaw, workOrdersRaw, hbRangeRaw, hbLatestRaw, moldEventsRaw] =
     await Promise.all([
       prisma.orgSettings.findUnique({
         where: { orgId: params.orgId },
@@ -218,6 +270,7 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
         select: {
           machineId: true,
           ts: true,
+          cycleCount: true,
           workOrderId: true,
           sku: true,
           goodDelta: true,
@@ -233,6 +286,13 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
         select: {
           machineId: true,
           ts: true,
+          workOrderId: true,
+          sku: true,
+          good: true,
+          scrap: true,
+          goodParts: true,
+          scrapParts: true,
+          cycleCount: true,
           oee: true,
           availability: true,
           performance: true,
@@ -257,6 +317,7 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
           orgId: params.orgId,
           machineId: { in: machineIds },
           kind: "downtime",
+          reasonCode: { not: "MOLD_CHANGE" },
           capturedAt: { gte: params.start, lte: params.end },
         },
         select: {
@@ -312,6 +373,20 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
           status: true,
         },
       }),
+      prisma.machineEvent.findMany({
+        where: {
+          orgId: params.orgId,
+          machineId: { in: machineIds },
+          eventType: "mold-change",
+          ts: { gte: moldStartLookback, lte: params.end },
+        },
+        orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+        select: {
+          machineId: true,
+          ts: true,
+          data: true,
+        },
+      }),
     ]);
 
   const timeZone = settings?.timezone || "UTC";
@@ -333,13 +408,13 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
   const hbRange = targetShiftName ? hbRangeRaw.filter((row) => inTargetShift(row.ts)) : hbRangeRaw;
 
   const cyclesByMachine = new Map<string, typeof cycles>();
-  const cyclesAllByMachine = new Map<string, typeof cyclesRaw>();
   const kpisByMachine = new Map<string, typeof kpis>();
   const eventsByMachine = new Map<string, typeof events>();
   const reasonsByMachine = new Map<string, typeof reasons>();
   const workOrdersByMachine = new Map<string, typeof workOrdersRaw>();
   const hbRangeByMachine = new Map<string, typeof hbRange>();
   const hbLatestByMachine = new Map(hbLatestRaw.map((row) => [row.machineId, row]));
+  const moldEventsByMachine = new Map<string, typeof moldEventsRaw>();
 
   for (const row of cycles) {
     const list = cyclesByMachine.get(row.machineId) ?? [];
@@ -347,12 +422,6 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
     cyclesByMachine.set(row.machineId, list);
   }
 
-  for (const row of cyclesRaw) {
-    const list = cyclesAllByMachine.get(row.machineId) ?? [];
-    list.push(row);
-    cyclesAllByMachine.set(row.machineId, list);
-  }
-
   for (const row of kpis) {
     const list = kpisByMachine.get(row.machineId) ?? [];
     list.push(row);
@@ -383,49 +452,227 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
     hbRangeByMachine.set(row.machineId, list);
   }
 
+  for (const row of moldEventsRaw) {
+    const list = moldEventsByMachine.get(row.machineId) ?? [];
+    list.push(row);
+    moldEventsByMachine.set(row.machineId, list);
+  }
+
   const machineRows: RecapMachine[] = machines.map((machine) => {
     const machineCycles = cyclesByMachine.get(machine.id) ?? [];
-    const machineCyclesAll = cyclesAllByMachine.get(machine.id) ?? [];
     const machineKpis = kpisByMachine.get(machine.id) ?? [];
     const machineEvents = eventsByMachine.get(machine.id) ?? [];
     const machineReasons = reasonsByMachine.get(machine.id) ?? [];
     const machineWorkOrders = workOrdersByMachine.get(machine.id) ?? [];
     const machineHbRange = hbRangeByMachine.get(machine.id) ?? [];
     const latestHb = hbLatestByMachine.get(machine.id) ?? null;
+    const machineMoldEvents = moldEventsByMachine.get(machine.id) ?? [];
 
-    const targetBySku = new Map<string, number>();
+    const dedupedCycles = dedupeByKey(
-    for (const wo of machineWorkOrders) {
+      machineCycles,
-      if (!wo.sku || wo.targetQty == null) continue;
+      (cycle) =>
-      targetBySku.set(wo.sku, (targetBySku.get(wo.sku) ?? 0) + Number(wo.targetQty));
+        `${cycle.ts.getTime()}:${safeNum(cycle.cycleCount) ?? "na"}:${workOrderKey(cycle.workOrderId)}:${skuKey(cycle.sku)}:${safeNum(cycle.goodDelta) ?? "na"}:${safeNum(cycle.scrapDelta) ?? "na"}`
+    );
+    const dedupedKpis = dedupeByKey(
+      machineKpis,
+      (kpi) =>
+        `${kpi.ts.getTime()}:${workOrderKey(kpi.workOrderId)}:${skuKey(kpi.sku)}:${safeNum(kpi.goodParts) ?? safeNum(kpi.good) ?? "na"}:${safeNum(kpi.scrapParts) ?? safeNum(kpi.scrap) ?? "na"}:${safeNum(kpi.cycleCount) ?? "na"}`
+    );
+    const machineWorkOrdersSorted = [...machineWorkOrders].sort(
+      (a, b) => b.updatedAt.getTime() - a.updatedAt.getTime()
+    );
+
+    const targetBySku = new Map<string, { sku: string; target: number }>();
+    for (const wo of machineWorkOrdersSorted) {
+      const sku = normalizeToken(wo.sku);
+      const target = safeNum(wo.targetQty);
+      if (!sku || target == null || target <= 0) continue;
+      const key = skuKey(sku);
+      const current = targetBySku.get(key);
+      if (current) {
+        current.target += Math.max(0, Math.trunc(target));
+      } else {
+        targetBySku.set(key, { sku, target: Math.max(0, Math.trunc(target)) });
+      }
     }
 
-    const skuMap = new Map<string, { sku: string; good: number; scrap: number; target: number | null }>();
+    type SkuAggregate = {
+      machineName: string;
+      sku: string;
+      good: number;
+      scrap: number;
+      target: number | null;
+    };
+    const skuMap = new Map<string, SkuAggregate>();
+    const rangeByWorkOrder = new Map<string, { goodParts: number; scrapParts: number; firstTs: Date | null; lastTs: Date | null }>();
+    const kpiLatestByWorkOrder = new Map<string, { good: number; scrap: number; ts: Date; sku: string | null }>();
+    let latestTelemetry: { ts: Date; workOrderId: string | null; sku: string | null } | null = null;
     let goodParts = 0;
     let scrapParts = 0;
 
-    for (const cycle of machineCycles) {
+    const ensureSkuRow = (skuInput: string | null) => {
-      const sku = cycle.sku || "N/A";
+      const skuToken = normalizeToken(skuInput) || "N/A";
-      const good = safeNum(cycle.goodDelta) ?? 0;
+      const key = skuKey(skuToken);
-      const scrap = safeNum(cycle.scrapDelta) ?? 0;
+      const existing = skuMap.get(key);
-      goodParts += good;
+      if (existing) return existing;
-      scrapParts += scrap;
+      const target = targetBySku.get(key)?.target ?? null;
-
+      const created: SkuAggregate = {
-      const row = skuMap.get(sku) ?? {
+        machineName: machine.name,
-        sku,
+        sku: skuToken,
         good: 0,
         scrap: 0,
-        target: targetBySku.has(sku) ? targetBySku.get(sku) ?? null : null,
+        target,
       };
-      row.good += good;
+      skuMap.set(key, created);
-      row.scrap += scrap;
+      return created;
-      skuMap.set(sku, row);
+    };
+
+    type KpiRangeAggregate = {
+      workOrderId: string | null;
+      sku: string | null;
+      minGood: number | null;
+      maxGood: number | null;
+      minScrap: number | null;
+      maxScrap: number | null;
+      firstTs: Date | null;
+      lastTs: Date | null;
+    };
+    const kpiRanges = new Map<string, KpiRangeAggregate>();
+
+    for (const kpi of dedupedKpis) {
+      if (!latestTelemetry || kpi.ts > latestTelemetry.ts) {
+        latestTelemetry = {
+          ts: kpi.ts,
+          workOrderId: normalizeToken(kpi.workOrderId) || null,
+          sku: normalizeToken(kpi.sku) || null,
+        };
+      }
+
+      const workOrderId = normalizeToken(kpi.workOrderId) || null;
+      const sku = normalizeToken(kpi.sku) || null;
+      const goodCounterRaw = safeNum(kpi.goodParts) ?? safeNum(kpi.good);
+      const scrapCounterRaw = safeNum(kpi.scrapParts) ?? safeNum(kpi.scrap);
+      const goodCounter = goodCounterRaw != null ? Math.max(0, Math.trunc(goodCounterRaw)) : null;
+      const scrapCounter = scrapCounterRaw != null ? Math.max(0, Math.trunc(scrapCounterRaw)) : null;
+
+      const woKey = workOrderKey(workOrderId);
+      if (woKey) {
+        const existingLatest = kpiLatestByWorkOrder.get(woKey);
+        if (!existingLatest || kpi.ts > existingLatest.ts) {
+          kpiLatestByWorkOrder.set(woKey, {
+            good: goodCounter ?? 0,
+            scrap: scrapCounter ?? 0,
+            ts: kpi.ts,
+            sku,
+          });
+        }
+      }
+
+      if ((goodCounter == null && scrapCounter == null) || (!workOrderId && !sku)) continue;
+
+      const key = `${woKey || "__none"}::${skuKey(sku) || "__none"}`;
+      const current = kpiRanges.get(key) ?? {
+        workOrderId,
+        sku,
+        minGood: null,
+        maxGood: null,
+        minScrap: null,
+        maxScrap: null,
+        firstTs: null,
+        lastTs: null,
+      };
+
+      if (goodCounter != null) {
+        current.minGood = current.minGood == null ? goodCounter : Math.min(current.minGood, goodCounter);
+        current.maxGood = current.maxGood == null ? goodCounter : Math.max(current.maxGood, goodCounter);
+      }
+      if (scrapCounter != null) {
+        current.minScrap = current.minScrap == null ? scrapCounter : Math.min(current.minScrap, scrapCounter);
+        current.maxScrap = current.maxScrap == null ? scrapCounter : Math.max(current.maxScrap, scrapCounter);
+      }
+      if (!current.firstTs || kpi.ts < current.firstTs) current.firstTs = kpi.ts;
+      if (!current.lastTs || kpi.ts > current.lastTs) current.lastTs = kpi.ts;
+      kpiRanges.set(key, current);
     }
 
+    if (kpiRanges.size > 0) {
+      for (const agg of kpiRanges.values()) {
+        const rangeGood = Math.max(0, (agg.maxGood ?? 0) - (agg.minGood ?? agg.maxGood ?? 0));
+        const rangeScrap = Math.max(0, (agg.maxScrap ?? 0) - (agg.minScrap ?? agg.maxScrap ?? 0));
+        const skuRow = ensureSkuRow(agg.sku);
+        skuRow.good += rangeGood;
+        skuRow.scrap += rangeScrap;
+        goodParts += rangeGood;
+        scrapParts += rangeScrap;
+
+        const woKey = workOrderKey(agg.workOrderId);
+        if (!woKey) continue;
+        const existing = rangeByWorkOrder.get(woKey) ?? {
+          goodParts: 0,
+          scrapParts: 0,
+          firstTs: null,
+          lastTs: null,
+        };
+        existing.goodParts += rangeGood;
+        existing.scrapParts += rangeScrap;
+        if (agg.firstTs && (!existing.firstTs || agg.firstTs < existing.firstTs)) existing.firstTs = agg.firstTs;
+        if (agg.lastTs && (!existing.lastTs || agg.lastTs > existing.lastTs)) existing.lastTs = agg.lastTs;
+        rangeByWorkOrder.set(woKey, existing);
+      }
+    } else {
+      for (const cycle of dedupedCycles) {
+        if (!latestTelemetry || cycle.ts > latestTelemetry.ts) {
+          latestTelemetry = {
+            ts: cycle.ts,
+            workOrderId: normalizeToken(cycle.workOrderId) || null,
+            sku: normalizeToken(cycle.sku) || null,
+          };
+        }
+        const skuRow = ensureSkuRow(normalizeToken(cycle.sku) || null);
+        const good = Math.max(0, Math.trunc(safeNum(cycle.goodDelta) ?? 0));
+        const scrap = Math.max(0, Math.trunc(safeNum(cycle.scrapDelta) ?? 0));
+        skuRow.good += good;
+        skuRow.scrap += scrap;
+        goodParts += good;
+        scrapParts += scrap;
+
+        const woKey = workOrderKey(cycle.workOrderId);
+        if (!woKey) continue;
+        const existing = rangeByWorkOrder.get(woKey) ?? {
+          goodParts: 0,
+          scrapParts: 0,
+          firstTs: null,
+          lastTs: null,
+        };
+        existing.goodParts += good;
+        existing.scrapParts += scrap;
+        if (!existing.firstTs || cycle.ts < existing.firstTs) existing.firstTs = cycle.ts;
+        if (!existing.lastTs || cycle.ts > existing.lastTs) existing.lastTs = cycle.ts;
+        rangeByWorkOrder.set(woKey, existing);
+      }
+    }
+
+    const openWorkOrders = machineWorkOrdersSorted.filter(
+      (wo) => String(wo.status).toUpperCase() !== "COMPLETED"
+    );
+    for (const wo of openWorkOrders) {
+      ensureSkuRow(normalizeToken(wo.sku) || null);
+    }
+    if (latestTelemetry?.sku) ensureSkuRow(latestTelemetry.sku);
+
     const bySku = [...skuMap.values()]
       .map((row) => {
+        const target = row.target ?? targetBySku.get(skuKey(row.sku))?.target ?? null;
         const produced = row.good + row.scrap;
-        const progressPct = row.target && row.target > 0 ? round2((produced / row.target) * 100) : null;
+        const progressPct = target && target > 0 ? round2((produced / target) * 100) : null;
-        return { ...row, progressPct };
+        return {
+          machineName: row.machineName,
+          sku: row.sku,
+          good: row.good,
+          scrap: row.scrap,
+          target,
+          progressPct,
+        };
       })
       .sort((a, b) => b.good - a.good);
 
@@ -438,7 +685,7 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
     let qualitySum = 0;
     let qualityCount = 0;
 
-    for (const kpi of machineKpis) {
+    for (const kpi of dedupedKpis) {
       const oee = safeNum(kpi.oee);
       const availability = safeNum(kpi.availability);
       const performance = safeNum(kpi.performance);
@@ -508,29 +755,13 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
       ongoingStopMin = round2(Math.max(0, (params.end.getTime() - downStart.getTime()) / 60000));
     }
 
-    const cyclesByWorkOrder = new Map<
+    const completed = machineWorkOrdersSorted
-      string,
-      { goodParts: number; firstTs: Date | null; lastTs: Date | null }
-    >();
-    for (const cycle of machineCycles) {
-      if (!cycle.workOrderId) continue;
-      const current = cyclesByWorkOrder.get(cycle.workOrderId) ?? {
-        goodParts: 0,
-        firstTs: null,
-        lastTs: null,
-      };
-      current.goodParts += safeNum(cycle.goodDelta) ?? 0;
-      if (!current.firstTs || cycle.ts < current.firstTs) current.firstTs = cycle.ts;
-      if (!current.lastTs || cycle.ts > current.lastTs) current.lastTs = cycle.ts;
-      cyclesByWorkOrder.set(cycle.workOrderId, current);
-    }
-
-    const completed = machineWorkOrders
       .filter((wo) => String(wo.status).toUpperCase() === "COMPLETED")
       .filter((wo) => wo.updatedAt >= params.start && wo.updatedAt <= params.end)
       .map((wo) => {
-        const progress = cyclesByWorkOrder.get(wo.workOrderId) ?? {
+        const progress = rangeByWorkOrder.get(workOrderKey(wo.workOrderId)) ?? {
           goodParts: 0,
+          scrapParts: 0,
           firstTs: null,
           lastTs: null,
         };
@@ -547,25 +778,53 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
       })
       .sort((a, b) => b.goodParts - a.goodParts);
 
-    const activeWo = machineWorkOrders.find((wo) => String(wo.status).toUpperCase() !== "COMPLETED") ?? null;
+    const telemetryWorkOrderKey = workOrderKey(latestTelemetry?.workOrderId);
+    const matchedTelemetryWo = telemetryWorkOrderKey
+      ? openWorkOrders.find((wo) => workOrderKey(wo.workOrderId) === telemetryWorkOrderKey) ?? null
+      : null;
+    const activeWo = matchedTelemetryWo ?? openWorkOrders[0] ?? null;
+    const activeWorkOrderId =
+      normalizeToken(latestTelemetry?.workOrderId) || normalizeToken(activeWo?.workOrderId) || null;
+    const activeWorkOrderSku =
+      normalizeToken(latestTelemetry?.sku) || normalizeToken(activeWo?.sku) || null;
+    const activeWorkOrderKey = workOrderKey(activeWorkOrderId);
+    const activeTargetSource =
+      activeWorkOrderKey
+        ? machineWorkOrdersSorted.find((wo) => workOrderKey(wo.workOrderId) === activeWorkOrderKey) ?? activeWo
+        : activeWo;
 
     let activeProgressPct: number | null = null;
     let activeStartedAt: string | null = null;
-    if (activeWo) {
+    if (activeWorkOrderId) {
-      const progress = cyclesByWorkOrder.get(activeWo.workOrderId);
+      const rangeProgress = activeWorkOrderKey ? rangeByWorkOrder.get(activeWorkOrderKey) : null;
-      const produced = (progress?.goodParts ?? 0) + (machineCycles
+      const cumulativeProgress = activeWorkOrderKey ? kpiLatestByWorkOrder.get(activeWorkOrderKey) : null;
-        .filter((row) => row.workOrderId === activeWo.workOrderId)
+      const producedForProgress = cumulativeProgress
-        .reduce((sum, row) => sum + (safeNum(row.scrapDelta) ?? 0), 0));
+        ? cumulativeProgress.good + cumulativeProgress.scrap
-      if (activeWo.targetQty && activeWo.targetQty > 0) {
+        : (rangeProgress?.goodParts ?? 0) + (rangeProgress?.scrapParts ?? 0);
-        activeProgressPct = round2((produced / activeWo.targetQty) * 100);
+      const targetQty = safeNum(activeTargetSource?.targetQty);
+      if (targetQty && targetQty > 0) {
+        activeProgressPct = round2((producedForProgress / targetQty) * 100);
       }
-      activeStartedAt = toIso(progress?.firstTs ?? activeWo.createdAt);
+      activeStartedAt = toIso(rangeProgress?.firstTs ?? activeWo?.createdAt ?? latestTelemetry?.ts ?? null);
     }
 
-    const cutoffTs = new Date(params.end.getTime() - MOLD_IDLE_MIN * 60000);
+    const moldActiveByIncident = new Map<string, number>();
-    const hasRecentCycle = machineCyclesAll.some((cycle) => cycle.ts >= cutoffTs && cycle.ts <= params.end);
+    for (const event of machineMoldEvents) {
-    const moldChangeInProgress =
+      const key = eventIncidentKey(event.data, "mold-change", event.ts);
-      !!activeWo && String(activeWo.status).toUpperCase() === "PENDING" && !hasRecentCycle;
+      const status = eventStatus(event.data);
+      if (status === "resolved") {
+        moldActiveByIncident.delete(key);
+        continue;
+      }
+      if (status === "active" || !status) {
+        moldActiveByIncident.set(key, moldStartMs(event.data, event.ts));
+      }
+    }
+    let moldChangeStartMs: number | null = null;
+    for (const startMs of moldActiveByIncident.values()) {
+      if (moldChangeStartMs == null || startMs > moldChangeStartMs) moldChangeStartMs = startMs;
+    }
+    const moldChangeInProgress = moldChangeStartMs != null;
 
     let uptimePct: number | null = null;
     if (machineHbRange.length) {
@@ -584,7 +843,7 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
       production: {
         goodParts,
         scrapParts,
-        totalCycles: machineCycles.length,
+        totalCycles: dedupedCycles.length,
         bySku,
       },
       oee: {
@@ -601,15 +860,16 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
       },
       workOrders: {
         completed,
-        active: activeWo
+        active: activeWorkOrderId
           ? {
-              id: activeWo.workOrderId,
+              id: activeWorkOrderId,
-              sku: activeWo.sku,
+              sku: activeWorkOrderSku,
               progressPct: activeProgressPct,
               startedAt: activeStartedAt,
             }
           : null,
         moldChangeInProgress,
+        moldChangeStartMs,
       },
       heartbeat: {
         lastSeenAt: toIso(latestTs),
@@ -623,6 +883,10 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
       start: params.start.toISOString(),
       end: params.end.toISOString(),
     },
+    availableShifts: orderedEnabledShifts.map((shift, idx) => ({
+      id: `shift${idx + 1}`,
+      name: shift.name,
+    })),
     machines: machineRows,
   };
 }

lib/recap/types.ts

@@ -1,4 +1,5 @@
 export type RecapSkuRow = {
+  machineName: string;
   sku: string;
   good: number;
   scrap: number;
@@ -46,6 +47,7 @@ export type RecapMachine = {
       startedAt: string | null;
     } | null;
     moldChangeInProgress: boolean;
+    moldChangeStartMs: number | null;
   };
   heartbeat: {
     lastSeenAt: string | null;
@@ -53,11 +55,56 @@ export type RecapMachine = {
   };
 };
 
+export type RecapTimelineSegment =
+  | {
+      type: "production";
+      startMs: number;
+      endMs: 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;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "idle";
+      startMs: number;
+      endMs: number;
+      label: string;
+    };
+
+export type RecapTimelineResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  segments: RecapTimelineSegment[];
+};
+
 export type RecapResponse = {
   range: {
     start: string;
     end: string;
   };
+  availableShifts: Array<{
+    id: string;
+    name: string;
+  }>;
   machines: RecapMachine[];
 };