changes

app/(app)/machines/[machineId]/MachineDetailClient.tsx

@@ -221,6 +221,16 @@ const WORK_ORDER_TEMPLATE_HEADERS = [
   "Active Cavities",
 ] as const;
 
+const WORK_ORDER_TEMPLATE_EXAMPLE_ROW = [
+  "*borra esta fila al subir excel)",
+  "SKU-12345",
+  35,
+  10000,
+  "MOLD-01",
+  8,
+  8,
+] as const;
+
 function normalizeKey(value: string) {
   return value.toLowerCase().replace(/[^a-z0-9]/g, "");
 }
@@ -654,7 +664,10 @@ export default function MachineDetailClient() {
   async function downloadWorkOrderTemplate() {
     const xlsx = await import("xlsx");
     const wb = xlsx.utils.book_new();
-    const ws = xlsx.utils.aoa_to_sheet([Array.from(WORK_ORDER_TEMPLATE_HEADERS)]);
+    const ws = xlsx.utils.aoa_to_sheet([
+      Array.from(WORK_ORDER_TEMPLATE_HEADERS),
+      Array.from(WORK_ORDER_TEMPLATE_EXAMPLE_ROW),
+    ]);
     xlsx.utils.book_append_sheet(wb, ws, "Work Orders");
     const wbout = xlsx.write(wb, { bookType: "xlsx", type: "array" });
     const blob = new Blob([wbout], {

app/(app)/reports/ReportsCharts.tsx

@@ -21,7 +21,7 @@ type SimpleTooltipProps<T> = {
   label?: string | number;
 };
 
-type ChartPoint = { ts: string; label: string; value: number };
+type ChartPoint = { ts: string; label: string; value: number | null };
 type CycleHistogramRow = {
   label: string;
   count: number;
@@ -135,7 +135,14 @@ export default function ReportsCharts({
                       "OEE",
                     ]}
                   />
-                  <Line type="monotone" dataKey="value" stroke="#34d399" dot={false} strokeWidth={2} />
+                  <Line
+                    type="linear"
+                    dataKey="value"
+                    stroke="#34d399"
+                    dot={false}
+                    strokeWidth={2}
+                    connectNulls={false}
+                  />
                 </LineChart>
               </ResponsiveContainer>
             ) : (

app/(app)/reports/ReportsPageClient.tsx

@@ -29,7 +29,7 @@ type ReportDowntime = {
   oeeDropCount: number;
 };
 
-type ReportTrendPoint = { t: string; v: number };
+type ReportTrendPoint = { t: string; v: number | null };
 
 type ReportPayload = {
   summary: ReportSummary;
@@ -78,6 +78,31 @@ function downsample<T>(rows: T[], max: number) {
   return rows.filter((_, idx) => idx % step === 0);
 }
 
+function downsampleTrendPreserveGaps(rows: ReportTrendPoint[], max: number) {
+  if (rows.length <= max) return rows;
+  const step = Math.ceil(rows.length / max);
+  const picked = new Set<number>();
+
+  picked.add(0);
+  picked.add(rows.length - 1);
+  for (let idx = 0; idx < rows.length; idx += step) picked.add(idx);
+
+  // Keep both sides of null/non-null transitions so chart gaps remain visible.
+  for (let idx = 1; idx < rows.length; idx += 1) {
+    const prevIsNull = rows[idx - 1]?.v == null;
+    const currIsNull = rows[idx]?.v == null;
+    if (prevIsNull !== currIsNull) {
+      picked.add(idx - 1);
+      picked.add(idx);
+    }
+  }
+
+  return [...picked]
+    .sort((a, b) => a - b)
+    .map((idx) => rows[idx])
+    .filter((row): row is ReportTrendPoint => row != null);
+}
+
 function formatTickLabel(ts: string, range: RangeKey) {
   const d = new Date(ts);
   if (Number.isNaN(d.getTime())) return ts;
@@ -107,7 +132,7 @@ function ReportsChartsSkeleton() {
 }
 
 function buildCsv(report: ReportPayload, t: Translator) {
-  const rows = new Map<string, Record<string, string | number>>();
+  const rows = new Map<string, Record<string, string | number | null>>();
   const addSeries = (series: ReportTrendPoint[], key: string) => {
     for (const p of series) {
       const row = rows.get(p.t) ?? { timestamp: p.t };
@@ -414,7 +439,7 @@ export default function ReportsPageClient({
 
   const oeeSeries = useMemo(() => {
     const rows = trend?.oee ?? [];
-    const trimmed = downsample(rows, 600);
+    const trimmed = downsampleTrendPreserveGaps(rows, 600);
     return trimmed.map((p) => ({
       ts: p.t,
       label: formatTickLabel(p.t, range),

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

@@ -3,6 +3,13 @@ import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
 import { coerceDowntimeRange, rangeToStart } from "@/lib/analytics/downtimeRange";
 import type { Prisma } from "@prisma/client";
+import {
+  applyDowntimeFilters,
+  loadDowntimeShiftContext,
+  normalizeMicrostopLtMin,
+  normalizeShiftFilter,
+  resolvePlannedFilter,
+} from "@/lib/analytics/downtimeFilters";
 
 const bad = (status: number, error: string) =>
   NextResponse.json({ ok: false, error }, { status });
@@ -26,6 +33,9 @@ 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 planned = resolvePlannedFilter(url.searchParams.get("planned"), includeMoldChange);
+  const shift = normalizeShiftFilter(url.searchParams.get("shift"));
+  const microstopLtMin = normalizeMicrostopLtMin(url.searchParams.get("microstopLtMin"));
 
   const limitRaw = url.searchParams.get("limit");
   const limit = Math.min(Math.max(Number(limitRaw || 200), 1), 500);
@@ -50,7 +60,6 @@ export async function GET(req: Request) {
     orgId,
     kind: "downtime",
     episodeId: { not: null },
-    ...(includeMoldChange ? {} : { reasonCode: { not: "MOLD_CHANGE" } }),
     capturedAt: {
       gte: start,
       ...(beforeDate ? { lt: beforeDate } : {}),
@@ -59,10 +68,11 @@ export async function GET(req: Request) {
     ...(reasonCode ? { reasonCode } : {}),
   };
 
-  const rows = await prisma.reasonEntry.findMany({
+  const scanTake = Math.min(Math.max(limit * 8, 1000), 5000);
+  const rowsRaw = await prisma.reasonEntry.findMany({
     where,
     orderBy: { capturedAt: "desc" },
-    take: limit,
+    take: scanTake,
     select: {
       id: true,
       episodeId: true,
@@ -80,6 +90,14 @@ export async function GET(req: Request) {
     },
   });
 
+  const shiftContext = shift === "all" ? null : await loadDowntimeShiftContext(orgId);
+  const rows = applyDowntimeFilters(rowsRaw, {
+    planned,
+    shift,
+    microstopLtMin,
+    shiftContext,
+  }).slice(0, limit);
+
   const events = rows.map((r) => {
     const startAt = r.capturedAt;
     const endAt =
@@ -116,7 +134,11 @@ export async function GET(req: Request) {
   });
 
   const nextBefore =
-    events.length > 0 ? events[events.length - 1]?.capturedAt ?? null : null;
+    events.length > 0
+      ? events[events.length - 1]?.capturedAt ?? null
+      : rowsRaw.length > 0
+      ? toISO(rowsRaw[rowsRaw.length - 1]?.capturedAt)
+      : null;
 
   return NextResponse.json({
     ok: true,
@@ -125,6 +147,9 @@ export async function GET(req: Request) {
     start,
     machineId: machineId ?? null,
     reasonCode: reasonCode ?? null,
+    planned,
+    shift,
+    microstopLtMin,
     includeMoldChange,
     limit,
     before: before ?? null,

app/api/analytics/pareto/route.ts

@@ -2,6 +2,13 @@ import { NextResponse } from "next/server";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
 import { coerceDowntimeRange, rangeToStart } from "@/lib/analytics/downtimeRange";
+import {
+  applyDowntimeFilters,
+  loadDowntimeShiftContext,
+  normalizeMicrostopLtMin,
+  normalizeShiftFilter,
+  resolvePlannedFilter,
+} from "@/lib/analytics/downtimeFilters";
 
 const bad = (status: number, error: string) =>
   NextResponse.json({ ok: false, error }, { status });
@@ -21,6 +28,9 @@ 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";
+  const planned = resolvePlannedFilter(url.searchParams.get("planned"), includeMoldChange);
+  const shift = normalizeShiftFilter(url.searchParams.get("shift"));
+  const microstopLtMin = normalizeMicrostopLtMin(url.searchParams.get("microstopLtMin"));
 
   if (kind !== "downtime" && kind !== "scrap" && kind !== "planned-downtime") {
     return bad(400, "Invalid kind (downtime|scrap|planned-downtime)");
@@ -35,41 +45,82 @@ export async function GET(req: Request) {
     if (!m) return bad(404, "Machine not found");
   }
 
-  // ✅ Scope by orgId (+ machineId if provided)
+  let itemsRaw: { reasonCode: string; reasonLabel: string; value: number; count: number }[] = [];
-  const grouped = await prisma.reasonEntry.groupBy({
-    by: ["reasonCode", "reasonLabel"],
-    where: {
-      orgId,
-      ...(machineId ? { machineId } : {}),
-      kind: kind === "planned-downtime" ? "downtime" : kind,
-      ...(kind === "downtime" && !includeMoldChange ? { reasonCode: { not: "MOLD_CHANGE" } } : {}),
-      ...(kind === "planned-downtime" ? { reasonCode: "MOLD_CHANGE" } : {}),
-      capturedAt: { gte: start },
-    },
-    _sum: {
-      durationSeconds: true,
-      scrapQty: true,
-    },
-    _count: { _all: true },
-  });
 
-  const itemsRaw = grouped
+  if (kind === "downtime" || kind === "planned-downtime") {
-    .map((g) => {
+    const baseRows = await prisma.reasonEntry.findMany({
-      const value =
+      where: {
-        kind === "downtime" || kind === "planned-downtime"
+        orgId,
-          ? Math.round(((g._sum.durationSeconds ?? 0) / 60) * 10) / 10 // minutes, 1 decimal
+        ...(machineId ? { machineId } : {}),
-          : g._sum.scrapQty ?? 0;
+        kind: "downtime",
+        capturedAt: { gte: start },
+      },
+      select: {
+        reasonCode: true,
+        reasonLabel: true,
+        durationSeconds: true,
+        capturedAt: true,
+        meta: true,
+        episodeId: true,
+      },
+    });
 
-      return {
+    const effectivePlanned = kind === "planned-downtime" ? "planned" : planned;
+    const shiftContext = shift === "all" ? null : await loadDowntimeShiftContext(orgId);
+    const filteredRows = applyDowntimeFilters(baseRows, {
+      planned: effectivePlanned,
+      shift,
+      microstopLtMin,
+      shiftContext,
+    });
+
+    const grouped = new Map<string, { reasonCode: string; reasonLabel: string; durationSeconds: number; count: number }>();
+    for (const row of filteredRows) {
+      const key = `${row.reasonCode}:::${row.reasonLabel ?? row.reasonCode}`;
+      const slot =
+        grouped.get(key) ??
+        {
+          reasonCode: row.reasonCode,
+          reasonLabel: row.reasonLabel ?? row.reasonCode,
+          durationSeconds: 0,
+          count: 0,
+        };
+      slot.durationSeconds += Math.max(0, row.durationSeconds ?? 0);
+      slot.count += 1;
+      grouped.set(key, slot);
+    }
+
+    itemsRaw = [...grouped.values()]
+      .map((g) => ({
+        reasonCode: g.reasonCode,
+        reasonLabel: g.reasonLabel,
+        value: Math.round((g.durationSeconds / 60) * 10) / 10,
+        count: g.count,
+      }))
+      .filter((x) => x.value > 0 || x.count > 0);
+  } else {
+    // Scrap path unchanged.
+    const grouped = await prisma.reasonEntry.groupBy({
+      by: ["reasonCode", "reasonLabel"],
+      where: {
+        orgId,
+        ...(machineId ? { machineId } : {}),
+        kind,
+        capturedAt: { gte: start },
+      },
+      _sum: { scrapQty: true },
+      _count: { _all: true },
+    });
+
+    itemsRaw = grouped
+      .map((g) => ({
         reasonCode: g.reasonCode,
         reasonLabel: g.reasonLabel ?? g.reasonCode,
-        value,
+        value: g._sum.scrapQty ?? 0,
         count: g._count._all,
-      };
+      }))
-    })
+      .filter((x) => 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);
 
@@ -111,6 +162,9 @@ export async function GET(req: Request) {
     orgId,
     machineId: machineId ?? null,
     kind,
+    planned: kind === "downtime" ? planned : kind === "planned-downtime" ? "planned" : "all",
+    shift,
+    microstopLtMin,
     includeMoldChange,
     range,       // ✅ now defined correctly
     start,       // ✅ now defined correctly

app/api/ingest/event/route.ts

@@ -517,6 +517,14 @@ export async function POST(req: Request) {
     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" || finalType === "mold-change"){
+      const fallbackIncidentKey =
+        clampText(
+          evData.incidentKey ??
+            dataObj.incidentKey ??
+            evDowntime?.incidentKey ??
+            evReason?.incidentKey,
+          128
+        ) ?? null;
       const moldIncidentKey =
         clampText(evData.incidentKey ?? dataObj.incidentKey, 128) ??
         (numberFrom(evData.start_ms ?? dataObj.start_ms) != null
@@ -533,7 +541,7 @@ export async function POST(req: Request) {
               detailLabel: "Cambio molde",
               reasonCode: "MOLD_CHANGE",
               reasonText: "Cambio molde",
-              incidentKey: moldIncidentKey ?? row.id,
+              incidentKey: moldIncidentKey ?? fallbackIncidentKey ?? row.id,
             } as Record<string, unknown>)
           :
         ({
@@ -544,7 +552,7 @@ export async function POST(req: Request) {
           detailLabel: "Unclassified",
           reasonCode: "UNCLASSIFIED",
           reasonText: "Unclassified",
-          incidentKey: row.id,
+          incidentKey: fallbackIncidentKey ?? row.id,
         } as Record<string, unknown>));
 
       const inferredKind: ReasonCatalogKind =
@@ -554,10 +562,18 @@ export async function POST(req: Request) {
       const resolved = resolveReason(reasonRaw, inferredKind, reasonCatalog, reasonCatalog.version);
 
       if (resolved.reasonCode) {
+        const continuityIncidentKey =
+          inferredKind === "downtime"
+            ? clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey ?? fallbackIncidentKey, 128) ?? row.id
+            : null;
+        const reasonMetaIncidentKey =
+          inferredKind === "downtime"
+            ? continuityIncidentKey
+            : clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128);
         const reasonId =
           clampText(reasonRaw.reasonId, 128) ??
           (inferredKind === "downtime"
-            ? `evt:${machine.id}:downtime:${clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id}`
+            ? `evt:${machine.id}:downtime:${continuityIncidentKey ?? row.id}`
             : `evt:${machine.id}:scrap:${clampText(reasonRaw.scrapEntryId, 128) ?? row.id}`);
 
         const workOrderId =
@@ -577,7 +593,7 @@ export async function POST(req: Request) {
             source: "ingest:event",
             eventId: row.id,
             eventType: row.eventType,
-            incidentKey: clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128),
+            incidentKey: reasonMetaIncidentKey,
             anomalyType:
               clampText(evRecord.anomalyType, 64) ??
               clampText(evDowntime?.anomalyType, 64) ??
@@ -595,7 +611,7 @@ export async function POST(req: Request) {
         };
 
         if (inferredKind === "downtime") {
-          const incidentKey = clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id;
+          const incidentKey = continuityIncidentKey ?? row.id;
           const durationSeconds =
             numberFrom(evDowntime?.durationSeconds) ??
             numberFrom(evData.duration_sec) ??
@@ -641,7 +657,7 @@ export async function POST(req: Request) {
                   source: "ingest:event",
                   eventId: row.id,
                   eventType: row.eventType,
-                  incidentKey: clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128),
+                  incidentKey: reasonMetaIncidentKey,
                   anomalyType:
                     clampText(evRecord.anomalyType, 64) ??
                     clampText(evDowntime?.anomalyType, 64) ??

app/api/reports/route.ts

@@ -47,6 +47,10 @@ function safeNum(v: unknown) {
   return typeof v === "number" && Number.isFinite(v) ? v : null;
 }
 
+function isProductionSnapshot(trackingEnabled: unknown, productionStarted: unknown) {
+  return trackingEnabled === true && productionStarted === true;
+}
+
 function toMs(value?: Date | null) {
   return value ? value.getTime() : 0;
 }
@@ -137,6 +141,8 @@ export async function GET(req: NextRequest) {
       good: true,
       scrap: true,
       target: true,
+      trackingEnabled: true,
+      productionStarted: true,
       machineId: true,
     },
   });
@@ -151,7 +157,9 @@ export async function GET(req: NextRequest) {
   let qualSum = 0;
   let qualCount = 0;
 
+  // OEE-family summaries are production-only to avoid mixing downtime/off windows.
   for (const k of kpiRows) {
+    if (!isProductionSnapshot(k.trackingEnabled, k.productionStarted)) continue;
     if (safeNum(k.oee) != null) {
       oeeSum += Number(k.oee);
       oeeCount += 1;
@@ -274,7 +282,7 @@ export async function GET(req: NextRequest) {
     else if (type === "oee-drop") oeeDropCount += 1;
   }
 
-  type TrendPoint = { t: string; v: number };
+  type TrendPoint = { t: string; v: number | null };
 
   const trend: {
     oee: TrendPoint[];
@@ -292,10 +300,18 @@ export async function GET(req: NextRequest) {
 
   for (const k of kpiRows) {
     const t = k.ts.toISOString();
-    if (safeNum(k.oee) != null) trend.oee.push({ t, v: Number(k.oee) });
+    if (!isProductionSnapshot(k.trackingEnabled, k.productionStarted)) {
-    if (safeNum(k.availability) != null) trend.availability.push({ t, v: Number(k.availability) });
+      // Preserve timeline gaps across non-production windows for OEE-family charting.
-    if (safeNum(k.performance) != null) trend.performance.push({ t, v: Number(k.performance) });
+      trend.oee.push({ t, v: null });
-    if (safeNum(k.quality) != null) trend.quality.push({ t, v: Number(k.quality) });
+      trend.availability.push({ t, v: null });
+      trend.performance.push({ t, v: null });
+      trend.quality.push({ t, v: null });
+    } else {
+      trend.oee.push({ t, v: safeNum(k.oee) != null ? Number(k.oee) : null });
+      trend.availability.push({ t, v: safeNum(k.availability) != null ? Number(k.availability) : null });
+      trend.performance.push({ t, v: safeNum(k.performance) != null ? Number(k.performance) : null });
+      trend.quality.push({ t, v: safeNum(k.quality) != null ? Number(k.quality) : null });
+    }
 
     const good = safeNum(k.good);
     const scrap = safeNum(k.scrap);

components/downtime/DowntimePageClient.tsx

@@ -246,18 +246,6 @@ function buildParetoFromEvents(events: ApiDowntimeEvent[]): ApiParetoRes | null
 }
 
 
-type ApiCoverageRes = {
-  ok: boolean;
-  error?: string;
-  orgId?: string;
-  machineId?: string | null;
-  range?: "24h" | "7d" | "30d";
-  start?: string;
-  receivedEpisodes?: number;
-  receivedMinutes?: number;
-  note?: string;
-};
-
 type Range = "24h" | "7d" | "30d";
 type Metric = "minutes" | "count";
 
@@ -1297,6 +1285,9 @@ export default function DowntimePageClient() {
   // client-only filters (shareable)
   const metric = ((sp.get("metric") as Metric) || "minutes") as Metric;
   const reasonCode = sp.get("reasonCode") || null;
+  const shift = (sp.get("shift") || "all").toUpperCase();
+  const planned = (sp.get("planned") as "all" | "planned" | "unplanned") || "all";
+  const microstopLtMin = sp.get("microstopLtMin") || "2";
 
   const hmDay = sp.get("hmDay");
   const hmHour = sp.get("hmHour");
@@ -1308,7 +1299,6 @@ export default function DowntimePageClient() {
 
 
   const [pareto, setPareto] = useState<ApiParetoRes | null>(null);
-  const [coverage, setCoverage] = useState<ApiCoverageRes | null>(null);
   const [loading, setLoading] = useState(true);
   const [err, setErr] = useState<string | null>(null);
   const [eventsRes, setEventsRes] = useState<ApiDowntimeEventsRes | null>(null);
@@ -1364,40 +1354,27 @@ export default function DowntimePageClient() {
         qs.set("kind", "downtime");
         qs.set("range", range);
         if (machineId) qs.set("machineId", machineId);
+        qs.set("shift", shift);
+        qs.set("planned", planned);
+        qs.set("microstopLtMin", microstopLtMin);
 
-        const [r1, r2] = await Promise.all([
+        const r1 = await fetch(`/api/analytics/pareto?${qs.toString()}`, {
-          fetch(`/api/analytics/pareto?${qs.toString()}`, {
+          cache: "no-cache",
-            cache: "no-cache",
+          credentials: "include",
-            credentials: "include",
+          signal: ac.signal,
-            signal: ac.signal,
+        });
-          }),
-          fetch(`/api/analytics/coverage?${qs.toString()}`, {
-            cache: "no-cache",
-            credentials: "include",
-            signal: ac.signal,
-          }),
-        ]);
 
         const j1raw = (await r1.json().catch(() => ({}))) as ApiParetoRes;
-        const j2 = (await r2.json().catch(() => ({}))) as ApiCoverageRes;
 
         if (!alive) return;
 
         if (!r1.ok || j1raw.ok === false) {
           setErr(j1raw?.error ?? "Failed to load pareto");
           setPareto(null);
-          setCoverage(null);
           setLoading(false);
           return;
         }
 
-        if (!r2.ok || j2.ok === false) {
-          // coverage is “nice to have” — don’t kill the page
-          setCoverage(null);
-        } else {
-          setCoverage(j2);
-        }
-
         setPareto(normalizeParetoRes(j1raw));
         setLoading(false);
       } catch (e: any) {
@@ -1412,7 +1389,7 @@ export default function DowntimePageClient() {
       alive = false;
       ac.abort();
     };
-  }, [range, machineId]);
+  }, [range, machineId, shift, planned, microstopLtMin]);
 
   useEffect(() => {
     let alive = true;
@@ -1462,6 +1439,9 @@ export default function DowntimePageClient() {
             qs.set("limit", String(eventsLimit));
             if (machineId) qs.set("machineId", machineId);
             if (reasonCode) qs.set("reasonCode", reasonCode);
+            qs.set("shift", shift);
+            qs.set("planned", planned);
+            qs.set("microstopLtMin", microstopLtMin);
             if (eventsBefore) qs.set("before", eventsBefore);
 
             const r = await fetch(`/api/analytics/downtime-events?${qs.toString()}`, {
@@ -1494,7 +1474,7 @@ export default function DowntimePageClient() {
             alive = false;
             ac.abort();
         };
-        }, [range, machineId, reasonCode, eventsLimit, eventsBefore]);
+        }, [range, machineId, reasonCode, shift, planned, microstopLtMin, eventsLimit, eventsBefore]);
 
   // Derived data
   const events = eventsRes?.events ?? [];
@@ -1582,7 +1562,7 @@ const totalDowntimeMin = paretoEffective?.totalMinutesLost ?? 0;
 
 useEffect(() => {
   setEventsBefore(null);
-}, [range, machineId, reasonCode]);
+}, [range, machineId, reasonCode, shift, planned, microstopLtMin]);
 
 const filteredEvents = useMemo(() => {
   let list = events;
@@ -1612,8 +1592,8 @@ const filteredEvents = useMemo(() => {
 
 
 
-// Use distinct episodes as "stops" (best available now)
+// Use filtered pareto totals so top filters always affect the KPI.
-const stops = coverage?.receivedEpisodes ?? totalStops;
+const stops = totalStops;
 
 // Window minutes for MTBF/Availability
 const windowMin =
@@ -1728,11 +1708,6 @@ const estImpactMxn = rate > 0 ? totalDowntimeMin * rate : 0;
   );
   
 
-    const shift = sp.get("shift") || "all";
-    const planned = (sp.get("planned") as "all" | "planned" | "unplanned") || "all";
-    const microstopLtMin = sp.get("microstopLtMin") || "2";
-    
-
     const filtersRow = (
     <div className="mt-4 flex items-center justify-between gap-4">
         {/* LEFT: range + metric + reset (never wrap) */}
@@ -2018,7 +1993,7 @@ const estImpactMxn = rate > 0 ? totalDowntimeMin * rate : 0;
             <KPI
                 label="Stops count"
                 value={fmtNum(stops, 0)}
-                sub="Distinct episodes (coverage)"
+                sub="Distinct episodes (filtered)"
                 accent="zinc"
             />
             <KPI
@@ -2247,29 +2222,25 @@ const estImpactMxn = rate > 0 ? totalDowntimeMin * rate : 0;
 
               {/* Coverage mini */}
               <div className="mt-4 rounded-2xl border border-white/10 bg-white/5 p-4">
-                <div className="text-sm font-semibold text-white">Coverage received</div>
+                <div className="text-sm font-semibold text-white">Filtered downtime summary</div>
                 <div className="mt-1 text-xs text-zinc-400">
-                  Sync health from Control Tower ingest
+                  Reflects the active range/machine/shift/planned/microstop filters
                 </div>
 
                 <div className="mt-3 grid grid-cols-2 gap-3">
                   <div className="rounded-xl border border-white/10 bg-black/20 p-3">
                     <div className="text-[11px] text-zinc-400">Episodes</div>
                     <div className="mt-1 text-base font-semibold text-white">
-                      {coverage?.receivedEpisodes != null ? fmtNum(coverage.receivedEpisodes, 0) : "—"}
+                      {fmtNum(stops, 0)}
                     </div>
                   </div>
                   <div className="rounded-xl border border-white/10 bg-black/20 p-3">
                     <div className="text-[11px] text-zinc-400">Minutes</div>
                     <div className="mt-1 text-base font-semibold text-white">
-                      {coverage?.receivedMinutes != null ? fmtNum(coverage.receivedMinutes, 1) : "—"}
+                      {fmtNum(totalDowntimeMin, 1)}
                     </div>
                   </div>
                 </div>
-
-                {coverage?.note ? (
-                  <div className="mt-3 text-[11px] text-zinc-500">{coverage.note}</div>
-                ) : null}
               </div>
             </div>
           </div>

fix4.md

@@ -0,0 +1,244 @@
+Task: Implement Control Tower changes only (no Node-RED edits), then run full verification with SQL + backfill script.
+
+Repository context:
+- Workspace root: Plastic-Dashboard
+- Target branch assumption: sandbox-main
+- Database: PostgreSQL via Prisma
+- Scope strictly limited to Control Tower code and scripts in this repo
+
+Hard constraints:
+1. Do NOT edit any Node-RED flow files or Node-RED runtime code.
+2. Do NOT change behavior outside the requested areas unless required for correctness.
+3. Preserve existing non-authoritative guard behavior for downtime reasons (PENDIENTE / UNCLASSIFIED).
+4. Run verification before and after backfill, and report results clearly.
+5. If lint/test has unrelated pre-existing failures, do not refactor unrelated modules.
+
+Implementation requirements:
+
+A) Downtime continuity fallback key fix
+File:
+- app/api/ingest/event/route.ts
+
+Goal:
+- Ensure fallback downtime reason identity/continuity uses episode continuity key (incidentKey) whenever present.
+- Use row.id only when incidentKey is truly absent.
+- Preserve guard that prevents non-authoritative values from overwriting authoritative manual reasons.
+
+Details:
+1. In the event ingestion logic where ReasonEntry payload is created for downtime-like events (including fallback UNCLASSIFIED and mold-change):
+- Derive a fallbackIncidentKey from available payload fields in this preference order:
+  - evData.incidentKey
+  - dataObj.incidentKey
+  - evDowntime?.incidentKey
+  - evReason?.incidentKey (if available)
+- Only if all are missing, fallback to row.id.
+
+2. For fallback reasonRaw objects:
+- For mold-change fallback, set incidentKey to moldIncidentKey ?? fallbackIncidentKey ?? row.id.
+- For unclassified fallback, set incidentKey to fallbackIncidentKey ?? row.id.
+
+3. Create one continuityIncidentKey (single source of truth) used consistently for:
+- downtime reasonId construction (evt:<machineId>:downtime:<continuityIncidentKey>)
+- ReasonEntry episodeId for downtime
+- meta.incidentKey in reason entry writes
+- manual-preservation guard queries by episodeId
+
+4. Keep non-authoritative guard semantics unchanged:
+- incoming non-authoritative reason should not overwrite existing authoritative reason for same episode
+- downtime-acknowledged/manual authoritative path remains preserved
+
+B) OEE trend from production-only snapshots
+File:
+- app/api/reports/route.ts
+
+Goal:
+- Build OEE trend from production-only snapshots:
+  - trackingEnabled = true
+  - productionStarted = true
+- Keep summary metrics behavior explicit and consistent with this filtering decision.
+
+Details:
+1. Include trackingEnabled and productionStarted in KPI snapshot select.
+2. Add helper like isProductionSnapshot(trackingEnabled, productionStarted).
+3. Compute OEE/Availability/Performance/Quality averages using production-only rows.
+4. For trend generation:
+- Iterate timeline in ts order.
+- For non-production snapshots, emit null points (for OEE and related KPI lines) so chart can render true gaps.
+- For production snapshots, emit actual numeric values (or null if value is missing).
+5. Keep downtime/event aggregates and cycle-based totals behavior intact unless explicitly tied to OEE production-only requirement.
+6. Keep logic explicit in code comments (short, concrete comments only where needed).
+
+C) Chart rendering behavior: no smoothing across gaps
+Files:
+- app/(app)/reports/ReportsCharts.tsx
+- app/(app)/reports/ReportsPageClient.tsx (if types/downsampling need updates)
+
+Goal:
+- OEE line interpolation must be linear.
+- Gaps must be rendered as gaps (no fake continuity through filtered/non-production windows).
+
+Details:
+1. In OEE line chart:
+- change Line type from monotone to linear
+- set connectNulls={false}
+2. Ensure frontend types allow nullable trend values for OEE points.
+3. If downsampling exists, preserve gap markers so null separators are not removed.
+- Keep null transition points when reducing point count.
+4. Ensure tooltip/value formatting handles nulls gracefully.
+
+Verification and execution steps:
+
+1) Run targeted checks first
+- run tests related to downtime guard if available:
+  - npm run test:downtime-reason-guard
+- run lint at least for changed files (or full lint if practical):
+  - npx eslint app/api/ingest/event/route.ts app/api/reports/route.ts app/(app)/reports/ReportsCharts.tsx app/(app)/reports/ReportsPageClient.tsx
+
+2) SQL Verification Pack (PRE-BACKFILL)
+Execute these exactly and capture output snapshots:
+
+A. Recent downtime reason quality mix
+SELECT
+  reasonCode,
+  COUNT(*) AS rows
+FROM "ReasonEntry"
+WHERE kind = 'downtime'
+  AND "capturedAt" >= NOW() - INTERVAL '7 days'
+GROUP BY reasonCode
+ORDER BY rows DESC;
+
+B. Episodes with conflicting reason codes
+SELECT
+  "orgId",
+  "machineId",
+  "episodeId",
+  COUNT(DISTINCT "reasonCode") AS distinct_codes,
+  MIN("capturedAt") AS first_seen,
+  MAX("capturedAt") AS last_seen
+FROM "ReasonEntry"
+WHERE kind = 'downtime'
+  AND "episodeId" IS NOT NULL
+  AND "capturedAt" >= NOW() - INTERVAL '14 days'
+GROUP BY "orgId", "machineId", "episodeId"
+HAVING COUNT(DISTINCT "reasonCode") > 1
+ORDER BY last_seen DESC
+LIMIT 200;
+
+C. Potential manual overwritten by non-authoritative check
+SELECT
+  re."orgId",
+  re."machineId",
+  re."episodeId",
+  re."reasonCode",
+  re."capturedAt",
+  re.meta
+FROM "ReasonEntry" re
+WHERE re.kind = 'downtime'
+  AND re."capturedAt" >= NOW() - INTERVAL '14 days'
+  AND re."reasonCode" IN ('PENDIENTE', 'UNCLASSIFIED')
+ORDER BY re."capturedAt" DESC
+LIMIT 200;
+
+D. Event continuity around downtime + ack
+SELECT
+  "machineId",
+  "eventType",
+  ts,
+  data->>'incidentKey' AS incident_key,
+  data->>'status' AS status,
+  data->>'is_update' AS is_update,
+  data->>'is_auto_ack' AS is_auto_ack
+FROM "MachineEvent"
+WHERE ts >= NOW() - INTERVAL '3 days'
+  AND "eventType" IN ('microstop', 'macrostop', 'downtime-acknowledged')
+ORDER BY ts DESC
+LIMIT 500;
+
+E. KPI production vs non-production counts
+SELECT
+  COALESCE("trackingEnabled", false) AS tracking_enabled,
+  COALESCE("productionStarted", false) AS production_started,
+  COUNT(*) AS rows
+FROM "MachineKpiSnapshot"
+WHERE ts >= NOW() - INTERVAL '7 days'
+GROUP BY 1,2
+ORDER BY rows DESC;
+
+F. Sharp OEE jumps in production snapshots
+WITH k AS (
+  SELECT
+    "machineId",
+    ts,
+    oee,
+    LAG(oee) OVER (PARTITION BY "machineId" ORDER BY ts) AS prev_oee
+  FROM "MachineKpiSnapshot"
+  WHERE ts >= NOW() - INTERVAL '7 days'
+    AND "trackingEnabled" = true
+    AND "productionStarted" = true
+    AND oee IS NOT NULL
+)
+SELECT
+  "machineId",
+  ts,
+  prev_oee,
+  oee,
+  ABS(oee - prev_oee) AS delta
+FROM k
+WHERE prev_oee IS NOT NULL
+  AND ABS(oee - prev_oee) >= 25
+ORDER BY delta DESC, ts DESC
+LIMIT 200;
+
+G. Trend point count comparison
+SELECT
+  'all' AS series,
+  COUNT(*) AS points
+FROM "MachineKpiSnapshot"
+WHERE ts >= NOW() - INTERVAL '24 hours'
+  AND oee IS NOT NULL
+UNION ALL
+SELECT
+  'production_only' AS series,
+  COUNT(*) AS points
+FROM "MachineKpiSnapshot"
+WHERE ts >= NOW() - INTERVAL '24 hours'
+  AND oee IS NOT NULL
+  AND "trackingEnabled" = true
+  AND "productionStarted" = true;
+
+3) Backfill run plan (must follow this order)
+A. Dry-run first:
+node scripts/backfill-downtime-reasons.mjs --dry-run --since 30d
+
+B. Review dry-run output:
+- candidates
+- sampleUpdates
+- incident distribution by machine
+- any suspicious replacements
+
+C. Apply scoped first (single machine from dry-run sample):
+node scripts/backfill-downtime-reasons.mjs --since 30d --machine-id <machine_uuid>
+
+4) SQL Verification Pack (POST-BACKFILL)
+- Re-run queries A, B, C at minimum.
+- Optionally rerun D/F/G for confidence.
+- Confirm reduction in stale PENDIENTE/UNCLASSIFIED rows where authoritative reason exists.
+- Confirm conflicting episode reason cases reduced or shifted as expected.
+
+Acceptance criteria checklist:
+- New downtime episodes retain authoritative manual reason and do not regress to PENDIENTE/UNCLASSIFIED.
+- Fallback downtime continuity now keys by incidentKey whenever available; row.id only when absent.
+- OEE trend no longer shows implausible 0/100 jumps from non-production snapshots.
+- OEE chart is linear and visually shows true gaps (no smoothing continuity across filtered windows).
+- Backfill dry-run and scoped apply outputs are captured and reasonable.
+- Post-run SQL confirms expected improvements without obvious regressions.
+
+Output format required from you:
+1. Files changed with concise reason per file.
+2. Exact diff summary for each modified file.
+3. Test/lint commands run + result.
+4. Pre-backfill SQL results (compact tables or summarized counts).
+5. Dry-run output summary (key fields + sample updates).
+6. Scoped apply command used and output summary.
+7. Post-backfill SQL delta summary (before vs after).
+8. Any blockers (env vars, DB auth, migration state, etc.) and exactly what is needed to unblock.

lib/analytics/downtimeFilters.ts

@@ -0,0 +1,204 @@
+import { prisma } from "@/lib/prisma";
+import { normalizeShiftOverrides } from "@/lib/settings";
+
+type PlannedFilter = "all" | "planned" | "unplanned";
+type ShiftFilter = "all" | "A" | "B" | "C";
+
+type ShiftLike = {
+  name: string;
+  startTime?: string | null;
+  endTime?: string | null;
+  start?: string | null;
+  end?: string | null;
+  enabled?: boolean;
+};
+
+type ShiftContext = {
+  timeZone: string;
+  shifts: ShiftLike[];
+  overrides: Record<string, ShiftLike[]> | undefined;
+};
+
+const SHIFT_ALIAS: ShiftFilter[] = ["A", "B", "C"];
+const TIME_RE = /^([01]\d|2[0-3]):([0-5]\d)$/;
+
+const WEEKDAY_KEY_MAP: Record<string, string> = {
+  Sun: "sun",
+  Mon: "mon",
+  Tue: "tue",
+  Wed: "wed",
+  Thu: "thu",
+  Fri: "fri",
+  Sat: "sat",
+};
+
+const WEEKDAY_KEYS = ["sun", "mon", "tue", "wed", "thu", "fri", "sat"] as const;
+
+function asRecord(value: unknown) {
+  return value && typeof value === "object" && !Array.isArray(value)
+    ? (value as Record<string, unknown>)
+    : null;
+}
+
+function parseTimeMinutes(value?: string | null) {
+  if (!value || !TIME_RE.test(value)) return null;
+  const [hh, mm] = value.split(":");
+  return Number(hh) * 60 + Number(mm);
+}
+
+function getLocalMinutes(ts: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      hour: "2-digit",
+      minute: "2-digit",
+      hourCycle: "h23",
+    }).formatToParts(ts);
+    const hours = Number(parts.find((p) => p.type === "hour")?.value ?? "0");
+    const minutes = Number(parts.find((p) => p.type === "minute")?.value ?? "0");
+    return hours * 60 + minutes;
+  } catch {
+    return ts.getUTCHours() * 60 + ts.getUTCMinutes();
+  }
+}
+
+function getLocalDayKey(ts: Date, timeZone: string) {
+  try {
+    const weekday = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      weekday: "short",
+    }).format(ts);
+    return WEEKDAY_KEY_MAP[weekday] ?? WEEKDAY_KEYS[ts.getUTCDay()];
+  } catch {
+    return WEEKDAY_KEYS[ts.getUTCDay()];
+  }
+}
+
+function resolveShiftAlias(context: ShiftContext, ts: Date): ShiftFilter | null {
+  const dayKey = getLocalDayKey(ts, context.timeZone);
+  const dayOverrides = context.overrides?.[dayKey];
+  const activeShifts = dayOverrides ?? context.shifts;
+  if (!activeShifts.length) return null;
+
+  const nowMin = getLocalMinutes(ts, context.timeZone);
+  let enabledOrdinal = 0;
+  for (const shift of activeShifts) {
+    if (shift.enabled === false) continue;
+    const start = parseTimeMinutes(shift.startTime ?? shift.start ?? null);
+    const end = parseTimeMinutes(shift.endTime ?? shift.end ?? null);
+    if (start == null || end == null) continue;
+
+    const alias = SHIFT_ALIAS[enabledOrdinal] ?? null;
+    enabledOrdinal += 1;
+    if (!alias) continue;
+
+    if (start <= end) {
+      if (nowMin >= start && nowMin < end) return alias;
+    } else if (nowMin >= start || nowMin < end) {
+      return alias;
+    }
+  }
+
+  return null;
+}
+
+function isMicrostopLike(row: {
+  episodeId?: string | null;
+  meta?: unknown;
+}) {
+  const episodeId = String(row.episodeId ?? "").toLowerCase();
+  if (episodeId.startsWith("microstop:")) return true;
+
+  const meta = asRecord(row.meta);
+  const anomalyType = String(meta?.anomalyType ?? "").toLowerCase();
+  if (anomalyType === "microstop") return true;
+
+  const eventType = String(meta?.eventType ?? "").toLowerCase();
+  return eventType === "microstop";
+}
+
+function normalizePlanned(raw: string | null): PlannedFilter {
+  const v = String(raw ?? "").trim().toLowerCase();
+  if (v === "planned") return "planned";
+  if (v === "unplanned") return "unplanned";
+  return "all";
+}
+
+export function resolvePlannedFilter(raw: string | null, includeMoldChange: boolean): PlannedFilter {
+  const normalized = normalizePlanned(raw);
+  if (raw != null && String(raw).trim() !== "") return normalized;
+  return includeMoldChange ? "all" : "unplanned";
+}
+
+export function normalizeShiftFilter(raw: string | null): ShiftFilter {
+  const v = String(raw ?? "").trim().toUpperCase();
+  if (v === "A" || v === "B" || v === "C") return v;
+  return "all";
+}
+
+export function normalizeMicrostopLtMin(raw: string | null) {
+  if (!raw) return null;
+  const n = Number(raw);
+  if (!Number.isFinite(n) || n <= 0) return null;
+  return n;
+}
+
+function passesPlannedFilter(reasonCode: string, planned: PlannedFilter) {
+  if (planned === "planned") return reasonCode === "MOLD_CHANGE";
+  if (planned === "unplanned") return reasonCode !== "MOLD_CHANGE";
+  return true;
+}
+
+export async function loadDowntimeShiftContext(orgId: string): Promise<ShiftContext> {
+  const [shifts, settings] = await Promise.all([
+    prisma.orgShift.findMany({
+      where: { orgId },
+      orderBy: { sortOrder: "asc" },
+      select: { name: true, startTime: true, endTime: true, enabled: true },
+    }),
+    prisma.orgSettings.findUnique({
+      where: { orgId },
+      select: { timezone: true, shiftScheduleOverridesJson: true },
+    }),
+  ]);
+
+  return {
+    timeZone: settings?.timezone || "UTC",
+    shifts,
+    overrides: normalizeShiftOverrides(settings?.shiftScheduleOverridesJson),
+  };
+}
+
+export function applyDowntimeFilters<T extends {
+  reasonCode: string;
+  capturedAt: Date;
+  durationSeconds?: number | null;
+  episodeId?: string | null;
+  meta?: unknown;
+}>(
+  rows: T[],
+  options: {
+    planned: PlannedFilter;
+    shift: ShiftFilter;
+    microstopLtMin: number | null;
+    shiftContext: ShiftContext | null;
+  }
+) {
+  return rows.filter((row) => {
+    if (!passesPlannedFilter(row.reasonCode, options.planned)) return false;
+
+    if (options.shift !== "all") {
+      if (!options.shiftContext) return false;
+      const alias = resolveShiftAlias(options.shiftContext, row.capturedAt);
+      if (alias !== options.shift) return false;
+    }
+
+    if (options.microstopLtMin != null && isMicrostopLike(row)) {
+      if (row.durationSeconds == null) return false;
+      const durationMin = row.durationSeconds / 60;
+      if (!(durationMin < options.microstopLtMin)) return false;
+    }
+
+    return true;
+  });
+}