updates

app/(app)/recap/RecapPageSkeletons.tsx

@@ -0,0 +1,30 @@
+/**
+ * Shared markup for loading states (used by `loading.tsx` and explicit `<Suspense>` in pages)
+ * so the recap UI always shows the same skeleton while server data is pending.
+ */
+export function RecapGridPageSkeleton() {
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-4 h-24 animate-pulse rounded-2xl border border-white/10 bg-black/40" />
+      <div className="grid grid-cols-1 gap-4 sm:grid-cols-2 xl:grid-cols-3">
+        {Array.from({ length: 6 }).map((_, index) => (
+          <div key={index} className="h-[220px] animate-pulse rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+    </div>
+  );
+}
+
+export function RecapDetailPageSkeleton() {
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="h-16 animate-pulse rounded-2xl border border-white/10 bg-black/40" />
+      <div className="mt-4 grid grid-cols-1 gap-3 sm:grid-cols-2 xl:grid-cols-4">
+        {Array.from({ length: 4 }).map((_, index) => (
+          <div key={index} className="h-24 animate-pulse rounded-2xl border border-white/10 bg-black/30" />
+        ))}
+      </div>
+      <div className="mt-4 h-48 animate-pulse rounded-2xl border border-white/10 bg-black/30" />
+    </div>
+  );
+}

app/(app)/recap/[machineId]/loading.tsx

@@ -1,13 +1,5 @@
+import { RecapDetailPageSkeleton } from "../RecapPageSkeletons";
+
 export default function LoadingRecapDetail() {
-  return (
+  return <RecapDetailPageSkeleton />;
-    <div className="p-4 sm:p-6">
-      <div className="h-16 animate-pulse rounded-2xl border border-white/10 bg-black/40" />
-      <div className="mt-4 grid grid-cols-1 gap-3 sm:grid-cols-2 xl:grid-cols-4">
-        {Array.from({ length: 4 }).map((_, index) => (
-          <div key={index} className="h-24 animate-pulse rounded-2xl border border-white/10 bg-black/30" />
-        ))}
-      </div>
-      <div className="mt-4 h-48 animate-pulse rounded-2xl border border-white/10 bg-black/30" />
-    </div>
-  );
 }

app/(app)/recap/[machineId]/page.tsx

@@ -1,9 +1,11 @@
+import { Suspense } from "react";
 import { notFound, redirect } from "next/navigation";
 import { requireSession } from "@/lib/auth/requireSession";
 import { getRecapMachineDetailCached, parseRecapDetailRangeInput } from "@/lib/recap/redesign";
+import { RecapDetailPageSkeleton } from "../RecapPageSkeletons";
 import RecapDetailClient from "./RecapDetailClient";
 
-export default async function RecapMachineDetailPage({
+async function RecapDetailData({
   params,
   searchParams,
 }: {
@@ -33,3 +35,17 @@ export default async function RecapMachineDetailPage({
     />
   );
 }
+
+export default function RecapMachineDetailPage({
+  params,
+  searchParams,
+}: {
+  params: Promise<{ machineId: string }>;
+  searchParams?: Promise<Record<string, string | string[] | undefined>>;
+}) {
+  return (
+    <Suspense fallback={<RecapDetailPageSkeleton />}>
+      <RecapDetailData params={params} searchParams={searchParams} />
+    </Suspense>
+  );
+}

app/(app)/recap/loading.tsx

@@ -1,12 +1,5 @@
+import { RecapGridPageSkeleton } from "./RecapPageSkeletons";
+
 export default function LoadingRecapGrid() {
-  return (
+  return <RecapGridPageSkeleton />;
-    <div className="p-4 sm:p-6">
-      <div className="mb-4 h-24 animate-pulse rounded-2xl border border-white/10 bg-black/40" />
-      <div className="grid grid-cols-1 gap-4 sm:grid-cols-2 xl:grid-cols-3">
-        {Array.from({ length: 6 }).map((_, index) => (
-          <div key={index} className="h-[220px] animate-pulse rounded-2xl border border-white/10 bg-white/5" />
-        ))}
-      </div>
-    </div>
-  );
 }

app/(app)/recap/page.tsx

@@ -1,9 +1,11 @@
+import { Suspense } from "react";
 import { redirect } from "next/navigation";
 import { requireSession } from "@/lib/auth/requireSession";
 import { getRecapSummaryCached } from "@/lib/recap/redesign";
 import RecapGridClient from "./RecapGridClient";
+import { RecapGridPageSkeleton } from "./RecapPageSkeletons";
 
-export default async function RecapPage() {
+async function RecapGridData() {
   const session = await requireSession();
   if (!session) redirect("/login?next=/recap");
 
@@ -14,3 +16,11 @@ export default async function RecapPage() {
 
   return <RecapGridClient initialData={initialData} />;
 }
+
+export default function RecapPage() {
+  return (
+    <Suspense fallback={<RecapGridPageSkeleton />}>
+      <RecapGridData />
+    </Suspense>
+  );
+}

app/api/ingest/cycle/route.ts

@@ -172,11 +172,35 @@ export async function POST(req: Request) {
     };
   });
 
+  const result = await prisma.machineCycle.createMany({
+    data: rows,
+    skipDuplicates: true,
+  });
+
   if (rows.length === 1) {
-    const row = await prisma.machineCycle.create({ data: rows[0] });
+    const row = await prisma.machineCycle.findFirst({
-    return NextResponse.json({ ok: true, id: row.id, ts: row.ts });
+      where: {
+        orgId: machine.orgId,
+        machineId: machine.id,
+        ts: rows[0].ts,
+        cycleCount: rows[0].cycleCount ?? null,
+      },
+      orderBy: { createdAt: "asc" },
+      select: { id: true, ts: true },
+    });
+    return NextResponse.json({
+      ok: true,
+      id: row?.id,
+      ts: row?.ts,
+      inserted: result.count,
+      duplicate: result.count === 0,
+    });
   }
 
-  const result = await prisma.machineCycle.createMany({ data: rows });
+  return NextResponse.json({
-  return NextResponse.json({ ok: true, count: result.count });
+    ok: true,
+    inserted: result.count,
+    requested: rows.length,
+    count: result.count,
+  });
 }

app/api/ingest/event/route.ts

@@ -80,6 +80,15 @@ function numberFrom(value: unknown) {
   }
   return null;
 }
+function parseSeqToBigInt(value: unknown): bigint | null {
+  if (value === null || value === undefined) return null;
+  if (typeof value === "number") {
+    if (!Number.isInteger(value) || value < 0) return null;
+    return BigInt(value);
+  }
+  if (typeof value === "string" && /^\d+$/.test(value)) return BigInt(value);
+  return null;
+}
 
 function canonicalText(value: unknown) {
   return String(value ?? "")
@@ -262,6 +271,8 @@ export async function POST(req: Request) {
 
   const machine = await getMachineAuth(String(machineId), apiKey);
   if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  const bodySeq = parseSeqToBigInt(bodyRecord.seq);
+  const bodySchemaVersion = clampText(bodyRecord.schemaVersion, 16);
   const orgSettings = await prisma.orgSettings.findUnique({
     where: { orgId: machine.orgId },
     select: { stoppageMultiplier: true, macroStoppageMultiplier: true, defaultsJson: true },
@@ -410,35 +421,90 @@ export async function POST(req: Request) {
     const activeWorkOrder = asRecord(evRecord.activeWorkOrder);
     const dataActiveWorkOrder = asRecord(evData.activeWorkOrder);
 
-    const row = await prisma.machineEvent.create({
+    // ✨ Cada evento puede traer su propio seq, o usar el del payload raíz
-      data: {
+    const evSeq = 
-        orgId: machine.orgId,
+      parseSeqToBigInt(evRecord.seq) ??
-        machineId: machine.id,
+      parseSeqToBigInt(evData.seq) ??
-        ts,
+      bodySeq;
-        topic: clampText(evRecord.topic ?? finalType, 64) ?? finalType,
+
-        eventType: finalType,
+    const evSchemaVersion = 
-        severity: sev,
+      clampText(evRecord.schemaVersion, 16) ??
-        requiresAck: !!evRecord.requires_ack,
+      bodySchemaVersion;
-        title,
+
-        description,
+    const eventData = {
-        data: toJsonValue(dataObj),
+      orgId: machine.orgId,
-        workOrderId:
+      machineId: machine.id,
-          clampText(evRecord.work_order_id, 64) ??
+      schemaVersion: evSchemaVersion,
-          clampText(evData.work_order_id, 64) ??
+      seq: evSeq,
-          clampText(activeWorkOrder?.id, 64) ??
+      ts,
-          clampText(dataActiveWorkOrder?.id, 64) ??
+      topic: clampText(evRecord.topic ?? finalType, 64) ?? finalType,
-          null,
+      eventType: finalType,
-        sku:
+      severity: sev,
-          clampText(evRecord.sku, 64) ??
+      requiresAck: !!evRecord.requires_ack,
-          clampText(evData.sku, 64) ??
+      title,
-          clampText(activeWorkOrder?.sku, 64) ??
+      description,
-          clampText(dataActiveWorkOrder?.sku, 64) ??
+      data: toJsonValue(dataObj),
-          null,
+      workOrderId:
-      },
+        clampText(evRecord.work_order_id, 64) ??
+        clampText(evData.work_order_id, 64) ??
+        clampText(activeWorkOrder?.id, 64) ??
+        clampText(dataActiveWorkOrder?.id, 64) ??
+        null,
+      sku:
+        clampText(evRecord.sku, 64) ??
+        clampText(evData.sku, 64) ??
+        clampText(activeWorkOrder?.sku, 64) ??
+        clampText(dataActiveWorkOrder?.sku, 64) ??
+        null,
+    };
+
+    // ✨ Idempotente: si ya existe (mismo orgId+machineId+seq), no inserta
+    const insertResult = await prisma.machineEvent.createMany({
+      data: [eventData],
+      skipDuplicates: true,
     });
 
+    // ✨ Buscar la fila (la recién creada o la duplicada existente)
+    let row;
+    if (evSeq != null) {
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          seq: evSeq,
+        },
+        orderBy: { ts: "asc" },
+      });
+    } else {
+      // Sin seq, buscar por ts (fallback compatibilidad con eventos viejos)
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          ts,
+          eventType: finalType,
+        },
+        orderBy: { ts: "desc" },
+      });
+    }
+
+    if (!row) {
+      skipped.push({ reason: "row_not_found_after_insert", seq: evSeq?.toString() });
+      continue;
+    }
+
+    const wasDuplicate = insertResult.count === 0;
+
+    // Si fue duplicado, no procesar reasonEntry ni alertas (ya se hicieron antes)
+    if (wasDuplicate) {
+      created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+      continue;  // ✨ saltar el resto del procesamiento
+    }
+
     created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
 
+    
+
     // If the payload carries a `reason`, create the corresponding ReasonEntry.
     // 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){

app/api/ingest/event/route.ts.bak

@@ -0,0 +1,670 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { getMachineAuth } from "@/lib/machineAuthCache";
+import { z } from "zod";
+import { evaluateAlertsForEvent } from "@/lib/alerts/engine";
+import { toJsonValue } from "@/lib/prismaJson";
+import {
+  findCatalogReason,
+  loadFallbackReasonCatalog,
+  normalizeReasonCatalog,
+  toReasonCode,
+  type ReasonCatalog,
+  type ReasonCatalogKind,
+} from "@/lib/reasonCatalog";
+
+const normalizeType = (t: unknown) =>
+  String(t ?? "")
+    .trim()
+    .toLowerCase()
+    .replace(/_/g, "-");
+
+function asRecord(value: unknown): Record<string, unknown> | null {
+  if (!value || typeof value !== "object" || Array.isArray(value)) return null;
+  return value as Record<string, unknown>;
+}
+
+const CANON_TYPE: Record<string, string> = {
+  // Node-RED
+  "production-stopped": "stop",
+  "oee-drop": "oee-drop",
+  "quality-spike": "quality-spike",
+  "predictive-oee-decline": "predictive-oee-decline",
+  "performance-degradation": "performance-degradation",
+
+  // legacy / synonyms
+  "macroparo": "macrostop",
+  "macro-stop": "macrostop",
+  "microparo": "microstop",
+  "micro-paro": "microstop",
+  "down": "stop",
+  "downtime-acknowledged": "downtime-acknowledged",
+  "scrap-manual-entry": "scrap-manual-entry",
+  "mold-change": "mold-change",
+};
+
+const ALLOWED_TYPES = new Set([
+  "slow-cycle",
+  "microstop",
+  "macrostop",
+  "offline",
+  "error",
+  "oee-drop",
+  "quality-spike",
+  "performance-degradation",
+  "predictive-oee-decline",
+  "downtime-acknowledged",
+  "scrap-manual-entry",
+  "mold-change",
+]);
+
+const machineIdSchema = z.string().uuid();
+const MAX_EVENTS = 100;
+
+//when no cycle time is configed
+const DEFAULT_MACROSTOP_SEC = 300;
+
+
+function clampText(value: unknown, maxLen: number) {
+  if (value === null || value === undefined) return null;
+  const text = String(value).trim().replace(/[\u0000-\u001f\u007f]/g, "");
+  if (!text) return null;
+  return text.length > maxLen ? text.slice(0, maxLen) : text;
+}
+
+function numberFrom(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 parseSeqToBigInt(value: unknown): bigint | null {
+  if (value === null || value === undefined) return null;
+  if (typeof value === "number") {
+    if (!Number.isInteger(value) || value < 0) return null;
+    return BigInt(value);
+  }
+  if (typeof value === "string" && /^\d+$/.test(value)) return BigInt(value);
+  return null;
+}
+
+function canonicalText(value: unknown) {
+  return String(value ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+}
+
+function parseReasonPath(rawPath: unknown) {
+  let category: string | null = null;
+  let detail: string | null = null;
+
+  if (Array.isArray(rawPath)) {
+    const first = rawPath[0];
+    const second = rawPath[1];
+    if (typeof first === "string") category = first;
+    if (typeof second === "string") detail = second;
+    if (asRecord(first)) category = clampText(first.id ?? first.label ?? first.value, 120);
+    if (asRecord(second)) detail = clampText(second.id ?? second.label ?? second.value, 120);
+  } else if (typeof rawPath === "string") {
+    const pieces = rawPath
+      .split(/>|\/|\\|\|/g)
+      .map((p) => p.trim())
+      .filter(Boolean);
+    category = pieces[0] ?? null;
+    detail = pieces[1] ?? null;
+  }
+
+  return {
+    category: clampText(category, 120),
+    detail: clampText(detail, 120),
+  };
+}
+
+function parseReasonTextPath(reasonText: unknown) {
+  const text = clampText(reasonText, 240);
+  if (!text) return { category: null as string | null, detail: null as string | null };
+  const pieces = text
+    .split(/>|\/|\\|\|/g)
+    .map((p) => p.trim())
+    .filter(Boolean);
+  return {
+    category: clampText(pieces[0] ?? null, 120),
+    detail: clampText(pieces[1] ?? null, 120),
+  };
+}
+
+function findCatalogReasonFlexible(
+  catalog: ReasonCatalog | null,
+  kind: ReasonCatalogKind,
+  categoryIdOrLabel: unknown,
+  detailIdOrLabel: unknown
+) {
+  const direct = findCatalogReason(catalog, kind, categoryIdOrLabel, detailIdOrLabel);
+  if (direct) return direct;
+  if (!catalog) return null;
+
+  const catNeedle = canonicalText(categoryIdOrLabel);
+  const detNeedle = canonicalText(detailIdOrLabel);
+  if (!catNeedle || !detNeedle) return null;
+
+  for (const category of catalog[kind] ?? []) {
+    const catMatch =
+      canonicalText(category.id) === catNeedle || canonicalText(category.label) === catNeedle;
+    if (!catMatch) continue;
+    for (const detail of category.details) {
+      const detMatch = canonicalText(detail.id) === detNeedle || canonicalText(detail.label) === detNeedle;
+      if (!detMatch) continue;
+      return {
+        categoryId: category.id,
+        categoryLabel: category.label,
+        detailId: detail.id,
+        detailLabel: detail.label,
+        reasonCode: toReasonCode(category.id, detail.id),
+        reasonLabel: `${category.label} > ${detail.label}`,
+      };
+    }
+  }
+  return null;
+}
+
+function getCatalogFromDefaults(defaultsJson: unknown) {
+  const defaults = asRecord(defaultsJson);
+  if (!defaults) return null;
+  return normalizeReasonCatalog(defaults.reasonCatalog ?? defaults.reasonCatalogData);
+}
+
+function resolveReason(
+  raw: Record<string, unknown>,
+  kind: ReasonCatalogKind,
+  catalog: ReasonCatalog | null,
+  fallbackVersion: number
+) {
+  const reasonPath = parseReasonPath(raw.reasonPath);
+  const reasonTextPath = parseReasonTextPath(raw.reasonText);
+  const categoryIdRaw = clampText(raw.categoryId ?? reasonPath.category ?? reasonTextPath.category, 64);
+  const detailIdRaw = clampText(raw.detailId ?? reasonPath.detail ?? reasonTextPath.detail, 64);
+  const fromCatalog = findCatalogReasonFlexible(catalog, kind, categoryIdRaw, detailIdRaw);
+
+  const categoryLabelRaw = clampText(raw.categoryLabel ?? reasonPath.category ?? reasonTextPath.category, 120);
+  const detailLabelRaw = clampText(raw.detailLabel ?? reasonPath.detail ?? reasonTextPath.detail, 120);
+
+  const reasonCode =
+    clampText(raw.reasonCode, 64)?.toUpperCase() ??
+    fromCatalog?.reasonCode ??
+    toReasonCode(categoryIdRaw ?? categoryLabelRaw, detailIdRaw ?? detailLabelRaw) ??
+    null;
+
+  const categoryId = fromCatalog?.categoryId ?? categoryIdRaw;
+  const detailId = fromCatalog?.detailId ?? detailIdRaw;
+  const categoryLabel = fromCatalog?.categoryLabel ?? categoryLabelRaw;
+  const detailLabel = fromCatalog?.detailLabel ?? detailLabelRaw;
+
+  const pathLabel =
+    clampText(raw.reasonText, 240) ??
+    fromCatalog?.reasonLabel ??
+    (categoryLabel && detailLabel ? `${categoryLabel} > ${detailLabel}` : null) ??
+    detailLabel ??
+    categoryLabel ??
+    reasonCode;
+
+  const catalogVersionRaw = numberFrom(raw.catalogVersion);
+  const catalogVersion = catalogVersionRaw != null ? Math.trunc(catalogVersionRaw) : fallbackVersion;
+
+  return {
+    type: kind,
+    categoryId,
+    categoryLabel,
+    detailId,
+    detailLabel,
+    reasonCode,
+    reasonLabel: pathLabel,
+    reasonText: pathLabel,
+    catalogVersion,
+  };
+}
+
+export async function POST(req: Request) {
+  const apiKey = req.headers.get("x-api-key");
+  if (!apiKey) return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
+
+  let body: unknown = await req.json().catch(() => null);
+
+  // ✅ if Node-RED sent an array as the whole body, unwrap it
+  if (Array.isArray(body)) body = body[0];
+  const bodyRecord = asRecord(body) ?? {};
+  const payloadRecord = asRecord(bodyRecord.payload) ?? {};
+
+  // ✅ accept multiple common keys
+  const machineId =
+    bodyRecord.machineId ??
+    bodyRecord.machine_id ??
+    (asRecord(bodyRecord.machine)?.id ?? null);
+  let rawEvent =
+    bodyRecord.event ??
+    bodyRecord.events ??
+    bodyRecord.anomalies ??
+    payloadRecord.event ??
+    payloadRecord.events ??
+    payloadRecord.anomalies ??
+    payloadRecord ??
+    bodyRecord.data; // sometimes "data"
+
+  const rawEventRecord = asRecord(rawEvent);
+  if (rawEventRecord?.event && typeof rawEventRecord.event === "object") rawEvent = rawEventRecord.event;
+  if (Array.isArray(rawEventRecord?.events)) rawEvent = rawEventRecord.events;
+
+  if (!machineId || !rawEvent) {
+    return NextResponse.json(
+      { ok: false, error: "Invalid payload", got: { hasMachineId: !!machineId, keys: Object.keys(bodyRecord) } },
+      { status: 400 }
+    );
+  }
+
+  if (!machineIdSchema.safeParse(String(machineId)).success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine id" }, { status: 400 });
+  }
+
+  const machine = await getMachineAuth(String(machineId), apiKey);
+  if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  const orgSettings = await prisma.orgSettings.findUnique({
+    where: { orgId: machine.orgId },
+    select: { stoppageMultiplier: true, macroStoppageMultiplier: true, defaultsJson: true },
+  });
+  const fallbackCatalog = await loadFallbackReasonCatalog();
+  const settingsCatalog = getCatalogFromDefaults(orgSettings?.defaultsJson);
+  const reasonCatalog = settingsCatalog ?? fallbackCatalog;
+
+  const defaultMicroMultiplier = Number(orgSettings?.stoppageMultiplier ?? 1.5);
+  const defaultMacroMultiplier = Math.max(
+    defaultMicroMultiplier,
+    Number(orgSettings?.macroStoppageMultiplier ?? 5)
+  );
+
+
+  // ✅ normalize to array no matter what
+  const events = Array.isArray(rawEvent) ? rawEvent : [rawEvent];
+  if (events.length > MAX_EVENTS) {
+    return NextResponse.json({ ok: false, error: "Too many events" }, { status: 400 });
+  }
+
+  const created: { id: string; ts: Date; eventType: string }[] = [];
+  const skipped: Array<Record<string, unknown>> = [];
+
+  for (const ev of events) {
+    const evRecord = asRecord(ev);
+    if (!evRecord) {
+      skipped.push({ reason: "invalid_event_object" });
+      continue;
+    }
+    const evData = asRecord(evRecord.data) ?? {};
+    // We'll re-check reason again after parsing `data` (it may be a JSON string)
+    let evReason = asRecord(evRecord.reason) ?? asRecord(evData.reason);
+    const evDowntime = asRecord(evRecord.downtime) ?? asRecord(evData.downtime);
+    // Some producers nest the reason under `downtime.reason`
+    if (!evReason) evReason = asRecord(evDowntime?.reason);
+
+    const rawType = evRecord.eventType ?? evRecord.anomaly_type ?? evRecord.topic ?? bodyRecord.topic ?? "";
+    const typ0 = normalizeType(rawType);
+    const typ = CANON_TYPE[typ0] ?? typ0;
+
+    // Determine timestamp
+    const tsMs =
+      (typeof evRecord.timestamp === "number" && evRecord.timestamp) ||
+      (typeof evData.timestamp === "number" && evData.timestamp) ||
+      (typeof evData.event_timestamp === "number" && evData.event_timestamp) ||
+      null;
+
+    const ts = tsMs ? new Date(tsMs) : new Date();
+
+    // Severity defaulting (do not skip on severity — store for audit)
+    let sev = String(evRecord.severity ?? "").trim().toLowerCase();
+    if (!sev) sev = "warning";
+
+    // Stop classification -> microstop/macrostop
+    let finalType = typ;
+    let stopSecForReason: number | null = null;
+    if (typ === "stop") {
+      const stopSec =
+        (typeof evData.stoppage_duration_seconds === "number" && evData.stoppage_duration_seconds) ||
+        (typeof evData.stop_duration_seconds === "number" && evData.stop_duration_seconds) ||
+        null;
+      stopSecForReason = stopSec != null ? Number(stopSec) : null;
+
+      if (stopSec != null) {
+        const theoretical = Number(evData.theoretical_cycle_time ?? evData.theoreticalCycleTime ?? 0) || 0;
+
+        const microMultiplier = Number(
+          evData.micro_threshold_multiplier ?? evData.threshold_multiplier ?? defaultMicroMultiplier
+        );
+        const macroMultiplier = Math.max(
+          microMultiplier,
+          Number(evData.macro_threshold_multiplier ?? defaultMacroMultiplier)
+        );
+
+        if (theoretical > 0) {
+          const macroThresholdSec = theoretical * macroMultiplier;
+          finalType = stopSec >= macroThresholdSec ? "macrostop" : "microstop";
+        } else {
+          finalType = stopSec >= DEFAULT_MACROSTOP_SEC ? "macrostop" : "microstop";
+        }
+      } else {
+        // missing duration -> conservative
+        finalType = "microstop";
+      }
+    }
+
+    if (!ALLOWED_TYPES.has(finalType)) {
+      skipped.push({ reason: "type_not_allowed", typ: finalType, sev });
+      continue;
+    }
+
+    const title =
+      clampText(evRecord.title, 160) ||
+      (finalType === "slow-cycle" ? "Slow Cycle Detected" :
+       finalType === "macrostop" ? "Macrostop Detected" :
+       finalType === "microstop" ? "Microstop Detected" :
+       "Event");
+
+    const description = clampText(evRecord.description, 1000);
+
+    // store full blob, ensure object
+    const rawData = evRecord.data ?? evRecord;
+    const parsedData = typeof rawData === "string"
+      ? (() => {
+          try {
+            return JSON.parse(rawData);
+          } catch {
+            return { raw: rawData };
+          }
+        })()
+      : rawData;
+    const dataObj: Record<string, unknown> =
+      parsedData && typeof parsedData === "object" && !Array.isArray(parsedData)
+        ? { ...(parsedData as Record<string, unknown>) }
+        : { raw: parsedData };
+    if (evRecord.status != null && dataObj.status == null) dataObj.status = evRecord.status;
+    if (evRecord.alert_id != null && dataObj.alert_id == null) dataObj.alert_id = evRecord.alert_id;
+    if (evRecord.is_update != null && dataObj.is_update == null) dataObj.is_update = evRecord.is_update;
+    if (evRecord.is_auto_ack != null && dataObj.is_auto_ack == null) dataObj.is_auto_ack = evRecord.is_auto_ack;
+    if (evReason && dataObj.reason == null) dataObj.reason = evReason;
+    if (evDowntime && dataObj.downtime == null) dataObj.downtime = evDowntime;
+
+    // If `data` was a JSON string, the earlier evReason lookup would miss it.
+    // Re-check here using the normalized object we will persist.
+    if (!evReason) evReason = asRecord(dataObj.reason);
+    if (!evReason) evReason = asRecord(asRecord(dataObj.downtime)?.reason);
+
+    // If we have a reasonText but missing ids, derive ids from the path-like string.
+    if (evReason) {
+      const hasCat = clampText((evReason as any).categoryId, 64) ?? clampText((evReason as any).categoryLabel, 120);
+      const hasDet = clampText((evReason as any).detailId, 64) ?? clampText((evReason as any).detailLabel, 120);
+      const rt = clampText((evReason as any).reasonText, 240);
+      if ((!hasCat || !hasDet) && rt) {
+        const parsed = parseReasonTextPath(rt);
+        const next = { ...evReason } as Record<string, unknown>;
+        // Preserve any explicit ids; only fill gaps.
+        if ((next as any).categoryId == null && parsed.category) next.categoryId = canonicalText(parsed.category);
+        if ((next as any).categoryLabel == null && parsed.category) next.categoryLabel = parsed.category;
+        if ((next as any).detailId == null && parsed.detail) next.detailId = canonicalText(parsed.detail);
+        if ((next as any).detailLabel == null && parsed.detail) next.detailLabel = parsed.detail;
+        evReason = next;
+      }
+    }
+
+    const activeWorkOrder = asRecord(evRecord.activeWorkOrder);
+    const dataActiveWorkOrder = asRecord(evData.activeWorkOrder);
+
+    // ✨ Cada evento puede traer su propio seq, o usar el del payload raíz
+    const evSeq = 
+      parseSeqToBigInt(evRecord.seq) ??
+      parseSeqToBigInt(evData.seq) ??
+      bodySeq;
+
+    const evSchemaVersion = 
+      clampText(evRecord.schemaVersion, 16) ??
+      bodySchemaVersion;
+
+    const eventData = {
+      orgId: machine.orgId,
+      machineId: machine.id,
+      schemaVersion: evSchemaVersion,
+      seq: evSeq,
+      ts,
+      topic: clampText(evRecord.topic ?? finalType, 64) ?? finalType,
+      eventType: finalType,
+      severity: sev,
+      requiresAck: !!evRecord.requires_ack,
+      title,
+      description,
+      data: toJsonValue(dataObj),
+      workOrderId:
+        clampText(evRecord.work_order_id, 64) ??
+        clampText(evData.work_order_id, 64) ??
+        clampText(activeWorkOrder?.id, 64) ??
+        clampText(dataActiveWorkOrder?.id, 64) ??
+        null,
+      sku:
+        clampText(evRecord.sku, 64) ??
+        clampText(evData.sku, 64) ??
+        clampText(activeWorkOrder?.sku, 64) ??
+        clampText(dataActiveWorkOrder?.sku, 64) ??
+        null,
+    };
+
+    // ✨ Idempotente: si ya existe (mismo orgId+machineId+seq), no inserta
+    const insertResult = await prisma.machineEvent.createMany({
+      data: [eventData],
+      skipDuplicates: true,
+    });
+
+    // ✨ Buscar la fila (la recién creada o la duplicada existente)
+    let row;
+    if (evSeq != null) {
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          seq: evSeq,
+        },
+        orderBy: { ts_server: "asc" },
+      });
+    } else {
+      // Sin seq, buscar por ts (fallback compatibilidad con eventos viejos)
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          ts,
+          eventType: finalType,
+        },
+        orderBy: { ts_server: "desc" },
+      });
+    }
+
+    if (!row) {
+      skipped.push({ reason: "row_not_found_after_insert", seq: evSeq?.toString() });
+      continue;
+    }
+
+    const wasDuplicate = insertResult.count === 0;
+
+    // Si fue duplicado, no procesar reasonEntry ni alertas (ya se hicieron antes)
+    if (wasDuplicate) {
+      created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+      continue;  // ✨ saltar el resto del procesamiento
+    }
+
+    created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+
+    
+
+    // If the payload carries a `reason`, create the corresponding ReasonEntry.
+    // 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" || 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",
+          detailId: "unclassified",
+          categoryLabel: "Unclassified",
+          detailLabel: "Unclassified",
+          reasonCode: "UNCLASSIFIED",
+          reasonText: "Unclassified",
+          incidentKey: row.id,
+        } as Record<string, unknown>));
+
+      const inferredKind: ReasonCatalogKind =
+        String(reasonRaw.type ?? "").toLowerCase() === "scrap" || finalType === "scrap-manual-entry"
+          ? "scrap"
+          : "downtime";
+      const resolved = resolveReason(reasonRaw, inferredKind, reasonCatalog, reasonCatalog.version);
+
+      if (resolved.reasonCode) {
+        const reasonId =
+          clampText(reasonRaw.reasonId, 128) ??
+          (inferredKind === "downtime"
+            ? `evt:${machine.id}:downtime:${clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id}`
+            : `evt:${machine.id}:scrap:${clampText(reasonRaw.scrapEntryId, 128) ?? row.id}`);
+
+        const workOrderId =
+          clampText(evRecord.work_order_id, 64) ??
+          clampText(evData.work_order_id, 64) ??
+          clampText(evRecord.workOrderId, 64) ??
+          null;
+
+        const commonWrite = {
+          reasonCode: resolved.reasonCode,
+          reasonLabel: resolved.reasonLabel ?? resolved.reasonCode,
+          reasonText: resolved.reasonText ?? null,
+          capturedAt: row.ts,
+          workOrderId,
+          schemaVersion: Math.max(1, Math.trunc(resolved.catalogVersion)),
+          meta: toJsonValue({
+            source: "ingest:event",
+            eventId: row.id,
+            eventType: row.eventType,
+            incidentKey: clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128),
+            anomalyType:
+              clampText(evRecord.anomalyType, 64) ??
+              clampText(evDowntime?.anomalyType, 64) ??
+              clampText(evRecord.anomaly_type, 64),
+            reason: {
+              type: resolved.type,
+              categoryId: resolved.categoryId,
+              categoryLabel: resolved.categoryLabel,
+              detailId: resolved.detailId,
+              detailLabel: resolved.detailLabel,
+              reasonText: resolved.reasonText,
+              catalogVersion: resolved.catalogVersion,
+            },
+          }),
+        };
+
+        if (inferredKind === "downtime") {
+          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;
+
+          await prisma.reasonEntry.upsert({
+            where: { reasonId },
+            create: {
+              orgId: machine.orgId,
+              machineId: machine.id,
+              reasonId,
+              kind: "downtime",
+              episodeId: incidentKey,
+              durationSeconds: durationSeconds != null ? Math.max(0, Math.trunc(durationSeconds)) : null,
+              episodeEndTs: episodeEndTsMs != null ? new Date(episodeEndTsMs) : null,
+              ...commonWrite,
+            },
+            update: {
+              kind: "downtime",
+              episodeId: incidentKey,
+              durationSeconds: durationSeconds != null ? Math.max(0, Math.trunc(durationSeconds)) : null,
+              episodeEndTs: episodeEndTsMs != null ? new Date(episodeEndTsMs) : null,
+              ...commonWrite,
+            },
+          });
+        } else {
+          const scrapEntryId =
+            clampText((reasonRaw as any).scrapEntryId, 128) ??
+            clampText(evRecord.id, 128) ??
+            clampText(evRecord.eventId, 128) ??
+            row.id;
+          const scrapQtyRaw =
+            numberFrom(evRecord.scrapDelta) ??
+            numberFrom(evData.scrapDelta) ??
+            numberFrom(evData.scrap_delta) ??
+            0;
+          const scrapQty = Math.max(0, Math.trunc(scrapQtyRaw));
+
+          await prisma.reasonEntry.upsert({
+            where: { reasonId },
+            create: {
+              orgId: machine.orgId,
+              machineId: machine.id,
+              reasonId,
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText((reasonRaw as any).scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+            update: {
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText((reasonRaw as any).scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+          });
+        }
+      }
+    }
+
+    try {
+      if (row.eventType !== "downtime-acknowledged" && row.eventType !== "scrap-manual-entry") {
+        await evaluateAlertsForEvent(row.id);
+      }
+    } catch (err) {
+      console.error("[alerts] evaluation failed", err);
+    }
+  }
+
+  return NextResponse.json({ ok: true, createdCount: created.length, created, skippedCount: skipped.length, skipped });
+}

app/api/ingest/heartbeat/route.ts

@@ -97,26 +97,38 @@ export async function POST(req: Request) {
     // 5) Store heartbeat
     // Keep your legacy fields, but store meta fields too.
     const tsServerNow = new Date();
-    const hb = await prisma.machineHeartbeat.create({
+    const hbRow = {
-      data: {
+      orgId,
-        orgId,
+      machineId: machine.id,
-        machineId: machine.id,
+      schemaVersion,
+      seq,
+      ts: tsDeviceDate,
+      tsServer: tsServerNow,
+      status: body.status ? String(body.status) : (body.online ? "RUN" : "STOP"),
+      message: body.message ? String(body.message) : null,
+      ip: body.ip ? String(body.ip) : null,
+      fwVersion: body.fwVersion ? String(body.fwVersion) : null,
+    };
 
-        // Phase 0 meta
+    const insertHb = await prisma.machineHeartbeat.createMany({
-        schemaVersion,
+      data: [hbRow],
-        seq,
+      skipDuplicates: true,
-        ts: tsDeviceDate,
-        tsServer: tsServerNow,
-
-        // Legacy payload compatibility
-        status: body.status ? String(body.status) : (body.online ? "RUN" : "STOP"),
-        message: body.message ? String(body.message) : null,
-        ip: body.ip ? String(body.ip) : null,
-        fwVersion: body.fwVersion ? String(body.fwVersion) : null,
-      },
     });
 
-    // Optional: update machine last seen (same as KPI)
+    const hb = await prisma.machineHeartbeat.findFirst({
+      where: {
+        orgId,
+        machineId: machine.id,
+        ts: tsDeviceDate,
+      },
+      orderBy: { tsServer: "asc" },
+    });
+
+    if (!hb) {
+      return NextResponse.json({ ok: false, error: "Server error", detail: "Heartbeat row missing" }, { status: 500 });
+    }
+
+    // Optional: update machine last seen (same as KPI) — also on duplicate HB so lastSeen is fresh
     await prisma.machine.update({
       where: { id: machine.id },
       data: {
@@ -132,6 +144,7 @@ export async function POST(req: Request) {
       id: hb.id,
       tsDevice: hb.ts,
       tsServer: hb.tsServer,
+      duplicate: insertHb.count === 0,
     });
   } catch (err: unknown) {
     const msg = err instanceof Error ? err.message : "Unknown error";

app/api/ingest/kpi/route.ts

@@ -222,44 +222,42 @@ export async function POST(req: Request) {
         : typeof woRecord.cavities === "number" && woRecord.cavities > 0
           ? woRecord.cavities
           : null;
-    // Write snapshot (ts = tsDevice; tsServer auto)
+    // Write snapshot (ts = tsDevice; tsServer auto). Idempotent on (org, machine, ts) to absorb retries.
-    const row = await prisma.machineKpiSnapshot.create({
+    const kpiData = {
-      data: {
+      orgId,
-        orgId,
+      machineId: machine.id,
-        machineId: machine.id,
+      schemaVersion,
-
+      seq,
-        // Phase 0 meta
+      ts: tsDeviceDate,
-        schemaVersion,
+      workOrderId: activeWorkOrderId || null,
-        seq,
+      sku: activeSku || null,
-        ts: tsDeviceDate, // store device-time in ts; server-time goes to ts_server
+      target: activeTargetQty,
-
+      good: good != null ? Math.trunc(good) : null,
-        // Work order fields
+      scrap: scrap != null ? Math.trunc(scrap) : null,
-        workOrderId: activeWorkOrderId || null,
+      cycleCount: snapshotCycleCount,
-        sku: activeSku || null,
+      goodParts: snapshotGoodParts,
-        target: activeTargetQty,
+      scrapParts: snapshotScrapParts,
-        good: good != null ? Math.trunc(good) : null,
+      cavities: safeCavities,
-        scrap: scrap != null ? Math.trunc(scrap) : null,
+      cycleTime: safeCycleTime,
-
+      actualCycle: typeof body.actualCycleTime === "number" ? body.actualCycleTime : null,
-        // Counters
+      availability: typeof k.availability === "number" ? k.availability : null,
-        cycleCount: snapshotCycleCount,
+      performance: typeof k.performance === "number" ? k.performance : null,
-        goodParts: snapshotGoodParts,
+      quality: typeof k.quality === "number" ? k.quality : null,
-        scrapParts: snapshotScrapParts,
+      oee: typeof k.oee === "number" ? k.oee : null,
-        cavities: safeCavities,
+      trackingEnabled: typeof body.trackingEnabled === "boolean" ? body.trackingEnabled : null,
-
+      productionStarted: typeof body.productionStarted === "boolean" ? body.productionStarted : null,
-        // Cycle times
+    };
-        cycleTime: safeCycleTime,
+    const insertKpi = await prisma.machineKpiSnapshot.createMany({
-        actualCycle: typeof body.actualCycleTime === "number" ? body.actualCycleTime : null,
+      data: [kpiData],
-
+      skipDuplicates: true,
-        // KPIs (0..100)
-        availability: typeof k.availability === "number" ? k.availability : null,
-        performance: typeof k.performance === "number" ? k.performance : null,
-        quality: typeof k.quality === "number" ? k.quality : null,
-        oee: typeof k.oee === "number" ? k.oee : null,
-
-        trackingEnabled: typeof body.trackingEnabled === "boolean" ? body.trackingEnabled : null,
-        productionStarted: typeof body.productionStarted === "boolean" ? body.productionStarted : null,
-      },
     });
+    const row = await prisma.machineKpiSnapshot.findFirst({
+      where: { orgId, machineId: machine.id, ts: tsDeviceDate },
+      orderBy: { tsServer: "asc" },
+    });
+    if (!row) {
+      return NextResponse.json({ ok: false, error: "Server error", detail: "KPI snapshot row missing" }, { status: 500 });
+    }
 
     if (activeWorkOrderId) {
       await prisma.machineWorkOrder.upsert({
@@ -330,6 +328,7 @@ export async function POST(req: Request) {
       id: row.id,
       tsDevice: row.ts,
       tsServer: row.tsServer,
+      duplicate: insertKpi.count === 0,
       trace: traceEnabled ? trace : undefined,
     });
   } catch (err: unknown) {

components/recap/RecapMachineCard.tsx

@@ -3,6 +3,7 @@
 import Link from "next/link";
 import { useEffect, useState } from "react";
 import { useI18n } from "@/lib/i18n/useI18n";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
 import type { RecapSummaryMachine, RecapTimelineResponse } from "@/lib/recap/types";
 import RecapMiniTimeline from "@/components/recap/RecapMiniTimeline";
 
@@ -42,7 +43,8 @@ export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Prop
   const timelineStart = timeline?.range.start ?? rangeStart;
   const timelineEnd = timeline?.range.end ?? rangeEnd;
   const hasTimelineData = timeline?.hasData ?? timelineSegments.length > 0;
-  const staleHeartbeat = machine.lastSeenMs == null ? true : nowMs - machine.lastSeenMs > 5 * 60 * 1000;
+  const staleHeartbeat =
+    machine.lastSeenMs == null ? true : nowMs - machine.lastSeenMs > RECAP_HEARTBEAT_STALE_MS;
 
   const lastSeenLabel =
     machine.lastActivityMin == null

components/recap/RecapProductionBySku.tsx

@@ -1,6 +1,7 @@
 "use client";
 
 import { useI18n } from "@/lib/i18n/useI18n";
+import { formatRecapProgressPercent } from "@/lib/recap/progressDisplay";
 import type { RecapSkuRow } from "@/lib/recap/types";
 
 type Props = {
@@ -8,7 +9,7 @@ type Props = {
 };
 
 export default function RecapProductionBySku({ rows }: Props) {
-  const { t } = useI18n();
+  const { t, locale } = useI18n();
 
   return (
     <div className="rounded-2xl border border-white/10 bg-black/40 p-4">
@@ -30,7 +31,8 @@ export default function RecapProductionBySku({ rows }: Props) {
             </thead>
             <tbody>
               {rows.slice(0, 10).map((row) => {
-                const progress = row.progressPct == null ? "--" : `${Math.round(row.progressPct)}%`;
+                const progress =
+                  row.progressPct == null ? "—" : formatRecapProgressPercent(row.progressPct, locale);
                 return (
                   <tr key={`${row.sku}:${row.machineName}`} className="border-b border-white/5">
                     <td className="py-2 pr-3">{row.sku}</td>

components/recap/RecapWorkOrderStatus.tsx

@@ -1,6 +1,7 @@
 "use client";
 
 import { useI18n } from "@/lib/i18n/useI18n";
+import { formatRecapProgressPercent, progressBarWidthPercent } from "@/lib/recap/progressDisplay";
 import type { RecapMachine } from "@/lib/recap/types";
 
 type Props = {
@@ -22,10 +23,13 @@ export default function RecapWorkOrderStatus({ workOrders }: Props) {
           <div className="mt-2 rounded-xl border border-white/10 bg-black/30 p-3 text-sm text-zinc-200">
             <div className="font-medium text-white">{workOrders.active.id}</div>
             <div className="text-zinc-400">SKU: {workOrders.active.sku || "--"}</div>
+            <div className="mt-1 text-xs text-zinc-300">
+              {t("recap.production.progress")}: {formatRecapProgressPercent(workOrders.active.progressPct, locale)}
+            </div>
             <div className="mt-2 h-2 rounded-full bg-white/10">
               <div
-                className="h-2 rounded-full bg-emerald-400"
+                className="h-2 rounded-full bg-emerald-400 transition-[width]"
-                style={{ width: `${Math.max(0, Math.min(100, workOrders.active.progressPct ?? 0))}%` }}
+                style={{ width: `${progressBarWidthPercent(workOrders.active.progressPct)}%` }}
               />
             </div>
             <div className="mt-2 text-xs text-zinc-400">

components/recap/RecapWorkOrders.tsx

@@ -1,6 +1,7 @@
 "use client";
 
 import { useI18n } from "@/lib/i18n/useI18n";
+import { formatRecapProgressPercent, progressBarWidthPercent } from "@/lib/recap/progressDisplay";
 import type { RecapWorkOrders as RecapWorkOrdersType } from "@/lib/recap/types";
 
 type Props = {
@@ -41,10 +42,14 @@ export default function RecapWorkOrders({ workOrders }: Props) {
             <div className="mt-2 rounded-lg border border-white/10 bg-black/20 p-3 text-sm text-zinc-200">
               <div className="font-medium text-white">{workOrders.active.id}</div>
               <div className="text-zinc-400">{t("recap.workOrders.sku")}: {workOrders.active.sku || "--"}</div>
+              <div className="mt-1 text-xs text-zinc-300">
+                {t("recap.production.progress")}:{" "}
+                {formatRecapProgressPercent(workOrders.active.progressPct, locale)}
+              </div>
               <div className="mt-2 h-2 rounded-full bg-white/10">
                 <div
-                  className="h-2 rounded-full bg-emerald-400"
+                  className="h-2 rounded-full bg-emerald-400 transition-[width]"
-                  style={{ width: `${Math.max(0, Math.min(100, workOrders.active.progressPct ?? 0))}%` }}
+                  style={{ width: `${progressBarWidthPercent(workOrders.active.progressPct)}%` }}
                 />
               </div>
               <div className="mt-2 text-xs text-zinc-400">

lib/recap/getRecapData.ts

@@ -218,6 +218,8 @@ 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 alertId = String(inner.alert_id ?? inner.alertId ?? "").trim();
+  if (alertId) return `${eventType}:${alertId}`;
   const startMs = safeNum(inner.start_ms) ?? safeNum(inner.startMs);
   if (startMs != null) return `${eventType}:${Math.trunc(startMs)}`;
   return `${eventType}:${ts.getTime()}`;
@@ -291,7 +293,7 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
   const machines = await prisma.machine.findMany({
     where: { orgId: params.orgId, ...machineFilter },
     orderBy: { name: "asc" },
-    select: { id: true, name: true, location: true },
+    select: { id: true, name: true, location: true, tsServer: true },
   });
 
   if (!machines.length) {
@@ -421,9 +423,9 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
         where: {
           orgId: params.orgId,
           machineId: { in: machineIds },
-          ts: { lte: params.end },
+          tsServer: { lte: params.end },
         },
-        orderBy: [{ machineId: "asc" }, { ts: "desc" }],
+        orderBy: [{ machineId: "asc" }, { tsServer: "desc" }],
         distinct: ["machineId"],
         select: {
           machineId: true,
@@ -814,8 +816,36 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
       );
     }
 
+    const firstProductionMsAfterMoldStart = (startMs: number) => {
+      let best: number | null = null;
+      for (const cycle of dedupedCycles) {
+        const t = cycle.ts.getTime();
+        if (t <= startMs) continue;
+        const g = safeNum(cycle.goodDelta) ?? 0;
+        const s = safeNum(cycle.scrapDelta) ?? 0;
+        if (g > 0 || s > 0) {
+          if (best == null || t < best) best = t;
+        }
+      }
+      for (const kpi of dedupedKpis) {
+        const t = kpi.ts.getTime();
+        if (t <= startMs) continue;
+        const g = safeNum(kpi.good) ?? safeNum(kpi.goodParts) ?? 0;
+        const s = safeNum(kpi.scrap) ?? safeNum(kpi.scrapParts) ?? 0;
+        if (g > 0 || s > 0) {
+          if (best == null || t < best) best = t;
+        }
+      }
+      return best;
+    };
+
     const moldActiveByIncident = new Map<string, number>();
     for (const event of machineMoldEvents) {
+      const inner = extractEventData(event.data);
+      const isUpdate = safeBool(inner.is_update ?? inner.isUpdate);
+      const isAutoAck = safeBool(inner.is_auto_ack ?? inner.isAutoAck);
+      if (isUpdate || isAutoAck) continue;
+
       const key = eventIncidentKey(event.data, "mold-change", event.ts);
       const status = eventStatus(event.data);
       if (status === "resolved") {
@@ -827,6 +857,12 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
         moldActiveByIncident.set(key, moldStartMs(event.data, event.ts));
       }
     }
+    for (const [k, startMs] of [...moldActiveByIncident.entries()]) {
+      const resumeMs = firstProductionMsAfterMoldStart(startMs);
+      if (resumeMs != null && resumeMs <= params.end.getTime()) {
+        moldActiveByIncident.delete(k);
+      }
+    }
     let moldChangeStartMs: number | null = null;
     for (const startMs of moldActiveByIncident.values()) {
       if (moldChangeStartMs == null || startMs > moldChangeStartMs) moldChangeStartMs = startMs;
@@ -879,7 +915,14 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
         moldChangeStartMs,
       },
       heartbeat: {
-        lastSeenAt: toIso(latestTs),
+        lastSeenAt: toIso(
+          (() => {
+            const hbMs = latestHb ? (latestHb.tsServer ?? latestHb.ts).getTime() : null;
+            const machineMs = machine.tsServer.getTime();
+            if (hbMs != null) return new Date(Math.max(hbMs, machineMs));
+            return machine.tsServer;
+          })()
+        ),
         uptimePct,
       },
     };

lib/recap/progressDisplay.ts

@@ -0,0 +1,27 @@
+/**
+ * Recap & work-order progress: large targets (e.g. 301k) make raw % < 1.
+ * Rounding to integer shows 0%; bar width 0.17% is invisible. Use decimals + a visual floor for the bar.
+ */
+
+/** "0.17%" with enough precision when needed; "—" for null. */
+export function formatRecapProgressPercent(
+  pct: number | null | undefined,
+  locale: string
+): string {
+  if (pct == null || Number.isNaN(pct)) return "—";
+  if (pct <= 0) return "0%";
+  if (pct < 10) {
+    return `${pct.toLocaleString(locale, { maximumFractionDigits: 2, minimumFractionDigits: 0 })}%`;
+  }
+  return `${Math.round(pct).toLocaleString(locale)}%`;
+}
+
+/**
+ * For CSS width %: keep proportional when ≥2%; below that, any positive progress
+ * needs a minimum or the bar looks like a single pixel.
+ */
+export function progressBarWidthPercent(pct: number | null | undefined): number {
+  if (pct == null || Number.isNaN(pct) || pct <= 0) return 0;
+  if (pct < 2) return Math.max(2, Math.min(100, pct));
+  return Math.min(100, pct);
+}

lib/recap/recapUiConstants.ts

@@ -0,0 +1,4 @@
+/**
+ * Client-safe recap thresholds. Kept in sync with OFFLINE logic in lib/recap/redesign.ts.
+ */
+export const RECAP_HEARTBEAT_STALE_MS = 10 * 60 * 1000;

lib/recap/redesign.ts

@@ -9,6 +9,7 @@ import {
   type TimelineCycleRow,
   type TimelineEventRow,
 } from "@/lib/recap/timeline";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
 import type {
   RecapDetailResponse,
   RecapMachine,
@@ -25,7 +26,7 @@ type DetailRangeInput = {
   end?: string | null;
 };
 
-const OFFLINE_THRESHOLD_MS = 10 * 60 * 1000;
+const OFFLINE_THRESHOLD_MS = RECAP_HEARTBEAT_STALE_MS;
 const TIMELINE_EVENT_LOOKBACK_MS = 24 * 60 * 60 * 1000;
 const RECAP_CACHE_TTL_SEC = 60;
 const WEEKDAY_KEYS: ShiftOverrideDay[] = ["sun", "mon", "tue", "wed", "thu", "fri", "sat"];

package.json

@@ -31,6 +31,7 @@
     "@types/nodemailer": "^7.0.4",
     "@types/react": "^19",
     "@types/react-dom": "^19",
+    "baseline-browser-mapping": "^2.10.22",
     "dotenv-cli": "^11.0.0",
     "eslint": "^9",
     "eslint-config-next": "16.0.10",

prisma/migrations/20260424200000_machine_cycle_unique_org_machine_ts_cycle/migration.sql

@@ -0,0 +1,18 @@
+-- Dedupe existing rows (keep oldest by createdAt, then id) before unique constraint.
+WITH ranked AS (
+  SELECT
+    "id",
+    ROW_NUMBER() OVER (
+      PARTITION BY "orgId", "machineId", "ts", "cycleCount"
+      ORDER BY "createdAt" ASC, "id" ASC
+    ) AS rn
+  FROM "MachineCycle"
+)
+DELETE FROM "MachineCycle" mc
+USING ranked r
+WHERE mc."id" = r."id"
+  AND r.rn > 1;
+
+-- One row per (org, machine, device ts, cycle counter) — blocks retry / fan-out duplicates.
+CREATE UNIQUE INDEX "MachineCycle_orgId_machineId_ts_cycleCount_key"
+  ON "MachineCycle" ("orgId", "machineId", "ts", "cycleCount");

prisma/migrations/20260424210000_kpi_heartbeat_unique_org_machine_ts/migration.sql

@@ -0,0 +1,35 @@
+-- Heartbeat: same device ts + machine = one row (retries / double POST).
+WITH ranked_hb AS (
+  SELECT
+    "id",
+    ROW_NUMBER() OVER (
+      PARTITION BY "orgId", "machineId", "ts"
+      ORDER BY "ts_server" ASC, "id" ASC
+    ) AS rn
+  FROM "MachineHeartbeat"
+)
+DELETE FROM "MachineHeartbeat" h
+USING ranked_hb r
+WHERE h."id" = r."id"
+  AND r.rn > 1;
+
+CREATE UNIQUE INDEX "MachineHeartbeat_orgId_machineId_ts_key"
+  ON "MachineHeartbeat" ("orgId", "machineId", "ts");
+
+-- KPI snapshot: same minute bucket (device ts) per machine — Node-RED aligns ts to minute.
+WITH ranked_kpi AS (
+  SELECT
+    "id",
+    ROW_NUMBER() OVER (
+      PARTITION BY "orgId", "machineId", "ts"
+      ORDER BY "ts_server" ASC, "id" ASC
+    ) AS rn
+  FROM "MachineKpiSnapshot"
+)
+DELETE FROM "MachineKpiSnapshot" k
+USING ranked_kpi r
+WHERE k."id" = r."id"
+  AND r.rn > 1;
+
+CREATE UNIQUE INDEX "MachineKpiSnapshot_orgId_machineId_ts_key"
+  ON "MachineKpiSnapshot" ("orgId", "machineId", "ts");

prisma/schema.prisma

@@ -8,65 +8,61 @@ datasource db {
 }
 
 model Org {
-  id        String   @id @default(uuid())
+  id                         String                      @id @default(uuid())
-  name      String
+  name                       String
-  slug      String   @unique
+  slug                       String                      @unique
-  createdAt DateTime @default(now())
+  createdAt                  DateTime                    @default(now())
-
+  machines                   Machine[]
-  members         OrgUser[]
+  events                     MachineEvent[]
-  sessions        Session[]
+  heartbeats                 MachineHeartbeat[]
-  machines        Machine[]
+  kpiSnapshots               MachineKpiSnapshot[]
-  heartbeats      MachineHeartbeat[]
+  members                    OrgUser[]
-  kpiSnapshots    MachineKpiSnapshot[]
+  reasonEntries              ReasonEntry[]
-  events          MachineEvent[]
+  sessions                   Session[]
-  workOrders      MachineWorkOrder[]
+  alertContacts              AlertContact[]
-  settings        OrgSettings?
+  alertNotifications         AlertNotification[]
-  shifts          OrgShift[]
+  alertPolicies              AlertPolicy?
-  machineSettings MachineSettings[]
+  downtimeActions            DowntimeAction[]
-  settingsAudits  SettingsAudit[]
-  invites         OrgInvite[]
-  alertPolicies   AlertPolicy[]
-  alertContacts   AlertContact[]
-  alertNotifications AlertNotification[]
-  financialProfile OrgFinancialProfile?
   locationFinancialOverrides LocationFinancialOverride[]
-  machineFinancialOverrides MachineFinancialOverride[]
+  machineFinancialOverrides  MachineFinancialOverride[]
-  productCostOverrides ProductCostOverride[]
+  machineSettings            MachineSettings[]
-  reasonEntries ReasonEntry[]
+  workOrders                 MachineWorkOrder[]
-  downtimeActions DowntimeAction[]
+  financialProfile           OrgFinancialProfile?
-
+  invites                    OrgInvite[]
+  settings                   OrgSettings?
+  shifts                     OrgShift[]
+  productCostOverrides       ProductCostOverride[]
+  settingsAudits             SettingsAudit[]
 }
 
 model User {
-  id           String   @id @default(uuid())
+  id                         String              @id @default(uuid())
-  email        String   @unique
+  email                      String              @unique
-  name         String?
+  name                       String?
-  phone        String?  @map("phone")
+  passwordHash               String
-  passwordHash String
+  isActive                   Boolean             @default(true)
-  isActive     Boolean  @default(true)
+  createdAt                  DateTime            @default(now())
-  createdAt    DateTime @default(now())
+  emailVerificationExpiresAt DateTime?           @map("email_verification_expires_at")
-  emailVerifiedAt           DateTime? @map("email_verified_at")
+  emailVerificationToken     String?             @unique @map("email_verification_token")
-  emailVerificationToken    String?   @unique @map("email_verification_token")
+  emailVerifiedAt            DateTime?           @map("email_verified_at")
-  emailVerificationExpiresAt DateTime? @map("email_verification_expires_at")
+  phone                      String?             @map("phone")
-
+  orgs                       OrgUser[]
-  orgs        OrgUser[]
+  sessions                   Session[]
-  sessions    Session[]
+  alertContacts              AlertContact[]
-  sentInvites OrgInvite[] @relation("OrgInviteInviter")
+  alertNotifications         AlertNotification[]
-  alertContacts AlertContact[]
+  downtimeActionsCreated     DowntimeAction[]    @relation("DowntimeActionCreator")
-  alertNotifications AlertNotification[]
+  downtimeActionsOwned       DowntimeAction[]    @relation("DowntimeActionOwner")
-  downtimeActionsOwned DowntimeAction[] @relation("DowntimeActionOwner")
+  sentInvites                OrgInvite[]         @relation("OrgInviteInviter")
-  downtimeActionsCreated DowntimeAction[] @relation("DowntimeActionCreator")
 }
 
 model OrgUser {
   id        String   @id @default(uuid())
   orgId     String
   userId    String
-  role      String   @default("MEMBER") // OWNER | ADMIN | MEMBER
+  role      String   @default("MEMBER")
   createdAt DateTime @default(now())
-
+  org       Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org  Org  @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  user      User     @relation(fields: [userId], references: [id], onDelete: Cascade)
-  user User @relation(fields: [userId], references: [id], onDelete: Cascade)
 
   @@unique([orgId, userId])
   @@index([userId])
@@ -74,19 +70,18 @@ model OrgUser {
 }
 
 model OrgInvite {
-  id         String   @id @default(uuid())
+  id         String    @id @default(uuid())
-  orgId      String   @map("org_id")
+  orgId      String    @map("org_id")
   email      String
-  role       String   @default("MEMBER") // OWNER | ADMIN | MEMBER
+  role       String    @default("MEMBER")
-  token      String   @unique
+  token      String    @unique
-  invitedBy  String?  @map("invited_by")
+  invitedBy  String?   @map("invited_by")
-  createdAt  DateTime @default(now()) @map("created_at")
+  createdAt  DateTime  @default(now()) @map("created_at")
-  expiresAt  DateTime @map("expires_at")
+  expiresAt  DateTime  @map("expires_at")
   acceptedAt DateTime? @map("accepted_at")
   revokedAt  DateTime? @map("revoked_at")
-
+  inviter    User?     @relation("OrgInviteInviter", fields: [invitedBy], references: [id])
-  org     Org   @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  org        Org       @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  inviter User? @relation("OrgInviteInviter", fields: [invitedBy], references: [id], onDelete: SetNull)
 
   @@index([orgId])
   @@index([orgId, email])
@@ -95,7 +90,7 @@ model OrgInvite {
 }
 
 model Session {
-  id         String    @id @default(uuid()) // cookie value
+  id         String    @id @default(uuid())
   orgId      String
   userId     String
   createdAt  DateTime  @default(now())
@@ -104,9 +99,8 @@ model Session {
   revokedAt  DateTime?
   ip         String?
   userAgent  String?
-
+  org        Org       @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org  Org  @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  user       User      @relation(fields: [userId], references: [id], onDelete: Cascade)
-  user User @relation(fields: [userId], references: [id], onDelete: Cascade)
 
   @@index([userId])
   @@index([orgId])
@@ -114,39 +108,36 @@ model Session {
 }
 
 model Machine {
-  id            String   @id @default(uuid())
+  id                   String                     @id @default(uuid())
-  orgId         String
+  orgId                String
-  name          String
+  name                 String
-  apiKey        String?  @unique
+  code                 String?
-  code          String?
+  createdAt            DateTime                   @default(now())
-  location      String?
+  location             String?
-  createdAt     DateTime @default(now())
+  updatedAt            DateTime                   @updatedAt
-  updatedAt     DateTime @updatedAt
+  apiKey               String?                    @unique
-  tsDevice      DateTime @default(now()) @map("ts")
+  schemaVersion        String?                    @map("schema_version")
-  tsServer      DateTime @default(now()) @map("ts_server")
+  seq                  BigInt?                    @map("seq")
-  schemaVersion String?  @map("schema_version")
+  tsDevice             DateTime                   @default(now()) @map("ts")
-  seq           BigInt?  @map("seq")
+  tsServer             DateTime                   @default(now()) @map("ts_server")
-  pairingCode   String?  @unique @map("pairing_code")
+  pairingCode          String?                    @unique @map("pairing_code")
-  pairingCodeExpiresAt DateTime? @map("pairing_code_expires_at")
+  pairingCodeExpiresAt DateTime?                  @map("pairing_code_expires_at")
-  pairingCodeUsedAt DateTime? @map("pairing_code_used_at")
+  pairingCodeUsedAt    DateTime?                  @map("pairing_code_used_at")
-
+  org                  Org                        @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org            Org                  @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  cycles               MachineCycle[]
-  heartbeats     MachineHeartbeat[]
+  events               MachineEvent[]
-  kpiSnapshots   MachineKpiSnapshot[]
+  heartbeats           MachineHeartbeat[]
-  events         MachineEvent[]
+  kpiSnapshots         MachineKpiSnapshot[]
-  cycles         MachineCycle[]
+  reasonEntries        ReasonEntry[]
-  workOrders     MachineWorkOrder[]
+  alertNotifications   AlertNotification[]
-  settings       MachineSettings?
+  downtimeActions      DowntimeAction[]
-  settingsAudits SettingsAudit[]
+  financialOverrides   MachineFinancialOverride[]
-  alertNotifications AlertNotification[]
+  settings             MachineSettings?
-  financialOverrides MachineFinancialOverride[]
+  workOrders           MachineWorkOrder[]
-  reasonEntries ReasonEntry[]
+  settingsAudits       SettingsAudit[]
-  downtimeActions DowntimeAction[]
-
 
   @@unique([orgId, name])
   @@index([orgId])
-  @@index([orgId, createdAt])
 }
 
 model MachineHeartbeat {
@@ -154,111 +145,97 @@ model MachineHeartbeat {
   orgId         String
   machineId     String
   ts            DateTime @default(now())
-  tsServer      DateTime @default(now()) @map("ts_server")
+  status        String
+  message       String?
+  ip            String?
+  fwVersion     String?
   schemaVersion String?  @map("schema_version")
   seq           BigInt?  @map("seq")
-
+  tsServer      DateTime @default(now()) @map("ts_server")
-  status    String
+  machine       Machine  @relation(fields: [machineId], references: [id], onDelete: Cascade)
-  message   String?
+  org           Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  ip        String?
-  fwVersion String?
-
-  org     Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
 
   @@index([orgId, machineId, ts])
-  @@index([orgId, machineId, tsServer])
 }
 
 model MachineKpiSnapshot {
-  id        String   @id @default(uuid())
+  id                String   @id @default(uuid())
-  orgId     String
+  orgId             String
-  machineId String
+  machineId         String
-  ts        DateTime @default(now())
+  ts                DateTime @default(now())
-
+  workOrderId       String?
-  workOrderId String?
+  sku               String?
-  sku         String?
+  target            Int?
-
+  good              Int?
-  target      Int?
+  scrap             Int?
-  good        Int?
+  cycleCount        Int?
-  scrap       Int?
+  goodParts         Int?
-  cycleCount  Int?
+  scrapParts        Int?
-  goodParts   Int?
+  cavities          Int?
-  scrapParts  Int?
+  cycleTime         Float?
-  cavities    Int?
+  actualCycle       Float?
-  cycleTime   Float? // theoretical/target
+  availability      Float?
-  actualCycle Float? // if you want (optional)
+  performance       Float?
-
+  quality           Float?
-  availability Float?
+  oee               Float?
-  performance  Float?
-  quality      Float?
-  oee          Float?
-
   trackingEnabled   Boolean?
   productionStarted Boolean?
-  tsServer          DateTime @default(now()) @map("ts_server")
   schemaVersion     String?  @map("schema_version")
   seq               BigInt?  @map("seq")
+  tsServer          DateTime @default(now()) @map("ts_server")
+  machine           Machine  @relation(fields: [machineId], references: [id], onDelete: Cascade)
+  org               Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
-  org     Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  @@unique([orgId, machineId, seq], map: "uq_kpi_org_machine_seq")
-  machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
-
   @@index([orgId, machineId, ts])
 }
 
 model MachineEvent {
-  id        String   @id @default(uuid())
+  id            String   @id @default(uuid())
-  orgId     String
+  orgId         String
-  machineId String
+  machineId     String
-  ts        DateTime @default(now())
+  ts            DateTime @default(now())
-
+  topic         String
-  topic         String // "anomaly-detected"
+  eventType     String
-  eventType     String // "slow-cycle"
+  severity      String
-  severity      String // "critical"
   requiresAck   Boolean  @default(false)
   title         String
   description   String?
-  tsServer      DateTime @default(now()) @map("ts_server")
+  data          Json?
+  workOrderId   String?
+  sku           String?
   schemaVersion String?  @map("schema_version")
   seq           BigInt?  @map("seq")
+  tsServer      DateTime @default(now()) @map("ts_server")
+  machine       Machine  @relation(fields: [machineId], references: [id], onDelete: Cascade)
+  org           Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
-  // store the raw data blob so we don't lose fields
+  @@unique([orgId, machineId, seq], map: "uq_event_org_machine_seq")
-  data Json?
-
-  workOrderId String?
-  sku         String?
-
-  org     Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
-
   @@index([orgId, machineId, ts])
   @@index([orgId, machineId, eventType, ts])
 }
 
 model MachineCycle {
-  id        String   @id @default(uuid())
+  id                   String   @id @default(uuid())
-  orgId     String
+  orgId                String
-  machineId String
+  machineId            String
-  ts        DateTime @default(now())
+  ts                   DateTime @default(now())
-
   cycleCount           Int?
   actualCycleTime      Float
   theoreticalCycleTime Float?
+  workOrderId          String?
+  sku                  String?
+  cavities             Int?
+  goodDelta            Int?
+  scrapDelta           Int?
+  createdAt            DateTime @default(now())
+  schemaVersion        String?  @map("schema_version")
+  seq                  BigInt?  @map("seq")
+  tsServer             DateTime @default(now()) @map("ts_server")
+  machine              Machine  @relation(fields: [machineId], references: [id])
 
-  workOrderId String?
+  @@unique([orgId, machineId, ts, cycleCount])
-  sku         String?
+  @@unique([orgId, machineId, seq], map: "uq_cycle_org_machine_seq")
-
-  cavities      Int?
-  goodDelta     Int?
-  scrapDelta    Int?
-  tsServer      DateTime @default(now()) @map("ts_server")
-  schemaVersion String?  @map("schema_version")
-  seq           BigInt?  @map("seq")
-
-  createdAt DateTime @default(now())
-
-  machine Machine @relation(fields: [machineId], references: [id])
-
   @@index([orgId, machineId, ts])
   @@index([orgId, machineId, cycleCount])
 }
@@ -272,14 +249,13 @@ model MachineWorkOrder {
   targetQty   Int?
   cycleTime   Float?
   status      String   @default("PENDING")
+  createdAt   DateTime @default(now())
+  updatedAt   DateTime @updatedAt
   goodParts   Int      @default(0) @map("good_parts")
   scrapParts  Int      @default(0) @map("scrap_parts")
   cycleCount  Int      @default(0) @map("cycle_count")
-  createdAt   DateTime @default(now())
+  machine     Machine  @relation(fields: [machineId], references: [id], onDelete: Cascade)
-  updatedAt   DateTime @updatedAt
+  org         Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-
-  org     Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
 
   @@unique([machineId, workOrderId])
   @@index([orgId, machineId])
@@ -296,14 +272,13 @@ model IngestLog {
   seq           BigInt?
   tsDevice      DateTime?
   tsServer      DateTime  @default(now())
-
+  ok            Boolean
-  ok        Boolean
+  status        Int
-  status    Int
+  errorCode     String?
-  errorCode String?
+  errorMsg      String?
-  errorMsg  String?
+  body          Json?
-  body      Json?
+  ip            String?
-  ip        String?
+  userAgent     String?
-  userAgent String?
 
   @@index([endpoint, tsServer])
   @@index([machineId, tsServer])
@@ -311,44 +286,42 @@ model IngestLog {
 }
 
 model OrgSettings {
-  orgId                   String   @id @map("org_id")
+  orgId                      String   @id @map("org_id")
-  timezone                String   @default("UTC")
+  timezone                   String   @default("UTC")
-  shiftChangeCompMin      Int      @default(10) @map("shift_change_comp_min")
+  shiftChangeCompMin         Int      @default(10) @map("shift_change_comp_min")
-  lunchBreakMin           Int      @default(30) @map("lunch_break_min")
+  lunchBreakMin              Int      @default(30) @map("lunch_break_min")
-  shiftScheduleOverridesJson Json? @map("shift_schedule_overrides_json")
+  stoppageMultiplier         Float    @default(1.5) @map("stoppage_multiplier")
-  stoppageMultiplier      Float    @default(1.5) @map("stoppage_multiplier")
+  oeeAlertThresholdPct       Float    @default(90) @map("oee_alert_threshold_pct")
-  oeeAlertThresholdPct    Float    @default(90) @map("oee_alert_threshold_pct")
+  macroStoppageMultiplier    Float    @default(5) @map("macro_stoppage_multiplier")
-  macroStoppageMultiplier Float    @default(5) @map("macro_stoppage_multiplier")
+  performanceThresholdPct    Float    @default(85) @map("performance_threshold_pct")
-  performanceThresholdPct Float    @default(85) @map("performance_threshold_pct")
+  qualitySpikeDeltaPct       Float    @default(5) @map("quality_spike_delta_pct")
-  qualitySpikeDeltaPct    Float    @default(5) @map("quality_spike_delta_pct")
+  alertsJson                 Json?    @map("alerts_json")
-  alertsJson              Json?    @map("alerts_json")
+  defaultsJson               Json?    @map("defaults_json")
-  defaultsJson            Json?    @map("defaults_json")
+  version                    Int      @default(1)
-  version                 Int      @default(1)
+  updatedAt                  DateTime @updatedAt @map("updated_at")
-  updatedAt               DateTime @updatedAt @map("updated_at")
+  updatedBy                  String?  @map("updated_by")
-  updatedBy               String?  @map("updated_by")
+  shiftScheduleOverridesJson Json?    @map("shift_schedule_overrides_json")
-
+  org                        Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org Org @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
   @@map("org_settings")
 }
 
 model OrgFinancialProfile {
-  orgId                   String   @id @map("org_id")
+  orgId                  String   @id @map("org_id")
-  defaultCurrency         String   @default("USD") @map("default_currency")
+  defaultCurrency        String   @default("USD") @map("default_currency")
-  machineCostPerMin       Float?   @map("machine_cost_per_min")
+  machineCostPerMin      Float?   @map("machine_cost_per_min")
-  operatorCostPerMin      Float?   @map("operator_cost_per_min")
+  operatorCostPerMin     Float?   @map("operator_cost_per_min")
-  ratedRunningKw          Float?   @map("rated_running_kw")
+  ratedRunningKw         Float?   @map("rated_running_kw")
-  idleKw                  Float?   @map("idle_kw")
+  idleKw                 Float?   @map("idle_kw")
-  kwhRate                 Float?   @map("kwh_rate")
+  kwhRate                Float?   @map("kwh_rate")
-  energyMultiplier        Float    @default(1.0) @map("energy_multiplier")
+  energyMultiplier       Float    @default(1.0) @map("energy_multiplier")
-  energyCostPerMin        Float?   @map("energy_cost_per_min")
+  energyCostPerMin       Float?   @map("energy_cost_per_min")
-  scrapCostPerUnit        Float?   @map("scrap_cost_per_unit")
+  scrapCostPerUnit       Float?   @map("scrap_cost_per_unit")
-  rawMaterialCostPerUnit  Float?   @map("raw_material_cost_per_unit")
+  rawMaterialCostPerUnit Float?   @map("raw_material_cost_per_unit")
-  createdAt               DateTime @default(now()) @map("created_at")
+  createdAt              DateTime @default(now()) @map("created_at")
-  updatedAt               DateTime @updatedAt @map("updated_at")
+  updatedAt              DateTime @updatedAt @map("updated_at")
-  updatedBy               String?  @map("updated_by")
+  updatedBy              String?  @map("updated_by")
-
+  org                    Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org Org @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
   @@map("org_financial_profiles")
 }
@@ -370,8 +343,7 @@ model LocationFinancialOverride {
   createdAt              DateTime @default(now()) @map("created_at")
   updatedAt              DateTime @updatedAt @map("updated_at")
   updatedBy              String?  @map("updated_by")
-
+  org                    Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org Org @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
   @@unique([orgId, location])
   @@index([orgId])
@@ -395,9 +367,8 @@ model MachineFinancialOverride {
   createdAt              DateTime @default(now()) @map("created_at")
   updatedAt              DateTime @updatedAt @map("updated_at")
   updatedBy              String?  @map("updated_by")
-
+  machine                Machine  @relation(fields: [machineId], references: [id], onDelete: Cascade)
-  org     Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  org                    Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
 
   @@unique([orgId, machineId])
   @@index([orgId])
@@ -405,16 +376,15 @@ model MachineFinancialOverride {
 }
 
 model ProductCostOverride {
-  id                    String   @id @default(uuid())
+  id                     String   @id @default(uuid())
-  orgId                 String   @map("org_id")
+  orgId                  String   @map("org_id")
-  sku                   String
+  sku                    String
-  currency              String?
+  currency               String?
-  rawMaterialCostPerUnit Float?  @map("raw_material_cost_per_unit")
+  rawMaterialCostPerUnit Float?   @map("raw_material_cost_per_unit")
-  createdAt             DateTime @default(now()) @map("created_at")
+  createdAt              DateTime @default(now()) @map("created_at")
-  updatedAt             DateTime @updatedAt @map("updated_at")
+  updatedAt              DateTime @updatedAt @map("updated_at")
-  updatedBy             String?  @map("updated_by")
+  updatedBy              String?  @map("updated_by")
-
+  org                    Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org Org @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
   @@unique([orgId, sku])
   @@index([orgId])
@@ -423,33 +393,30 @@ model ProductCostOverride {
 
 model AlertPolicy {
   id         String   @id @default(uuid())
-  orgId      String   @map("org_id")
+  orgId      String   @unique @map("org_id")
   policyJson Json     @map("policy_json")
   updatedAt  DateTime @updatedAt @map("updated_at")
   updatedBy  String?  @map("updated_by")
+  org        Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
-  org Org @relation(fields: [orgId], references: [id], onDelete: Cascade)
-
-  @@unique([orgId])
   @@index([orgId])
   @@map("alert_policies")
 }
 
 model AlertContact {
-  id        String   @id @default(uuid())
+  id            String              @id @default(uuid())
-  orgId     String   @map("org_id")
+  orgId         String              @map("org_id")
-  userId    String?  @map("user_id")
+  userId        String?             @map("user_id")
-  name      String
+  name          String
-  roleScope String   @map("role_scope") // MEMBER | ADMIN | OWNER | CUSTOM
+  roleScope     String              @map("role_scope")
-  email     String?
+  email         String?
-  phone     String?
+  phone         String?
-  eventTypes Json?   @map("event_types") // optional allowlist (array of strings)
+  eventTypes    Json?               @map("event_types")
-  isActive  Boolean  @default(true) @map("is_active")
+  isActive      Boolean             @default(true) @map("is_active")
-  createdAt DateTime @default(now()) @map("created_at")
+  createdAt     DateTime            @default(now()) @map("created_at")
-  updatedAt DateTime @updatedAt @map("updated_at")
+  updatedAt     DateTime            @updatedAt @map("updated_at")
-
+  org           Org                 @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org  Org  @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  user          User?               @relation(fields: [userId], references: [id])
-  user User? @relation(fields: [userId], references: [id], onDelete: SetNull)
   notifications AlertNotification[]
 
   @@unique([orgId, userId])
@@ -459,24 +426,23 @@ model AlertContact {
 }
 
 model AlertNotification {
-  id        String   @id @default(uuid())
+  id        String        @id @default(uuid())
-  orgId     String   @map("org_id")
+  orgId     String        @map("org_id")
-  machineId String   @map("machine_id")
+  machineId String        @map("machine_id")
-  eventId   String   @map("event_id")
+  eventId   String        @map("event_id")
-  eventType String   @map("event_type")
+  eventType String        @map("event_type")
-  ruleId    String   @map("rule_id")
+  ruleId    String        @map("rule_id")
   role      String
   channel   String
-  contactId String?  @map("contact_id")
+  contactId String?       @map("contact_id")
-  userId    String?  @map("user_id")
+  userId    String?       @map("user_id")
-  sentAt    DateTime @default(now()) @map("sent_at")
+  sentAt    DateTime      @default(now()) @map("sent_at")
   status    String
   error     String?
-
+  contact   AlertContact? @relation(fields: [contactId], references: [id])
-  org     Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  machine   Machine       @relation(fields: [machineId], references: [id], onDelete: Cascade)
-  machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
+  org       Org           @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  contact AlertContact? @relation(fields: [contactId], references: [id], onDelete: SetNull)
+  user      User?         @relation(fields: [userId], references: [id])
-  user    User?   @relation(fields: [userId], references: [id], onDelete: SetNull)
 
   @@index([orgId, machineId, sentAt])
   @@index([orgId, eventId, role, channel])
@@ -493,8 +459,7 @@ model OrgShift {
   endTime   String  @map("end_time")
   sortOrder Int     @map("sort_order")
   enabled   Boolean @default(true)
-
+  org       Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org Org @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
   @@index([orgId])
   @@index([orgId, sortOrder])
@@ -507,9 +472,8 @@ model MachineSettings {
   overridesJson Json?    @map("overrides_json")
   updatedAt     DateTime @updatedAt @map("updated_at")
   updatedBy     String?  @map("updated_by")
-
+  machine       Machine  @relation(fields: [machineId], references: [id], onDelete: Cascade)
-  org     Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  org           Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
 
   @@index([orgId])
   @@map("machine_settings")
@@ -523,9 +487,8 @@ model SettingsAudit {
   source      String
   payloadJson Json     @map("payload_json")
   createdAt   DateTime @default(now()) @map("created_at")
-
+  machine     Machine? @relation(fields: [machineId], references: [id], onDelete: Cascade)
-  org     Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  org         Org      @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  machine Machine? @relation(fields: [machineId], references: [id], onDelete: Cascade)
 
   @@index([orgId, createdAt])
   @@index([machineId, createdAt])
@@ -533,75 +496,58 @@ model SettingsAudit {
 }
 
 model ReasonEntry {
-  id            String   @id @default(uuid())
+  id              String    @id @default(uuid())
-  orgId         String
+  orgId           String
-  machineId     String
+  machineId       String
-
+  reasonId        String    @unique
-  // idempotency key from Edge (rsn_<ulid>)
+  kind            String
-  reasonId      String   @unique
-
-  // "downtime" | "scrap"
-  kind          String
-
-  // For downtime reasons
   episodeId       String?
   durationSeconds Int?
   episodeEndTs    DateTime?
+  scrapEntryId    String?
+  scrapQty        Int?
+  scrapUnit       String?
+  reasonCode      String
+  reasonLabel     String?
+  reasonText      String?
+  capturedAt      DateTime
+  workOrderId     String?
+  meta            Json?
+  schemaVersion   Int       @default(1)
+  createdAt       DateTime  @default(now())
+  machine         Machine   @relation(fields: [machineId], references: [id], onDelete: Cascade)
+  org             Org       @relation(fields: [orgId], references: [id], onDelete: Cascade)
 
-  // For scrap reasons
-  scrapEntryId String?
-  scrapQty     Int?
-  scrapUnit    String?
-
-  // Required reason
-  reasonCode   String
-  reasonLabel  String?
-  reasonText   String?
-
-  capturedAt    DateTime
-  workOrderId   String?
-  meta          Json?
-  schemaVersion Int @default(1)
-
-  createdAt DateTime @default(now())
-
-  org     Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
-
-  @@index([orgId, machineId, capturedAt])
-  @@index([orgId, kind, capturedAt])
   @@unique([orgId, kind, episodeId])
   @@unique([orgId, kind, scrapEntryId])
+  @@index([orgId, machineId, capturedAt])
+  @@index([orgId, kind, capturedAt])
 }
 
 model DowntimeAction {
-  id        String   @id @default(uuid())
+  id             String    @id @default(uuid())
-  orgId     String   @map("org_id")
+  orgId          String    @map("org_id")
-  machineId String?  @map("machine_id")
+  machineId      String?   @map("machine_id")
-  reasonCode String? @map("reason_code")
+  reasonCode     String?   @map("reason_code")
-  hmDay     Int?     @map("hm_day")
+  hmDay          Int?      @map("hm_day")
-  hmHour    Int?     @map("hm_hour")
+  hmHour         Int?      @map("hm_hour")
-
+  title          String
-  title     String
+  notes          String?
-  notes     String?
+  status         String    @default("open")
-  status    String   @default("open")
+  priority       String    @default("medium")
-  priority  String   @default("medium")
+  dueDate        DateTime? @map("due_date")
-  dueDate   DateTime? @map("due_date")
+  reminderAt     DateTime? @map("reminder_at")
-  reminderAt DateTime? @map("reminder_at")
   lastReminderAt DateTime? @map("last_reminder_at")
-  reminderStage String? @map("reminder_stage")
+  completedAt    DateTime? @map("completed_at")
-  completedAt DateTime? @map("completed_at")
+  ownerUserId    String?   @map("owner_user_id")
-
+  createdBy      String?   @map("created_by")
-  ownerUserId String? @map("owner_user_id")
+  createdAt      DateTime  @default(now()) @map("created_at")
-  createdBy   String? @map("created_by")
+  updatedAt      DateTime  @updatedAt @map("updated_at")
-
+  reminderStage  String?   @map("reminder_stage")
-  createdAt DateTime @default(now()) @map("created_at")
+  creator        User?     @relation("DowntimeActionCreator", fields: [createdBy], references: [id])
-  updatedAt DateTime @updatedAt @map("updated_at")
+  machine        Machine?  @relation(fields: [machineId], references: [id])
-
+  org            Org       @relation(fields: [orgId], references: [id], onDelete: Cascade)
-  org       Org     @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  ownerUser      User?     @relation("DowntimeActionOwner", fields: [ownerUserId], references: [id])
-  machine   Machine? @relation(fields: [machineId], references: [id], onDelete: SetNull)
-  ownerUser User?   @relation("DowntimeActionOwner", fields: [ownerUserId], references: [id], onDelete: SetNull)
-  creator   User?   @relation("DowntimeActionCreator", fields: [createdBy], references: [id], onDelete: SetNull)
 
   @@index([orgId])
   @@index([orgId, machineId])