pre-bemis

LOGGING.md

@@ -0,0 +1,84 @@
+# Logging & debugging errors
+
+## Where errors are logged
+
+### 1. **Log file** (JSON lines)
+
+- **Path:** `LOG_FILE` env var, or **`/tmp/mis-control-tower.log`** if unset.
+- **Contents:** JSON lines for `requireSession.error`, `getOverviewData.error`, `OverviewPage.getOverviewData.error`, plus any `logLine(...)` usage (e.g. health, signup).
+
+**View recent entries:**
+```bash
+tail -f /tmp/mis-control-tower.log
+```
+
+**Or with a custom path:**
+```bashls -la
+export LOG_FILE=/var/log/mis-control-tower.log
+# then start the app; tail that path
+tail -f /var/log/mis-control-tower.log
+```
+
+### 2. **Process stdout / stderr**
+
+- **`console.error`** and **`console.log`** go to the process that runs Next.js.
+- **Dev:** terminal where you run `npm run dev`.
+- **Production:** PM2 logs (`pm2 logs`), Docker (`docker logs ...`), systemd (`journalctl -u your-service -f`), etc.
+
+### 3. **Debug logs API** (optional)
+
+- **URL:** `GET /api/debug/logs?key=YOUR_DEBUG_LOGS_KEY`
+- **Purpose:** Returns the last 100 lines of the log file as JSON.
+- **Setup:** Add to `.env`:
+  ```
+  DEBUG_LOGS_KEY=your-secret-string
+  ```
+- **Usage:**  
+  `curl "https://mis.maliountech.com.mx/api/debug/logs?key=your-secret-string"`
+- If `DEBUG_LOGS_KEY` is unset or the `key` param is wrong, the route returns 401.
+
+## Error events we log
+
+| Event | When |
+|-------|------|
+| `requireSession.error` | Session lookup (cookies / DB) fails |
+| `getOverviewData.error` | Overview data fetch (DB) fails |
+| `OverviewPage.getOverviewData.error` | Overview page catch-around fetch fails |
+
+Each includes `message` and `stack` when available.
+
+## Quick checks when you see "Internal Server Error"
+
+1. **Tail the log file:**  
+   `tail -f /tmp/mis-control-tower.log`  
+   (or `$LOG_FILE` if you set it.)
+
+2. **Check process logs:**  
+   Wherever `next start` or `npm run dev` runs (PM2, Docker, systemd). Look for `[requireSession]`, `[getOverviewData]`, `[OverviewPage]`, or `[middleware]`.
+
+3. **Call the debug API** (if configured):  
+   `curl "https://your-domain/api/debug/logs?key=YOUR_DEBUG_LOGS_KEY"`  
+   and inspect the `entries` array for recent errors.
+
+## KPI quality trace (Node-RED vs processing)
+
+Use this when `Quality` is shown as `0` and you need to see exactly what was received and saved.
+
+1. Enable trace logging:
+   `TRACE_KPI_INGEST=1`
+
+2. Send KPI payloads as usual from Node-RED.
+
+3. Inspect logs:
+   `tail -f /tmp/mis-control-tower.log`
+   or:
+   `curl "https://your-domain/api/debug/logs?key=YOUR_DEBUG_LOGS_KEY"`
+
+4. Look for event `ingest.kpi.trace`, which includes:
+   `trace.rawQualityCandidates` (raw payload values found at multiple paths),
+   `trace.normalizedQuality` (post-normalization),
+   `trace.persistedQuality` (value written to DB).
+
+Optional one-shot trace without env var:
+- Send header `x-debug-ingest: 1` on a KPI request.
+- The response will include a `trace` object with the same quality details.

README.md

@@ -75,7 +75,24 @@ sudo systemctl daemon-reload
 sudo systemctl enable --now mis-control-tower-reminders.timer
 ```
 
-## Learn More
+## Production build and deploy
+
+**Dev uses Turbopack, production build uses Webpack.** Next.js 16 defaults to Turbopack for both, but Turbopack production builds have known issues. This project uses:
+
+- `npm run dev` → `next dev --turbopack` (fast dev)
+- `npm run build` → `next build --webpack` (stable production build)
+
+**When deploying** (e.g. for `https://mis.maliountech.com.mx`):
+
+1. **Build:** Run `npm run build` (Webpack).
+2. **Start:** Run `npm run start` (or your process manager) to serve the built app.
+3. If you previously built with Turbopack, run `rm -rf .next` then `npm run build` for a clean Webpack build.
+4. Hard-refresh the browser (or clear site data) after redeploying so clients don’t load old Turbopack chunks.
+
+## Logging and debugging
+
+See **[LOGGING.md](./LOGGING.md)** for where errors are logged (log file, process stdout, optional `/api/debug/logs`), how to tail them, and how to debug "Internal Server Error".
+
 
 To learn more about Next.js, take a look at the following resources:
 

app/(app)/error.tsx

@@ -0,0 +1,31 @@
+"use client";
+
+import { useEffect } from "react";
+
+export default function AppError({
+  error,
+  reset,
+}: {
+  error: Error & { digest?: string };
+  reset: () => void;
+}) {
+  useEffect(() => {
+    console.error("[App Error]", error);
+  }, [error]);
+
+  return (
+    <div className="flex min-h-[50vh] flex-col items-center justify-center gap-4 p-6">
+      <h2 className="text-lg font-semibold text-white">Something went wrong</h2>
+      <p className="max-w-md text-center text-sm text-zinc-400">
+        An error occurred while loading this page. Please try again.
+      </p>
+      <button
+        type="button"
+        onClick={() => reset()}
+        className="rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-sm text-white hover:bg-white/10"
+      >
+        Try again
+      </button>
+    </div>
+  );
+}

app/(app)/financial/FinancialClient.tsx

@@ -76,6 +76,8 @@ export default function FinancialClient({
   const [currencyFilter, setCurrencyFilter] = useState("");
   const [loading, setLoading] = useState(() => initialMachines.length === 0);
   const skipInitialImpactRef = useRef(true);
+  const forceRefreshRef = useRef(false);
+  const [refreshSeed, setRefreshSeed] = useState(0);
 
   const locations = useMemo(() => {
     const seen = new Set<string>();
@@ -158,6 +160,8 @@ export default function FinancialClient({
       if (locationFilter) params.set("location", locationFilter);
       if (skuFilter) params.set("sku", skuFilter);
       if (currencyFilter) params.set("currency", currencyFilter);
+      const forceRefresh = forceRefreshRef.current;
+      if (forceRefresh) params.set("refresh", "1");
 
       try {
         const res = await fetch(`/api/financial/impact?${params.toString()}`, {
@@ -169,6 +173,8 @@ export default function FinancialClient({
         setImpact(json);
       } catch {
         if (alive) setImpact(null);
+      } finally {
+        if (forceRefresh) forceRefreshRef.current = false;
       }
     }
 
@@ -177,7 +183,7 @@ export default function FinancialClient({
       alive = false;
       controller.abort();
     };
-  }, [currencyFilter, initialImpact, locationFilter, machineFilter, range, role, skuFilter]);
+  }, [currencyFilter, initialImpact, locationFilter, machineFilter, range, refreshSeed, role, skuFilter]);
 
   const selectedSummary = impact?.currencySummaries?.[0] ?? null;
   const chartData = selectedSummary?.byDay ?? [];
@@ -193,6 +199,10 @@ export default function FinancialClient({
 
   const htmlHref = `/api/financial/export/pdf?${exportQuery}`;
   const csvHref = `/api/financial/export/excel?${exportQuery}`;
+  const handleRefresh = () => {
+    forceRefreshRef.current = true;
+    setRefreshSeed((prev) => prev + 1);
+  };
 
   if (role && role !== "OWNER") {
     return (
@@ -212,6 +222,13 @@ export default function FinancialClient({
           <p className="text-sm text-zinc-400">{t("financial.subtitle")}</p>
         </div>
         <div className="flex w-full flex-col gap-3 sm:w-auto sm:flex-row">
+          <button
+            type="button"
+            onClick={handleRefresh}
+            className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-zinc-200 hover:bg-white/10 sm:w-auto"
+          >
+            {t("financial.refresh")}
+          </button>
           <a
             className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-zinc-200 hover:bg-white/10 sm:w-auto"
             href={htmlHref}
@@ -288,7 +305,7 @@ export default function FinancialClient({
           </div>
 
           <div className="mt-4 h-64">
-            <ResponsiveContainer width="100%" height="100%">
+            <ResponsiveContainer width="100%" height="100%" minHeight={200}>
               <AreaChart data={chartData}>
                 <defs>
                   <linearGradient id="slowFill" x1="0" y1="0" x2="0" y2="1">

app/(app)/financial/page.tsx

@@ -1,7 +1,7 @@
 import { redirect } from "next/navigation";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
-import { computeFinancialImpact } from "@/lib/financial/impact";
+import { getFinancialImpactCached } from "@/lib/financial/cache";
 import FinancialClient from "./FinancialClient";
 
 const RANGE_MS = 7 * 24 * 60 * 60 * 1000;
@@ -28,7 +28,7 @@ export default async function FinancialPage() {
 
   const end = new Date();
   const start = new Date(end.getTime() - RANGE_MS);
-  const impact = await computeFinancialImpact({
+  const impact = await getFinancialImpactCached({
     orgId: session.orgId,
     start,
     end,

app/(app)/layout.tsx

@@ -1,31 +1,22 @@
 import { AppShell } from "@/components/layout/AppShell";
 import { cookies } from "next/headers";
 import { redirect } from "next/navigation";
-import { prisma } from "@/lib/prisma";
 
 const COOKIE_NAME = "mis_session";
 
-export default async function AppLayout({ children }: { children: React.ReactNode }) {
+export const dynamic = "force-dynamic";
+
+export default async function AppLayout({
+  children,
+}: {
+  children: React.ReactNode;
+}) {
   const cookieJar = await cookies();
   const sessionId = cookieJar.get(COOKIE_NAME)?.value;
   const themeCookie = cookieJar.get("mis_theme")?.value;
   const initialTheme = themeCookie === "light" ? "light" : "dark";
 
-  if (!sessionId) redirect("/login?next=/machines");
+  if (!sessionId) redirect("/login");
-
-  // validate session in DB (don’t trust cookie existence)
-  const session = await prisma.session.findFirst({
-    where: {
-      id: sessionId,
-      revokedAt: null,
-      expiresAt: { gt: new Date() },
-    },
-    include: { user: true, org: true },
-  });
-
-  if (!session || !session.user?.isActive || !session.user?.emailVerifiedAt) {
-    redirect("/login?next=/machines");
-  }
 
   return <AppShell initialTheme={initialTheme}>{children}</AppShell>;
 }

app/(app)/loading.tsx

@@ -0,0 +1,13 @@
+export default function AppLoading() {
+  return (
+    <div className="p-4 sm:p-6 space-y-6 animate-pulse">
+      <div className="h-7 w-48 rounded-lg bg-white/10" />
+      <div className="grid gap-4 md:grid-cols-2 xl:grid-cols-3">
+        {Array.from({ length: 3 }).map((_, idx) => (
+          <div key={idx} className="h-28 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+      <div className="h-80 rounded-2xl border border-white/10 bg-white/5" />
+    </div>
+  );
+}

app/(app)/machines/MachinesClient.tsx

@@ -19,6 +19,7 @@ type MachineRow = {
     fwVersion?: string | null;
   };
 };
+const LIVE_REFRESH_MS = 5000;
 
 function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
   if (!ts) return fallback;
@@ -52,7 +53,7 @@ export default function MachinesClient({ initialMachines = [] }: { initialMachin
   const { t, locale } = useI18n();
   const router = useRouter();
   const [machines, setMachines] = useState<MachineRow[]>(() => initialMachines);
-  const [loading, setLoading] = useState(false);
+  const [loading, setLoading] = useState(() => initialMachines.length === 0);
   const [showCreate, setShowCreate] = useState(false);
   const [createName, setCreateName] = useState("");
   const [createCode, setCreateCode] = useState("");
@@ -69,28 +70,36 @@ export default function MachinesClient({ initialMachines = [] }: { initialMachin
 
   useEffect(() => {
     let alive = true;
+    let timer: ReturnType<typeof setTimeout> | null = null;
 
-    async function load() {
+    async function load(initial: boolean) {
       try {
+        if (!initial && typeof document !== "undefined" && document.hidden) {
+          return;
+        }
+
         const res = await fetch("/api/machines", { cache: "no-store" });
         const json = await res.json();
         if (alive) {
           setMachines(json.machines ?? []);
-          setLoading(false);
+          if (initial) setLoading(false);
         }
       } catch {
-        if (alive) setLoading(false);
+        if (alive && initial) setLoading(false);
+      } finally {
+        if (!alive) return;
+        timer = setTimeout(() => {
+          void load(false);
+        }, LIVE_REFRESH_MS);
       }
     }
 
-    load();
+    void load(initialMachines.length === 0);
-    const t = setInterval(load, 15000);
-
     return () => {
       alive = false;
-      clearInterval(t);
+      if (timer) clearTimeout(timer);
     };
-  }, []);
+  }, [initialMachines.length]);
 
   async function createMachine() {
     if (!createName.trim()) {

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

@@ -128,6 +128,7 @@ const TOL = 0.10;
 const DEFAULT_MICRO_MULT = 1.5;
 const DEFAULT_MACRO_MULT = 5;
 const NORMAL_TOL_SEC = 0.1;
+const LIVE_REFRESH_MS = 5000;
 
 const BUCKET = {
   normal: {
@@ -289,6 +290,24 @@ function rowsToWorkOrders(rows: WorkOrderRow[]): WorkOrderUpload[] {
   return out;
 }
 
+function toErrorMessage(value: unknown, fallback: string): string {
+  if (typeof value === "string" && value.trim().length > 0) return value;
+  if (value && typeof value === "object") {
+    const maybeMessage =
+      ("message" in value && typeof value.message === "string" && value.message) ||
+      ("error" in value && typeof value.error === "string" && value.error) ||
+      ("text" in value && typeof value.text === "string" && value.text) ||
+      null;
+    if (maybeMessage && maybeMessage.trim().length > 0) return maybeMessage;
+    try {
+      return JSON.stringify(value);
+    } catch {
+      return fallback;
+    }
+  }
+  return fallback;
+}
+
 export default function MachineDetailClient() {
   const { t, locale } = useI18n();
   const { screenlessMode } = useScreenlessMode();
@@ -319,9 +338,14 @@ export default function MachineDetailClient() {
     if (!machineId) return;
 
     let alive = true;
+    let timer: ReturnType<typeof setTimeout> | null = null;
 
-    async function load() {
+    async function load(initial: boolean) {
       try {
+        if (!initial && typeof document !== "undefined" && document.hidden) {
+          return;
+        }
+
         const res = await fetch(`/api/machines/${machineId}?windowSec=3600&events=critical`, {
           cache: "no-cache",
           credentials: "include",
@@ -329,7 +353,7 @@ export default function MachineDetailClient() {
 
         if (res.status === 304) {
           if (!alive) return;
-          setLoading(false);
+          if (initial) setLoading(false);
           return;
         }
 
@@ -338,8 +362,8 @@ export default function MachineDetailClient() {
         if (!alive) return;
 
         if (!res.ok || json?.ok === false) {
-          setError(json?.error ?? t("machine.detail.error.failed"));
+          setError(toErrorMessage(json?.error, t("machine.detail.error.failed")));
-          setLoading(false);
+          if (initial) setLoading(false);
           return;
         }
 
@@ -350,19 +374,25 @@ export default function MachineDetailClient() {
         setThresholds(json.thresholds ?? null);
         setActiveStoppage(json.activeStoppage ?? null);
         setError(null);
-        setLoading(false);
+        if (initial) setLoading(false);
       } catch {
         if (!alive) return;
-        setError(t("machine.detail.error.network"));
+        if (initial) {
-        setLoading(false);
+          setError(t("machine.detail.error.network"));
+          setLoading(false);
+        }
+      } finally {
+        if (!alive) return;
+        timer = setTimeout(() => {
+          void load(false);
+        }, LIVE_REFRESH_MS);
       }
     }
 
-    load();
+    void load(true);
-    const timer = setInterval(load, 15000);
     return () => {
       alive = false;
-      clearInterval(timer);
+      if (timer) clearTimeout(timer);
     };
   }, [machineId, t]);
 
@@ -479,7 +509,7 @@ export default function MachineDetailClient() {
         } else {
           setUploadState({
             status: "error",
-            message: json?.error ?? t("machine.detail.workOrders.uploadError"),
+            message: toErrorMessage(json?.error, t("machine.detail.workOrders.uploadError")),
           });
         }
         event.target.value = "";
@@ -508,7 +538,7 @@ export default function MachineDetailClient() {
       const res = await fetch(`/api/machines/${machineId}`, { method: "DELETE" });
       const data = await res.json().catch(() => ({}));
       if (!res.ok || !data.ok) {
-        throw new Error(data.error || t("machines.delete.error.failed"));
+        throw new Error(toErrorMessage(data?.error, t("machines.delete.error.failed")));
       }
       router.push("/machines");
     } catch (err: unknown) {
@@ -886,9 +916,10 @@ export default function MachineDetailClient() {
 
   const cycleDerived = useMemo(() => {
     const rows = cycles ?? [];
+    const fallbackIdeal = cycleTarget && cycleTarget > 0 ? cycleTarget : null;
 
     const mapped: CycleDerivedRow[] = rows.map((cycle) => {
-      const ideal = cycle.ideal ?? null;
+      const ideal = cycle.ideal ?? fallbackIdeal;
       const actual = cycle.actual ?? null;
       const extra = ideal != null && actual != null ? actual - ideal : null;
 
@@ -914,7 +945,7 @@ export default function MachineDetailClient() {
     const avgDeltaPct = deltas.length ? deltas.reduce((a, b) => a + b, 0) / deltas.length : null;
 
     return { mapped, counts, avgDeltaPct };
-  }, [cycles, thresholds]);
+  }, [cycles, cycleTarget, thresholds]);
 
   const deviationSeries = useMemo(() => {
     const last = cycleDerived.mapped.slice(-100);
@@ -1313,7 +1344,7 @@ export default function MachineDetailClient() {
                 className="h-[380px] rounded-3xl border border-white/10 bg-black/30 p-4 backdrop-blur"
                 style={{ boxShadow: "var(--app-chart-shadow)" }}
               >
-                <ResponsiveContainer width="100%" height="100%">
+                <ResponsiveContainer width="100%" height="100%" minHeight={200}>
                   <ComposedChart data={deviationSeries}>
                     <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
                     <XAxis
@@ -1407,7 +1438,7 @@ export default function MachineDetailClient() {
                 className="h-[380px] rounded-3xl border border-white/10 bg-black/30 p-4 backdrop-blur"
                 style={{ boxShadow: "var(--app-chart-shadow)" }}
               >
-                <ResponsiveContainer width="100%" height="100%">
+                <ResponsiveContainer width="100%" height="100%" minHeight={200}>
                   <BarChart data={impactAgg.rows}>
                     <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
                     <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)" }} />

app/(app)/machines/loading.tsx

@@ -0,0 +1,22 @@
+export default function MachinesLoading() {
+  return (
+    <div className="p-4 sm:p-6 space-y-6 animate-pulse">
+      <div className="flex flex-col gap-3 sm:flex-row sm:items-center sm:justify-between">
+        <div className="space-y-2">
+          <div className="h-6 w-36 rounded-lg bg-white/10" />
+          <div className="h-4 w-60 rounded-lg bg-white/5" />
+        </div>
+        <div className="flex w-full gap-2 sm:w-auto">
+          <div className="h-9 w-full rounded-xl border border-emerald-400/40 bg-emerald-500/10 sm:w-36" />
+          <div className="h-9 w-full rounded-xl border border-white/10 bg-white/5 sm:w-32" />
+        </div>
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-3">
+        {Array.from({ length: 6 }).map((_, idx) => (
+          <div key={idx} className="h-40 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+    </div>
+  );
+}

app/(app)/machines/page.tsx

@@ -1,6 +1,10 @@
 import { redirect } from "next/navigation";
-import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
+import {
+  fetchLatestHeartbeats,
+  fetchMachineBase,
+  mergeMachineOverviewRows,
+} from "@/lib/machines/withLatest";
 import MachinesClient from "./MachinesClient";
 
 function toIso(value?: Date | null) {
@@ -11,34 +15,32 @@ export default async function MachinesPage() {
   const session = await requireSession();
   if (!session) redirect("/login?next=/machines");
 
-  const machines = await prisma.machine.findMany({
+  const machines = await fetchMachineBase(session.orgId);
-    where: { orgId: session.orgId },
+  const heartbeats = await fetchLatestHeartbeats(
-    orderBy: { createdAt: "desc" },
+    session.orgId,
-    select: {
+    machines.map((machine) => machine.id)
-      id: true,
+  );
-      name: true,
+  const rows = mergeMachineOverviewRows({
-      code: true,
+    machines,
-      location: true,
+    heartbeats,
-      createdAt: true,
+    includeKpi: false,
-      updatedAt: true,
-      heartbeats: {
-        orderBy: { tsServer: "desc" },
-        take: 1,
-        select: { ts: true, tsServer: true, status: true, message: true, ip: true, fwVersion: true },
-      },
-    },
   });
 
-  const initialMachines = machines.map((machine) => ({
+  const initialMachines = rows.map((machine) => ({
-    ...machine,
+    id: machine.id,
-    latestHeartbeat: machine.heartbeats[0]
+    name: machine.name,
+    code: machine.code ?? null,
+    location: machine.location ?? null,
+    latestHeartbeat: machine.latestHeartbeat
       ? {
-          ...machine.heartbeats[0],
+          ts: toIso(machine.latestHeartbeat.ts) ?? "",
-          ts: toIso(machine.heartbeats[0].ts) ?? "",
+          tsServer: toIso(machine.latestHeartbeat.tsServer),
-          tsServer: toIso(machine.heartbeats[0].tsServer),
+          status: machine.latestHeartbeat.status,
+          message: machine.latestHeartbeat.message ?? null,
+          ip: machine.latestHeartbeat.ip ?? null,
+          fwVersion: machine.latestHeartbeat.fwVersion ?? null,
         }
       : null,
-    heartbeats: undefined,
   }));
 
   return <MachinesClient initialMachines={initialMachines} />;

app/(app)/overview/OverviewClient.tsx

@@ -1,57 +1,13 @@
 "use client";
 
 import Link from "next/link";
-import { useEffect, useMemo, useState } from "react";
+import { Suspense, lazy, useEffect, useMemo, useState } from "react";
 import { useI18n } from "@/lib/i18n/useI18n";
-
+import type { EventRow, Heartbeat, MachineRow } from "./types";
-type Heartbeat = {
-  ts: string;
-  tsServer?: string | null;
-  status: string;
-  message?: string | null;
-  ip?: string | null;
-  fwVersion?: string | null;
-};
-
-type Kpi = {
-  ts: string;
-  oee?: number | null;
-  availability?: number | null;
-  performance?: number | null;
-  quality?: number | null;
-  workOrderId?: string | null;
-  sku?: string | null;
-  good?: number | null;
-  scrap?: number | null;
-  target?: number | null;
-  cycleTime?: number | null;
-};
-
-type MachineRow = {
-  id: string;
-  name: string;
-  code?: string | null;
-  location?: string | null;
-  latestHeartbeat: Heartbeat | null;
-  latestKpi?: Kpi | null;
-};
-
-type EventRow = {
-  id: string;
-  ts: string;
-  topic?: string;
-  eventType: string;
-  severity: string;
-  title: string;
-  description?: string | null;
-  requiresAck: boolean;
-  machineId?: string;
-  machineName?: string;
-  source: "ingested";
-};
 
 const OFFLINE_MS = 30000;
 const MAX_EVENT_MACHINES = 6;
+const OverviewTimeline = lazy(() => import("./OverviewTimeline"));
 
 function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
   if (!ts) return fallback;
@@ -87,17 +43,20 @@ function fmtNum(v?: number | null) {
   return `${Math.round(v)}`;
 }
 
-function severityClass(sev?: string) {
+function OverviewTimelineSkeleton() {
-  const s = (sev ?? "").toLowerCase();
+  return (
-  if (s === "critical") return "bg-red-500/15 text-red-300";
+    <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-2">
-  if (s === "warning") return "bg-yellow-500/15 text-yellow-300";
+      <div className="mb-3 flex items-center justify-between">
-  if (s === "info") return "bg-blue-500/15 text-blue-300";
+        <div className="h-4 w-32 rounded bg-white/10" />
-  return "bg-white/10 text-zinc-200";
+        <div className="h-3 w-20 rounded bg-white/5" />
-}
+      </div>
-
+      <div className="space-y-3">
-function sourceClass(src: EventRow["source"]) {
+        {Array.from({ length: 4 }).map((_, idx) => (
-  if (src === "ingested") return "bg-white/10 text-zinc-200";
+          <div key={idx} className="h-20 rounded-xl border border-white/10 bg-black/20" />
-  return "bg-white/10 text-zinc-200";
+        ))}
+      </div>
+    </div>
+  );
 }
 
 export default function OverviewClient({
@@ -111,7 +70,7 @@ export default function OverviewClient({
   const [machines, setMachines] = useState<MachineRow[]>(() => initialMachines);
   const [events, setEvents] = useState<EventRow[]>(() => initialEvents);
   const [loading, setLoading] = useState(false);
-  const [eventsLoading, setEventsLoading] = useState(false);
+  const [eventsLoading, setEventsLoading] = useState(() => initialEvents.length === 0);
 
   useEffect(() => {
     let alive = true;
@@ -119,9 +78,12 @@ export default function OverviewClient({
     async function load() {
       try {
         setEventsLoading(true);
-        const res = await fetch(`/api/overview?events=critical&eventMachines=${MAX_EVENT_MACHINES}`, {
+        const res = await fetch(
-          cache: "no-cache",
+          `/api/overview?detail=1&events=critical&eventMachines=${MAX_EVENT_MACHINES}`,
-        });
+          {
+            cache: "no-cache",
+          }
+        );
         if (res.status === 304) {
           if (alive) setLoading(false);
           return;
@@ -166,6 +128,7 @@ export default function OverviewClient({
     let goodSum = 0;
     let scrapSum = 0;
     let targetSum = 0;
+    let hasKpi = false;
 
     for (const m of machines) {
       const hb = m.latestHeartbeat;
@@ -183,22 +146,35 @@ export default function OverviewClient({
       if (k?.oee != null) {
         oeeSum += Number(k.oee);
         oeeCount += 1;
+        hasKpi = true;
       }
       if (k?.availability != null) {
         availSum += Number(k.availability);
         availCount += 1;
+        hasKpi = true;
       }
       if (k?.performance != null) {
         perfSum += Number(k.performance);
         perfCount += 1;
+        hasKpi = true;
       }
       if (k?.quality != null) {
         qualSum += Number(k.quality);
         qualCount += 1;
+        hasKpi = true;
+      }
+      if (k?.good != null) {
+        goodSum += Number(k.good);
+        hasKpi = true;
+      }
+      if (k?.scrap != null) {
+        scrapSum += Number(k.scrap);
+        hasKpi = true;
+      }
+      if (k?.target != null) {
+        targetSum += Number(k.target);
+        hasKpi = true;
       }
-      if (k?.good != null) goodSum += Number(k.good);
-      if (k?.scrap != null) scrapSum += Number(k.scrap);
-      if (k?.target != null) targetSum += Number(k.target);
     }
 
     return {
@@ -212,9 +188,9 @@ export default function OverviewClient({
       availability: availCount ? availSum / availCount : null,
       performance: perfCount ? perfSum / perfCount : null,
       quality: qualCount ? qualSum / qualCount : null,
-      goodSum,
+      goodSum: hasKpi ? goodSum : null,
-      scrapSum,
+      scrapSum: hasKpi ? scrapSum : null,
-      targetSum,
+      targetSum: hasKpi ? targetSum : null,
     };
   }, [machines]);
 
@@ -238,27 +214,6 @@ export default function OverviewClient({
     return list;
   }, [machines]);
 
-  const formatEventType = (eventType?: string) => {
-    if (!eventType) return "";
-    const key = `overview.event.${eventType}`;
-    const label = t(key);
-    return label === key ? eventType : label;
-  };
-
-  const formatSource = (source?: string) => {
-    if (!source) return "";
-    const key = `overview.source.${source}`;
-    const label = t(key);
-    return label === key ? source : label;
-  };
-
-  const formatSeverity = (severity?: string) => {
-    if (!severity) return "";
-    const key = `overview.severity.${severity}`;
-    const label = t(key);
-    return label === key ? severity.toUpperCase() : label;
-  };
-
   return (
     <div className="p-4 sm:p-6">
       <div className="mb-6 flex flex-col gap-4 sm:flex-row sm:items-start sm:justify-between">
@@ -409,56 +364,9 @@ export default function OverviewClient({
           )}
         </div>
 
-        <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-2">
+        <Suspense fallback={<OverviewTimelineSkeleton />}>
-          <div className="mb-3 flex items-center justify-between">
+          <OverviewTimeline events={events} eventsLoading={eventsLoading} locale={locale} t={t} />
-            <div className="text-sm font-semibold text-white">{t("overview.timeline")}</div>
+        </Suspense>
-            <div className="text-xs text-zinc-400">
-              {events.length} {t("overview.items")}
-            </div>
-          </div>
-
-          {events.length === 0 && !eventsLoading ? (
-            <div className="text-sm text-zinc-400">{t("overview.noEvents")}</div>
-          ) : (
-            <div className="h-[360px] space-y-3 overflow-y-auto no-scrollbar">
-              {events.map((e) => (
-                <div key={`${e.id}-${e.source}`} className="rounded-xl border border-white/10 bg-black/20 p-4">
-                  <div className="flex items-start justify-between gap-3">
-                    <div className="min-w-0">
-                      <div className="flex flex-wrap items-center gap-2">
-                        <span className={`rounded-full px-2 py-0.5 text-xs ${severityClass(e.severity)}`}>
-                          {formatSeverity(e.severity)}
-                        </span>
-                        <span className="rounded-full bg-white/10 px-2 py-0.5 text-xs text-zinc-200">
-                          {formatEventType(e.eventType)}
-                        </span>
-                        <span className={`rounded-full px-2 py-0.5 text-xs ${sourceClass(e.source)}`}>
-                          {formatSource(e.source)}
-                        </span>
-                        {e.requiresAck ? (
-                          <span className="rounded-full bg-white/10 px-2 py-0.5 text-xs text-white">
-                            {t("overview.ack")}
-                          </span>
-                        ) : null}
-                      </div>
-
-                      <div className="mt-2 truncate text-sm font-semibold text-white">
-                        {e.machineName ? `${e.machineName}: ` : ""}
-                        {e.title}
-                      </div>
-                      {e.description ? (
-                        <div className="mt-1 text-sm text-zinc-300">{e.description}</div>
-                      ) : null}
-                    </div>
-                    <div className="shrink-0 text-xs text-zinc-400">
-                      {secondsAgo(e.ts, locale, t("common.never"))}
-                    </div>
-                  </div>
-                </div>
-              ))}
-            </div>
-          )}
-        </div>
       </div>
     </div>
   );

app/(app)/overview/OverviewTimeline.tsx

@@ -0,0 +1,129 @@
+"use client";
+
+import type { EventRow } from "./types";
+
+type Translator = (key: string, vars?: Record<string, string | number>) => string;
+
+function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
+  if (!ts) return fallback;
+  const diff = Math.floor((Date.now() - new Date(ts).getTime()) / 1000);
+  const rtf = new Intl.RelativeTimeFormat(locale, { numeric: "auto" });
+  if (diff < 60) return rtf.format(-diff, "second");
+  if (diff < 3600) return rtf.format(-Math.floor(diff / 60), "minute");
+  return rtf.format(-Math.floor(diff / 3600), "hour");
+}
+
+function severityClass(sev?: string) {
+  const s = (sev ?? "").toLowerCase();
+  if (s === "critical") return "bg-red-500/15 text-red-300";
+  if (s === "warning") return "bg-yellow-500/15 text-yellow-300";
+  if (s === "info") return "bg-blue-500/15 text-blue-300";
+  return "bg-white/10 text-zinc-200";
+}
+
+function sourceClass(src: EventRow["source"]) {
+  if (src === "ingested") return "bg-white/10 text-zinc-200";
+  return "bg-white/10 text-zinc-200";
+}
+
+function formatEventType(eventType: string | undefined, t: Translator) {
+  if (!eventType) return "";
+  const key = `overview.event.${eventType}`;
+  const label = t(key);
+  return label === key ? eventType : label;
+}
+
+function formatSource(source: string | undefined, t: Translator) {
+  if (!source) return "";
+  const key = `overview.source.${source}`;
+  const label = t(key);
+  return label === key ? source : label;
+}
+
+function formatSeverity(severity: string | undefined, t: Translator) {
+  if (!severity) return "";
+  const key = `overview.severity.${severity}`;
+  const label = t(key);
+  return label === key ? severity.toUpperCase() : label;
+}
+
+export default function OverviewTimeline({
+  events,
+  eventsLoading,
+  locale,
+  t,
+}: {
+  events: EventRow[];
+  eventsLoading: boolean;
+  locale: string;
+  t: Translator;
+}) {
+  if (eventsLoading && events.length === 0) {
+    return (
+      <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-2 animate-pulse">
+        <div className="mb-3 flex items-center justify-between">
+          <div className="h-4 w-32 rounded bg-white/10" />
+          <div className="h-3 w-20 rounded bg-white/5" />
+        </div>
+        <div className="space-y-3">
+          {Array.from({ length: 4 }).map((_, idx) => (
+            <div key={idx} className="h-20 rounded-xl border border-white/10 bg-black/20" />
+          ))}
+        </div>
+      </div>
+    );
+  }
+
+  return (
+    <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-2">
+      <div className="mb-3 flex items-center justify-between">
+        <div className="text-sm font-semibold text-white">{t("overview.timeline")}</div>
+        <div className="text-xs text-zinc-400">
+          {events.length} {t("overview.items")}
+        </div>
+      </div>
+
+      {events.length === 0 && !eventsLoading ? (
+        <div className="text-sm text-zinc-400">{t("overview.noEvents")}</div>
+      ) : (
+        <div className="h-[360px] space-y-3 overflow-y-auto no-scrollbar">
+          {events.map((e) => (
+            <div key={`${e.id}-${e.source}`} className="rounded-xl border border-white/10 bg-black/20 p-4">
+              <div className="flex items-start justify-between gap-3">
+                <div className="min-w-0">
+                  <div className="flex flex-wrap items-center gap-2">
+                    <span className={`rounded-full px-2 py-0.5 text-xs ${severityClass(e.severity)}`}>
+                      {formatSeverity(e.severity, t)}
+                    </span>
+                    <span className="rounded-full bg-white/10 px-2 py-0.5 text-xs text-zinc-200">
+                      {formatEventType(e.eventType, t)}
+                    </span>
+                    <span className={`rounded-full px-2 py-0.5 text-xs ${sourceClass(e.source)}`}>
+                      {formatSource(e.source, t)}
+                    </span>
+                    {e.requiresAck ? (
+                      <span className="rounded-full bg-white/10 px-2 py-0.5 text-xs text-white">
+                        {t("overview.ack")}
+                      </span>
+                    ) : null}
+                  </div>
+
+                  <div className="mt-2 truncate text-sm font-semibold text-white">
+                    {e.machineName ? `${e.machineName}: ` : ""}
+                    {e.title}
+                  </div>
+                  {e.description ? (
+                    <div className="mt-1 text-sm text-zinc-300">{e.description}</div>
+                  ) : null}
+                </div>
+                <div className="shrink-0 text-xs text-zinc-400">
+                  {secondsAgo(e.ts, locale, t("common.never"))}
+                </div>
+              </div>
+            </div>
+          ))}
+        </div>
+      )}
+    </div>
+  );
+}

app/(app)/overview/loading.tsx

@@ -0,0 +1,30 @@
+export default function OverviewLoading() {
+  return (
+    <div className="p-4 sm:p-6 space-y-6 animate-pulse">
+      <div className="flex flex-col gap-3 sm:flex-row sm:items-center sm:justify-between">
+        <div className="space-y-2">
+          <div className="h-6 w-40 rounded-lg bg-white/10" />
+          <div className="h-4 w-64 rounded-lg bg-white/5" />
+        </div>
+        <div className="h-9 w-40 rounded-xl border border-white/10 bg-white/5" />
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 xl:grid-cols-3">
+        {Array.from({ length: 3 }).map((_, idx) => (
+          <div key={idx} className="h-36 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-4">
+        {Array.from({ length: 4 }).map((_, idx) => (
+          <div key={idx} className="h-24 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 xl:grid-cols-3">
+        <div className="h-64 rounded-2xl border border-white/10 bg-white/5 xl:col-span-1" />
+        <div className="h-64 rounded-2xl border border-white/10 bg-white/5 xl:col-span-2" />
+      </div>
+    </div>
+  );
+}

app/(app)/overview/page.tsx

@@ -1,6 +1,8 @@
 import { redirect } from "next/navigation";
 import { requireSession } from "@/lib/auth/requireSession";
-import { getOverviewData } from "@/lib/overview/getOverviewData";
+import { getOverviewSummary } from "@/lib/overview/getOverviewSummary";
+import type { getOverviewData } from "@/lib/overview/getOverviewData";
+import { logLine } from "@/lib/logger";
 import OverviewClient from "./OverviewClient";
 
 function toIso(value?: Date | null) {
@@ -11,12 +13,18 @@ export default async function OverviewPage() {
   const session = await requireSession();
   if (!session) redirect("/login?next=/overview");
 
-  const { machines, events } = await getOverviewData({
+  let machines: Awaited<ReturnType<typeof getOverviewData>>["machines"];
-    orgId: session.orgId,
+  let events: Awaited<ReturnType<typeof getOverviewData>>["events"] = [];
-    eventsMode: "critical",
+  try {
-    eventsWindowSec: 21600,
+    const data = await getOverviewSummary({ orgId: session.orgId });
-    eventMachines: 6,
+    machines = data.machines;
-  });
+  } catch (err) {
+    const message = err instanceof Error ? err.message : String(err);
+    const stack = err instanceof Error ? err.stack : undefined;
+    logLine("OverviewPage.getOverviewSummary.error", { message, stack });
+    console.error("[OverviewPage] getOverviewSummary:", err);
+    machines = [];
+  }
 
   const initialMachines = machines.map((machine) => ({
     ...machine,

app/(app)/overview/types.ts

@@ -0,0 +1,45 @@
+export type Heartbeat = {
+  ts: string;
+  tsServer?: string | null;
+  status: string;
+  message?: string | null;
+  ip?: string | null;
+  fwVersion?: string | null;
+};
+
+export type Kpi = {
+  ts: string;
+  oee?: number | null;
+  availability?: number | null;
+  performance?: number | null;
+  quality?: number | null;
+  workOrderId?: string | null;
+  sku?: string | null;
+  good?: number | null;
+  scrap?: number | null;
+  target?: number | null;
+  cycleTime?: number | null;
+};
+
+export type MachineRow = {
+  id: string;
+  name: string;
+  code?: string | null;
+  location?: string | null;
+  latestHeartbeat: Heartbeat | null;
+  latestKpi?: Kpi | null;
+};
+
+export type EventRow = {
+  id: string;
+  ts: string;
+  topic?: string;
+  eventType: string;
+  severity: string;
+  title: string;
+  description?: string | null;
+  requiresAck: boolean;
+  machineId?: string;
+  machineName?: string;
+  source: "ingested";
+};

app/(app)/reports/ReportsCharts.tsx

@@ -0,0 +1,249 @@
+"use client";
+
+import {
+  Bar,
+  BarChart,
+  CartesianGrid,
+  Cell,
+  Line,
+  LineChart,
+  ResponsiveContainer,
+  Tooltip,
+  XAxis,
+  YAxis,
+} from "recharts";
+
+type Translator = (key: string, vars?: Record<string, string | number>) => string;
+type TooltipPayload<T> = { payload?: T; name?: string; value?: number | string };
+type SimpleTooltipProps<T> = {
+  active?: boolean;
+  payload?: Array<TooltipPayload<T>>;
+  label?: string | number;
+};
+
+type ChartPoint = { ts: string; label: string; value: number };
+type CycleHistogramRow = {
+  label: string;
+  count: number;
+  rangeStart?: number;
+  rangeEnd?: number;
+  overflow?: "low" | "high";
+  minValue?: number;
+  maxValue?: number;
+};
+
+function CycleTooltip({ active, payload, t }: SimpleTooltipProps<CycleHistogramRow> & { t: Translator }) {
+  if (!active || !payload?.length) return null;
+  const p = payload[0]?.payload;
+  if (!p) return null;
+
+  let detail = "";
+  if (p.overflow === "low") {
+    detail = `${t("reports.tooltip.below")} ${p.rangeEnd?.toFixed(1)}s`;
+  } else if (p.overflow === "high") {
+    detail = `${t("reports.tooltip.above")} ${p.rangeStart?.toFixed(1)}s`;
+  } else if (p.rangeStart != null && p.rangeEnd != null) {
+    detail = `${p.rangeStart.toFixed(1)}s - ${p.rangeEnd.toFixed(1)}s`;
+  }
+
+  const extreme =
+    p.overflow && (p.minValue != null || p.maxValue != null)
+      ? `${t("reports.tooltip.extremes")}: ${p.minValue?.toFixed(1) ?? "--"}s - ${p.maxValue?.toFixed(1) ?? "--"}s`
+      : "";
+
+  return (
+    <div className="rounded-xl border border-white/10 bg-zinc-950/95 px-4 py-3 shadow-lg">
+      <div className="text-sm font-semibold text-white">{p.label}</div>
+      <div className="mt-2 space-y-1 text-xs text-zinc-300">
+        <div>
+          {t("reports.tooltip.cycles")}: <span className="text-white">{p.count}</span>
+        </div>
+        {detail ? (
+          <div>
+            {t("reports.tooltip.range")}: <span className="text-white">{detail}</span>
+          </div>
+        ) : null}
+        {extreme ? <div className="text-zinc-400">{extreme}</div> : null}
+      </div>
+    </div>
+  );
+}
+
+function DowntimeTooltip({
+  active,
+  payload,
+  t,
+}: SimpleTooltipProps<{ name?: string; value?: number }> & { t: Translator }) {
+  if (!active || !payload?.length) return null;
+  const row = payload[0]?.payload ?? {};
+  const label = row.name ?? payload[0]?.name ?? "";
+  const value = row.value ?? payload[0]?.value ?? 0;
+
+  return (
+    <div className="rounded-xl border border-white/10 bg-zinc-950/95 px-4 py-3 shadow-lg">
+      <div className="text-sm font-semibold text-white">{label}</div>
+      <div className="mt-2 text-xs text-zinc-300">
+        {t("reports.tooltip.downtime")}: <span className="text-white">{Number(value)} min</span>
+      </div>
+    </div>
+  );
+}
+
+export default function ReportsCharts({
+  oeeSeries,
+  downtimeSeries,
+  downtimeColors,
+  cycleHistogram,
+  scrapSeries,
+  lossRows,
+  locale,
+  t,
+}: {
+  oeeSeries: ChartPoint[];
+  downtimeSeries: { name: string; value: number }[];
+  downtimeColors: Record<string, string>;
+  cycleHistogram: CycleHistogramRow[];
+  scrapSeries: ChartPoint[];
+  lossRows: Array<{ label: string; value: string }>;
+  locale: string;
+  t: Translator;
+}) {
+  return (
+    <>
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-2">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.oeeTrend")}</div>
+          <div className="h-[260px] rounded-2xl border border-white/10 bg-black/25 p-4">
+            {oeeSeries.length ? (
+              <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+                <LineChart data={oeeSeries}>
+                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)" }} />
+                  <YAxis domain={[0, 100]} tick={{ fill: "var(--app-chart-tick)" }} />
+                  <Tooltip
+                    contentStyle={{
+                      background: "var(--app-chart-tooltip-bg)",
+                      border: "1px solid var(--app-chart-tooltip-border)",
+                    }}
+                    labelStyle={{ color: "var(--app-chart-label)" }}
+                    labelFormatter={(_, payload) => {
+                      const row = payload?.[0]?.payload;
+                      return row?.ts ? new Date(row.ts).toLocaleString(locale) : "";
+                    }}
+                    formatter={(val: number | string | undefined) => [
+                      val == null ? "--" : `${Number(val).toFixed(1)}%`,
+                      "OEE",
+                    ]}
+                  />
+                  <Line type="monotone" dataKey="value" stroke="#34d399" dot={false} strokeWidth={2} />
+                </LineChart>
+              </ResponsiveContainer>
+            ) : (
+              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
+                {t("reports.noTrend")}
+              </div>
+            )}
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.downtimePareto")}</div>
+          <div className="h-[260px] rounded-2xl border border-white/10 bg-black/25 p-4">
+            {downtimeSeries.length ? (
+              <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+                <BarChart data={downtimeSeries}>
+                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                  <XAxis dataKey="name" tick={{ fill: "var(--app-chart-tick)" }} />
+                  <YAxis tick={{ fill: "var(--app-chart-tick)" }} />
+                  <Tooltip content={<DowntimeTooltip t={t} />} />
+                  <Bar dataKey="value" radius={[10, 10, 0, 0]} isAnimationActive={false}>
+                    {downtimeSeries.map((row, idx) => (
+                      <Cell key={`${row.name}-${idx}`} fill={downtimeColors[row.name] ?? "#94a3b8"} />
+                    ))}
+                  </Bar>
+                </BarChart>
+              </ResponsiveContainer>
+            ) : (
+              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
+                {t("reports.noTrend")}
+              </div>
+            )}
+          </div>
+        </div>
+      </div>
+
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-3">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.cycleDistribution")}</div>
+          <div className="h-[220px] rounded-2xl border border-white/10 bg-black/25 p-4">
+            {cycleHistogram.length ? (
+              <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+                <BarChart data={cycleHistogram}>
+                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)", fontSize: 10 }} />
+                  <YAxis tick={{ fill: "var(--app-chart-tick)" }} />
+                  <Tooltip content={<CycleTooltip t={t} />} />
+                  <Bar dataKey="count" radius={[8, 8, 0, 0]} fill="#60a5fa" isAnimationActive={false} />
+                </BarChart>
+              </ResponsiveContainer>
+            ) : (
+              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
+                {t("reports.noCycle")}
+              </div>
+            )}
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.scrapTrend")}</div>
+          <div className="h-[220px] rounded-2xl border border-white/10 bg-black/25 p-4">
+            {scrapSeries.length ? (
+              <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+                <LineChart data={scrapSeries}>
+                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)" }} />
+                  <YAxis domain={[0, 100]} tick={{ fill: "var(--app-chart-tick)" }} />
+                  <Tooltip
+                    contentStyle={{
+                      background: "var(--app-chart-tooltip-bg)",
+                      border: "1px solid var(--app-chart-tooltip-border)",
+                    }}
+                    labelStyle={{ color: "var(--app-chart-label)" }}
+                    labelFormatter={(_, payload) => {
+                      const row = payload?.[0]?.payload;
+                      return row?.ts ? new Date(row.ts).toLocaleString(locale) : "";
+                    }}
+                    formatter={(val: number | string | undefined) => [
+                      val == null ? "--" : `${Number(val).toFixed(1)}%`,
+                      t("reports.scrapRate"),
+                    ]}
+                  />
+                  <Line type="monotone" dataKey="value" stroke="#f97316" dot={false} strokeWidth={2} />
+                </LineChart>
+              </ResponsiveContainer>
+            ) : (
+              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
+                {t("reports.noDowntime")}
+              </div>
+            )}
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.topLossDrivers")}</div>
+          <div className="space-y-3 text-sm text-zinc-300">
+            {lossRows.map((row) => (
+              <div
+                key={row.label}
+                className="flex items-center justify-between rounded-xl border border-white/10 bg-black/20 p-3"
+              >
+                <span>{row.label}</span>
+                <span className="text-xs text-zinc-400">{row.value}</span>
+              </div>
+            ))}
+          </div>
+        </div>
+      </div>
+    </>
+  );
+}

app/(app)/reports/downtime-pareto/page.tsx

@@ -1,12 +1,13 @@
 import { redirect } from "next/navigation";
 
-export default function LegacyDowntimeParetoPage({
+export default async function LegacyDowntimeParetoPage({
   searchParams,
 }: {
-  searchParams: Record<string, string | string[] | undefined>;
+  searchParams: Promise<Record<string, string | string[] | undefined>>;
 }) {
+  const params = await searchParams;
   const qs = new URLSearchParams();
-  for (const [k, v] of Object.entries(searchParams)) {
+  for (const [k, v] of Object.entries(params)) {
     if (typeof v === "string") qs.set(k, v);
     else if (Array.isArray(v)) v.forEach((vv) => qs.append(k, vv));
   }

app/(app)/reports/page.tsx

@@ -1,19 +1,9 @@
 "use client";
 
-import { useEffect, useMemo, useState } from "react";
+import { Suspense, lazy, useEffect, useMemo, useState } from "react";
 import { useI18n } from "@/lib/i18n/useI18n";
-import {
+
-  Bar,
+const ReportsCharts = lazy(() => import("./ReportsCharts"));
-  BarChart,
-  CartesianGrid,
-  Cell,
-  Line,
-  LineChart,
-  ResponsiveContainer,
-  Tooltip,
-  XAxis,
-  YAxis,
-} from "recharts";
 
 type RangeKey = "24h" | "7d" | "30d" | "custom";
 
@@ -68,13 +58,6 @@ type ReportPayload = {
 type MachineOption = { id: string; name: string };
 type FilterOptions = { workOrders: string[]; skus: string[] };
 type Translator = (key: string, vars?: Record<string, string | number>) => string;
-type TooltipPayload<T> = { payload?: T; name?: string; value?: number | string };
-type SimpleTooltipProps<T> = {
-  active?: boolean;
-  payload?: Array<TooltipPayload<T>>;
-  label?: string | number;
-};
-type CycleHistogramRow = ReportPayload["distribution"]["cycleTime"][number];
 
 function fmtPct(v?: number | null) {
   if (v === null || v === undefined || Number.isNaN(v)) return "--";
@@ -106,56 +89,20 @@ function formatTickLabel(ts: string, range: RangeKey) {
   return `${month}-${day}`;
 }
 
-function CycleTooltip({ active, payload, t }: SimpleTooltipProps<CycleHistogramRow> & { t: Translator }) {
+function ReportsChartsSkeleton() {
-  if (!active || !payload?.length) return null;
-  const p = payload[0]?.payload;
-  if (!p) return null;
-
-  let detail = "";
-  if (p.overflow === "low") {
-    detail = `${t("reports.tooltip.below")} ${p.rangeEnd?.toFixed(1)}s`;
-  } else if (p.overflow === "high") {
-    detail = `${t("reports.tooltip.above")} ${p.rangeStart?.toFixed(1)}s`;
-  } else if (p.rangeStart != null && p.rangeEnd != null) {
-    detail = `${p.rangeStart.toFixed(1)}s - ${p.rangeEnd.toFixed(1)}s`;
-  }
-
-  const extreme =
-    p.overflow && (p.minValue != null || p.maxValue != null)
-      ? `${t("reports.tooltip.extremes")}: ${p.minValue?.toFixed(1) ?? "--"}s - ${p.maxValue?.toFixed(1) ?? "--"}s`
-      : "";
-
   return (
-    <div className="rounded-xl border border-white/10 bg-zinc-950/95 px-4 py-3 shadow-lg">
+    <>
-      <div className="text-sm font-semibold text-white">{p.label}</div>
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-2">
-      <div className="mt-2 space-y-1 text-xs text-zinc-300">
+        {Array.from({ length: 2 }).map((_, idx) => (
-        <div>
+          <div key={idx} className="h-[320px] rounded-2xl border border-white/10 bg-white/5" />
-          {t("reports.tooltip.cycles")}: <span className="text-white">{p.count}</span>
+        ))}
-        </div>
-        {detail ? (
-          <div>
-            {t("reports.tooltip.range")}: <span className="text-white">{detail}</span>
-          </div>
-        ) : null}
-        {extreme ? <div className="text-zinc-400">{extreme}</div> : null}
       </div>
-    </div>
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-3">
-  );
+        {Array.from({ length: 3 }).map((_, idx) => (
-}
+          <div key={idx} className="h-[280px] rounded-2xl border border-white/10 bg-white/5" />
-
+        ))}
-function DowntimeTooltip({ active, payload, t }: SimpleTooltipProps<{ name?: string; value?: number }> & { t: Translator }) {
-  if (!active || !payload?.length) return null;
-  const row = payload[0]?.payload ?? {};
-  const label = row.name ?? payload[0]?.name ?? "";
-  const value = row.value ?? payload[0]?.value ?? 0;
-
-  return (
-    <div className="rounded-xl border border-white/10 bg-zinc-950/95 px-4 py-3 shadow-lg">
-      <div className="text-sm font-semibold text-white">{label}</div>
-      <div className="mt-2 text-xs text-zinc-300">
-        {t("reports.tooltip.downtime")}: <span className="text-white">{Number(value)} min</span>
       </div>
-    </div>
+    </>
   );
 }
 
@@ -534,6 +481,21 @@ export default function ReportsPage() {
     Microstop: "#FF7A00",
   };
 
+  const lossRows = useMemo(
+    () => [
+      { label: t("reports.loss.macrostop"), value: fmtDuration(downtime?.macrostopSec) },
+      { label: t("reports.loss.microstop"), value: fmtDuration(downtime?.microstopSec) },
+      { label: t("reports.loss.slowCycle"), value: downtime ? `${downtime.slowCycleCount}` : "--" },
+      { label: t("reports.loss.qualitySpike"), value: downtime ? `${downtime.qualitySpikeCount}` : "--" },
+      { label: t("reports.loss.oeeDrop"), value: downtime ? `${downtime.oeeDropCount}` : "--" },
+      {
+        label: t("reports.loss.perfDegradation"),
+        value: downtime ? `${downtime.performanceDegradationCount}` : "--",
+      },
+    ],
+    [downtime, t]
+  );
+
   const machineLabel = useMemo(() => {
     if (!machineId) return t("reports.filter.allMachines");
     return machines.find((m) => m.id === machineId)?.name ?? machineId;
@@ -696,147 +658,18 @@ export default function ReportsPage() {
         ))}
       </div>
 
-      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-2">
+      <Suspense fallback={<ReportsChartsSkeleton />}>
-        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+        <ReportsCharts
-          <div className="mb-2 text-sm font-semibold text-white">{t("reports.oeeTrend")}</div>
+          oeeSeries={oeeSeries}
-          <div className="h-[260px] rounded-2xl border border-white/10 bg-black/25 p-4">
+          downtimeSeries={downtimeSeries}
-            {oeeSeries.length ? (
+          downtimeColors={downtimeColors}
-              <ResponsiveContainer width="100%" height="100%">
+          cycleHistogram={cycleHistogram}
-                <LineChart data={oeeSeries}>
+          scrapSeries={scrapSeries}
-                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+          lossRows={lossRows}
-                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)" }} />
+          locale={locale}
-                  <YAxis domain={[0, 100]} tick={{ fill: "var(--app-chart-tick)" }} />
+          t={t}
-                  <Tooltip
+        />
-                    contentStyle={{
+      </Suspense>
-                      background: "var(--app-chart-tooltip-bg)",
-                      border: "1px solid var(--app-chart-tooltip-border)",
-                    }}
-                    labelStyle={{ color: "var(--app-chart-label)" }}
-                    labelFormatter={(_, payload) => {
-                      const row = payload?.[0]?.payload;
-                      return row?.ts ? new Date(row.ts).toLocaleString(locale) : "";
-                    }}
-                    formatter={(val: number | string | undefined) => [
-                      val == null ? "--" : `${Number(val).toFixed(1)}%`,
-                      "OEE",
-                    ]}
-                  />
-                  <Line type="monotone" dataKey="value" stroke="#34d399" dot={false} strokeWidth={2} />
-                </LineChart>
-              </ResponsiveContainer>
-            ) : (
-              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
-                {t("reports.noTrend")}
-              </div>
-            )}
-          </div>
-        </div>
-
-        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
-          <div className="mb-2 text-sm font-semibold text-white">{t("reports.downtimePareto")}</div>
-          <div className="h-[260px] rounded-2xl border border-white/10 bg-black/25 p-4">
-            {downtimeSeries.length ? (
-              <ResponsiveContainer width="100%" height="100%">
-                <BarChart data={downtimeSeries}>
-                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
-                  <XAxis dataKey="name" tick={{ fill: "var(--app-chart-tick)" }} />
-                  <YAxis tick={{ fill: "var(--app-chart-tick)" }} />
-                  <Tooltip content={<DowntimeTooltip t={t} />} />
-                  <Bar dataKey="value" radius={[10, 10, 0, 0]} isAnimationActive={false}>
-                    {downtimeSeries.map((row, idx) => (
-                      <Cell key={`${row.name}-${idx}`} fill={downtimeColors[row.name] ?? "#94a3b8"} />
-                    ))}
-                  </Bar>
-                </BarChart>
-              </ResponsiveContainer>
-            ) : (
-              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
-                {t("reports.noTrend")}
-              </div>
-            )}
-          </div>
-        </div>
-      </div>
-
-      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-3">
-        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
-          <div className="mb-2 text-sm font-semibold text-white">{t("reports.cycleDistribution")}</div>
-          <div className="h-[220px] rounded-2xl border border-white/10 bg-black/25 p-4">
-            {cycleHistogram.length ? (
-              <ResponsiveContainer width="100%" height="100%">
-                <BarChart data={cycleHistogram}>
-                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
-                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)", fontSize: 10 }} />
-                  <YAxis tick={{ fill: "var(--app-chart-tick)" }} />
-                  <Tooltip content={<CycleTooltip t={t} />} />
-                  <Bar dataKey="count" radius={[8, 8, 0, 0]} fill="#60a5fa" isAnimationActive={false} />
-                </BarChart>
-              </ResponsiveContainer>
-            ) : (
-              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
-                {t("reports.noCycle")}
-              </div>
-            )}
-          </div>
-        </div>
-
-        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
-          <div className="mb-2 text-sm font-semibold text-white">{t("reports.scrapTrend")}</div>
-          <div className="h-[220px] rounded-2xl border border-white/10 bg-black/25 p-4">
-            {scrapSeries.length ? (
-              <ResponsiveContainer width="100%" height="100%">
-                <LineChart data={scrapSeries}>
-                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
-                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)" }} />
-                  <YAxis domain={[0, 100]} tick={{ fill: "var(--app-chart-tick)" }} />
-                  <Tooltip
-                    contentStyle={{
-                      background: "var(--app-chart-tooltip-bg)",
-                      border: "1px solid var(--app-chart-tooltip-border)",
-                    }}
-                    labelStyle={{ color: "var(--app-chart-label)" }}
-                    labelFormatter={(_, payload) => {
-                      const row = payload?.[0]?.payload;
-                      return row?.ts ? new Date(row.ts).toLocaleString(locale) : "";
-                    }}
-                    formatter={(val: number | string | undefined) => [
-                      val == null ? "--" : `${Number(val).toFixed(1)}%`,
-                      t("reports.scrapRate"),
-                    ]}
-                  />
-                  <Line type="monotone" dataKey="value" stroke="#f97316" dot={false} strokeWidth={2} />
-                </LineChart>
-              </ResponsiveContainer>
-            ) : (
-              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
-                {t("reports.noDowntime")}
-              </div>
-            )}
-          </div>
-        </div>
-
-        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
-          <div className="mb-2 text-sm font-semibold text-white">{t("reports.topLossDrivers")}</div>
-          <div className="space-y-3 text-sm text-zinc-300">
-            {[
-              { label: t("reports.loss.macrostop"), value: fmtDuration(downtime?.macrostopSec) },
-              { label: t("reports.loss.microstop"), value: fmtDuration(downtime?.microstopSec) },
-              { label: t("reports.loss.slowCycle"), value: downtime ? `${downtime.slowCycleCount}` : "--" },
-              { label: t("reports.loss.qualitySpike"), value: downtime ? `${downtime.qualitySpikeCount}` : "--" },
-              { label: t("reports.loss.oeeDrop"), value: downtime ? `${downtime.oeeDropCount}` : "--" },
-              {
-                label: t("reports.loss.perfDegradation"),
-                value: downtime ? `${downtime.performanceDegradationCount}` : "--",
-              },
-            ].map((row) => (
-              <div key={row.label} className="flex items-center justify-between rounded-xl border border-white/10 bg-black/20 p-3">
-                <span>{row.label}</span>
-                <span className="text-xs text-zinc-400">{row.value}</span>
-              </div>
-            ))}
-          </div>
-        </div>
-      </div>
 
       <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-2">
         <div className="rounded-2xl border border-white/10 bg-white/5 p-5">

app/(app)/settings/page.tsx

@@ -1,9 +1,10 @@
 "use client";
 
-import { useCallback, useEffect, useMemo, useState } from "react";
+import { useCallback, useEffect, useMemo, useRef, useState } from "react";
 import { AlertsConfig } from "@/components/settings/AlertsConfig";
 import { FinancialCostConfig } from "@/components/settings/FinancialCostConfig";
 import { useI18n } from "@/lib/i18n/useI18n";
+import { SHIFT_OVERRIDE_DAYS, type ShiftOverrideDay } from "@/lib/settings";
 import { useScreenlessMode } from "@/lib/ui/screenlessMode";
 
 
@@ -25,6 +26,7 @@ type SettingsPayload = {
 
   shiftSchedule: {
     shifts: Shift[];
+    overrides?: Partial<Record<ShiftOverrideDay, Shift[]>>;
     shiftChangeCompensationMin: number;
     lunchBreakMin: number;
   };
@@ -88,6 +90,7 @@ const DEFAULT_SETTINGS: SettingsPayload = {
   modules: { screenlessMode: false },
   shiftSchedule: {
     shifts: [],
+    overrides: {},
     shiftChangeCompensationMin: 10,
     lunchBreakMin: 30,
   },
@@ -199,6 +202,21 @@ function normalizeShift(raw: unknown, fallbackName: string): Shift {
   return { name, start, end, enabled };
 }
 
+function normalizeShiftOverrides(
+  raw: unknown,
+  fallbackName: (index: number) => string
+): Partial<Record<ShiftOverrideDay, Shift[]>> {
+  const record = asRecord(raw);
+  if (!record) return {};
+  const out: Partial<Record<ShiftOverrideDay, Shift[]>> = {};
+  for (const day of SHIFT_OVERRIDE_DAYS) {
+    const shiftsRaw = Array.isArray(record[day]) ? (record[day] as unknown[]) : null;
+    if (!shiftsRaw) continue;
+    out[day] = shiftsRaw.map((shift, idx) => normalizeShift(shift, fallbackName(idx + 1)));
+  }
+  return out;
+}
+
 function normalizeSettings(raw: unknown, fallbackName: (index: number) => string): SettingsPayload {
   const record = asRecord(raw);
   const modules = asRecord(record?.modules) ?? {};
@@ -217,6 +235,7 @@ function normalizeSettings(raw: unknown, fallbackName: (index: number) => string
   const shifts = shiftsRaw.length
     ? shiftsRaw.map((s, idx) => normalizeShift(s, fallbackName(idx + 1)))
     : [{ name: fallbackName(1), ...DEFAULT_SHIFT }];
+  const overrides = normalizeShiftOverrides(shiftSchedule.overrides, fallbackName);
   const thresholds = asRecord(record.thresholds) ?? {};
   const alerts = asRecord(record.alerts) ?? {};
   const defaults = asRecord(record.defaults) ?? {};
@@ -227,6 +246,7 @@ function normalizeSettings(raw: unknown, fallbackName: (index: number) => string
     timezone: String(record.timezone ?? DEFAULT_SETTINGS.timezone),
     shiftSchedule: {
       shifts,
+      overrides,
       shiftChangeCompensationMin: Number(
         shiftSchedule.shiftChangeCompensationMin ?? DEFAULT_SETTINGS.shiftSchedule.shiftChangeCompensationMin
       ),
@@ -326,16 +346,26 @@ export default function SettingsPage() {
   const [inviteStatus, setInviteStatus] = useState<string | null>(null);
   const [inviteSubmitting, setInviteSubmitting] = useState(false);
   const [activeTab, setActiveTab] = useState<(typeof SETTINGS_TABS)[number]["id"]>("general");
+  const hasMountedRef = useRef(false);
   const defaultShiftName = useCallback(
     (index: number) => t("settings.shift.defaultName", { index }),
     [t]
   );
+  const shiftOverrideDays = useMemo(
+    () =>
+      SHIFT_OVERRIDE_DAYS.map((day) => ({
+        key: day,
+        label: t(`settings.shiftOverrides.${day}`),
+      })),
+    [t]
+  );
 
-  const loadSettings = useCallback(async () => {
+  const loadSettings = useCallback(async (forceRefresh = false) => {
     setLoading(true);
     setError(null);
     try {
-      const response = await fetch("/api/settings", { cache: "no-store" });
+      const url = forceRefresh ? "/api/settings?refresh=1" : "/api/settings";
+      const response = await fetch(url, { cache: forceRefresh ? "no-store" : "default" });
       const { data, text } = await readResponse(response);
       const api = unwrapApiResponse(data);
       if (!response.ok || !api.ok) {
@@ -350,7 +380,7 @@ export default function SettingsPage() {
     } finally {
       setLoading(false);
     }
-  }, [defaultShiftName, t]);
+  }, [defaultShiftName, t, setScreenlessMode]);
 
   const buildInviteUrl = useCallback((token: string) => {
     if (typeof window === "undefined") return `/invite/${token}`;
@@ -380,10 +410,14 @@ export default function SettingsPage() {
     }
   }, [t]);
 
+  // Only run once on mount to prevent infinite loops from dependency changes
   useEffect(() => {
+    if (hasMountedRef.current) return;
+    hasMountedRef.current = true;
     loadSettings();
     loadTeam();
-  }, [loadSettings, loadTeam]);
+    // eslint-disable-next-line react-hooks/exhaustive-deps
+  }, []);
 
   const updateShift = useCallback((index: number, patch: Partial<Shift>) => {
     setDraft((prev) => {
@@ -448,6 +482,96 @@ export default function SettingsPage() {
     });
   }, []);
 
+  const toggleShiftOverride = useCallback((day: ShiftOverrideDay) => {
+    setDraft((prev) => {
+      if (!prev) return prev;
+      const overrides = { ...(prev.shiftSchedule.overrides ?? {}) };
+      if (overrides[day]) {
+        delete overrides[day];
+      } else {
+        overrides[day] = prev.shiftSchedule.shifts.map((shift) => ({ ...shift }));
+      }
+      return {
+        ...prev,
+        shiftSchedule: {
+          ...prev.shiftSchedule,
+          overrides,
+        },
+      };
+    });
+  }, []);
+
+  const updateShiftOverride = useCallback((day: ShiftOverrideDay, index: number, patch: Partial<Shift>) => {
+    setDraft((prev) => {
+      if (!prev) return prev;
+      const current = prev.shiftSchedule.overrides?.[day];
+      if (!current) return prev;
+      const overrides = { ...(prev.shiftSchedule.overrides ?? {}) };
+      overrides[day] = current.map((shift, idx) => (idx === index ? { ...shift, ...patch } : shift));
+      return {
+        ...prev,
+        shiftSchedule: {
+          ...prev.shiftSchedule,
+          overrides,
+        },
+      };
+    });
+  }, []);
+
+  const addShiftOverride = useCallback(
+    (day: ShiftOverrideDay) => {
+      setDraft((prev) => {
+        if (!prev) return prev;
+        const overrides = { ...(prev.shiftSchedule.overrides ?? {}) };
+        const current = overrides[day] ? [...overrides[day]!] : [];
+        if (current.length >= 3) return prev;
+        const nextIndex = current.length + 1;
+        current.push({ name: defaultShiftName(nextIndex), ...DEFAULT_SHIFT });
+        overrides[day] = current;
+        return {
+          ...prev,
+          shiftSchedule: {
+            ...prev.shiftSchedule,
+            overrides,
+          },
+        };
+      });
+    },
+    [defaultShiftName]
+  );
+
+  const removeShiftOverride = useCallback((day: ShiftOverrideDay, index: number) => {
+    setDraft((prev) => {
+      if (!prev) return prev;
+      const current = prev.shiftSchedule.overrides?.[day];
+      if (!current) return prev;
+      const overrides = { ...(prev.shiftSchedule.overrides ?? {}) };
+      overrides[day] = current.filter((_, idx) => idx !== index);
+      return {
+        ...prev,
+        shiftSchedule: {
+          ...prev.shiftSchedule,
+          overrides,
+        },
+      };
+    });
+  }, []);
+
+  const clearShiftOverride = useCallback((day: ShiftOverrideDay) => {
+    setDraft((prev) => {
+      if (!prev) return prev;
+      const overrides = { ...(prev.shiftSchedule.overrides ?? {}) };
+      overrides[day] = [];
+      return {
+        ...prev,
+        shiftSchedule: {
+          ...prev.shiftSchedule,
+          overrides,
+        },
+      };
+    });
+  }, []);
+
   const updateThreshold = useCallback(
     (
       key:
@@ -665,7 +789,7 @@ export default function SettingsPage() {
         </div>
         <div className="flex w-full flex-wrap items-center gap-2 sm:w-auto">
           <button
-            onClick={loadSettings}
+            onClick={() => loadSettings(true)}
             className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-white hover:bg-white/10 sm:w-auto"
           >
             {t("settings.refresh")}
@@ -994,6 +1118,119 @@ export default function SettingsPage() {
               </div>
             </div>
           </div>
+
+          <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+            <div className="mb-2 text-sm font-semibold text-white">{t("settings.shiftOverrides.title")}</div>
+            <div className="text-xs text-zinc-400">{t("settings.shiftOverrides.subtitle")}</div>
+            <div className="mt-4 grid grid-cols-1 gap-3 md:grid-cols-2">
+              {shiftOverrideDays.map((day) => {
+                const dayOverrides = draft.shiftSchedule.overrides?.[day.key];
+                const overrideShifts = dayOverrides ?? [];
+                const isCustom = dayOverrides !== undefined;
+                return (
+                  <div key={day.key} className="rounded-xl border border-white/10 bg-black/20 p-3">
+                    <div className="flex items-center justify-between gap-2">
+                      <div className="text-sm font-semibold text-white">{day.label}</div>
+                      <button
+                        type="button"
+                        onClick={() => toggleShiftOverride(day.key)}
+                        className="rounded-lg border border-white/10 bg-white/5 px-2 py-1 text-xs text-white"
+                      >
+                        {isCustom
+                          ? t("settings.shiftOverrides.useDefault")
+                          : t("settings.shiftOverrides.customize")}
+                      </button>
+                    </div>
+
+                    {!isCustom && (
+                      <div className="mt-2 text-xs text-zinc-400">{t("settings.shiftOverrides.inherits")}</div>
+                    )}
+
+                    {isCustom && (
+                      <>
+                        {overrideShifts.length === 0 ? (
+                          <div className="mt-2 text-xs text-zinc-400">
+                            {t("settings.shiftOverrides.dayOff")}
+                          </div>
+                        ) : (
+                          <div className="mt-3 space-y-2">
+                            {overrideShifts.map((shift, index) => (
+                              <div key={`${day.key}-${index}`} className="rounded-lg border border-white/10 bg-black/30 p-2">
+                                <div className="flex items-center justify-between gap-2">
+                                  <input
+                                    value={shift.name}
+                                    onChange={(event) =>
+                                      updateShiftOverride(day.key, index, { name: event.target.value })
+                                    }
+                                    className="w-full rounded-md border border-white/10 bg-black/30 px-2 py-1 text-xs text-white"
+                                  />
+                                  <button
+                                    type="button"
+                                    onClick={() => removeShiftOverride(day.key, index)}
+                                    className="rounded-lg border border-white/10 bg-white/5 px-2 py-1 text-xs text-white"
+                                  >
+                                    {t("settings.shiftRemove")}
+                                  </button>
+                                </div>
+                                <div className="mt-2 flex items-center gap-2">
+                                  <input
+                                    type="time"
+                                    value={shift.start}
+                                    onChange={(event) =>
+                                      updateShiftOverride(day.key, index, { start: event.target.value })
+                                    }
+                                    className="w-full rounded-md border border-white/10 bg-black/30 px-2 py-1 text-xs text-white"
+                                  />
+                                  <span className="text-xs text-zinc-400">{t("settings.shiftTo")}</span>
+                                  <input
+                                    type="time"
+                                    value={shift.end}
+                                    onChange={(event) =>
+                                      updateShiftOverride(day.key, index, { end: event.target.value })
+                                    }
+                                    className="w-full rounded-md border border-white/10 bg-black/30 px-2 py-1 text-xs text-white"
+                                  />
+                                </div>
+                                <div className="mt-2 flex items-center gap-2 text-xs text-zinc-400">
+                                  <input
+                                    type="checkbox"
+                                    checked={shift.enabled}
+                                    onChange={(event) =>
+                                      updateShiftOverride(day.key, index, { enabled: event.target.checked })
+                                    }
+                                    className="h-4 w-4 rounded border border-white/20 bg-black/20"
+                                  />
+                                  {t("settings.shiftEnabled")}
+                                </div>
+                              </div>
+                            ))}
+                          </div>
+                        )}
+
+                        <div className="mt-3 flex flex-wrap gap-2">
+                          <button
+                            type="button"
+                            onClick={() => addShiftOverride(day.key)}
+                            disabled={overrideShifts.length >= 3}
+                            className="rounded-lg border border-white/10 bg-white/5 px-2 py-1 text-xs text-white disabled:opacity-40"
+                          >
+                            {t("settings.shiftAdd")}
+                          </button>
+                          <button
+                            type="button"
+                            onClick={() => clearShiftOverride(day.key)}
+                            className="rounded-lg border border-white/10 bg-white/5 px-2 py-1 text-xs text-white"
+                          >
+                            {t("settings.shiftOverrides.clear")}
+                          </button>
+                        </div>
+                      </>
+                    )}
+                  </div>
+                );
+              })}
+            </div>
+          </div>
         </div>
       )}
 

app/api/analytics/pareto/route.ts

@@ -64,7 +64,7 @@ export async function GET(req: Request) {
         count: g._count._all,
       };
     })
-    .filter((x) => x.value > 0);
+    .filter((x) => (kind === "downtime" ? x.value > 0 || x.count > 0 : x.value > 0));
 
   itemsRaw.sort((a, b) => b.value - a.value);
 

app/api/debug/logs/route.ts

@@ -0,0 +1,45 @@
+import type { NextRequest } from "next/server";
+import { NextResponse } from "next/server";
+import fs from "fs";
+import { getLogPath } from "@/lib/logger";
+
+const MAX_LINES = 100;
+
+/**
+ * GET /api/debug/logs?key=YOUR_DEBUG_LOGS_KEY
+ *
+ * Returns the last MAX_LINES from the app log file. Set DEBUG_LOGS_KEY in .env
+ * and call with ?key=... to view. If DEBUG_LOGS_KEY is unset, returns 401.
+ */
+export async function GET(req: NextRequest) {
+  const key = req.nextUrl.searchParams.get("key");
+  const secret = process.env.DEBUG_LOGS_KEY;
+
+  if (!secret || key !== secret) {
+    return NextResponse.json({ error: "Unauthorized" }, { status: 401 });
+  }
+
+  const logPath = getLogPath();
+  try {
+    const raw = fs.readFileSync(logPath, "utf8");
+    const lines = raw.split("\n").filter(Boolean);
+    const recent = lines.slice(-MAX_LINES);
+    return NextResponse.json({
+      logPath,
+      lines: recent.length,
+      entries: recent.map((line) => {
+        try {
+          return JSON.parse(line) as Record<string, unknown>;
+        } catch {
+          return { raw: line };
+        }
+      }),
+    });
+  } catch (err) {
+    const message = err instanceof Error ? err.message : String(err);
+    return NextResponse.json(
+      { error: "Failed to read log file", detail: message, logPath },
+      { status: 500 }
+    );
+  }
+}

app/api/debug/perf/route.ts

@@ -0,0 +1,31 @@
+import type { NextRequest } from "next/server";
+import { NextResponse } from "next/server";
+import { logLine } from "@/lib/logger";
+
+export const dynamic = "force-dynamic";
+
+type PerfPayload = {
+  event?: string;
+  data?: Record<string, unknown>;
+};
+
+export async function POST(req: NextRequest) {
+  try {
+    const body = (await req.json()) as PerfPayload;
+    const type = typeof body?.event === "string" ? body.event : "nav";
+    const data = body?.data && typeof body.data === "object" ? body.data : {};
+    const userAgent = req.headers.get("user-agent") ?? "";
+
+    logLine("perf.client", {
+      type,
+      userAgent,
+      ...data,
+    });
+
+    return NextResponse.json({ ok: true });
+  } catch (err) {
+    const message = err instanceof Error ? err.message : String(err);
+    logLine("perf.client.error", { message });
+    return NextResponse.json({ ok: false, error: "Bad payload" }, { status: 400 });
+  }
+}

app/api/financial/costs/route.ts

@@ -1,8 +1,17 @@
 import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { createHash } from "crypto";
+import { revalidateTag } from "next/cache";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
 import { Prisma } from "@prisma/client";
 import { z } from "zod";
+import {
+  FINANCIAL_CONFIG_SWR_SEC,
+  FINANCIAL_CONFIG_TTL_SEC,
+  getFinancialConfig,
+  type FinancialConfigPayload,
+} from "@/lib/financial/cache";
 
 function canManageFinancials(role?: string | null) {
   return role === "OWNER";
@@ -101,18 +110,37 @@ async function ensureOrgFinancialProfile(
   });
 }
 
-async function loadFinancialConfig(orgId: string) {
+function toMs(value?: Date | string | null) {
-  const [org, locations, machines, products] = await Promise.all([
+  if (!value) return 0;
-    prisma.orgFinancialProfile.findUnique({ where: { orgId } }),
+  const date = typeof value === "string" ? new Date(value) : value;
-    prisma.locationFinancialOverride.findMany({ where: { orgId }, orderBy: { location: "asc" } }),
+  const ms = date.getTime();
-    prisma.machineFinancialOverride.findMany({ where: { orgId }, orderBy: { createdAt: "desc" } }),
+  return Number.isNaN(ms) ? 0 : ms;
-    prisma.productCostOverride.findMany({ where: { orgId }, orderBy: { sku: "asc" } }),
-  ]);
-
-  return { org, locations, machines, products };
 }
 
-export async function GET() {
+function maxUpdatedMs(rows: Array<{ updatedAt?: Date | string | null }>) {
+  let max = 0;
+  for (const row of rows) {
+    const ms = toMs(row.updatedAt);
+    if (ms > max) max = ms;
+  }
+  return max;
+}
+
+function buildConfigEtag(orgId: string, payload: FinancialConfigPayload) {
+  const parts = [
+    orgId,
+    toMs(payload.org?.updatedAt),
+    maxUpdatedMs(payload.locations ?? []),
+    maxUpdatedMs(payload.machines ?? []),
+    maxUpdatedMs(payload.products ?? []),
+    payload.locations?.length ?? 0,
+    payload.machines?.length ?? 0,
+    payload.products?.length ?? 0,
+  ];
+  return `W/"${createHash("sha1").update(parts.join("|")).digest("hex")}"`;
+}
+
+export async function GET(req: NextRequest) {
   const session = await requireSession();
   if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
 
@@ -124,9 +152,25 @@ export async function GET() {
     return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
   }
 
+  const url = new URL(req.url);
+  const refresh = url.searchParams.get("refresh") === "1";
+
   await prisma.$transaction((tx) => ensureOrgFinancialProfile(tx, session.orgId, session.userId));
-  const payload = await loadFinancialConfig(session.orgId);
+  const payload = await getFinancialConfig(session.orgId, { refresh });
-  return NextResponse.json({ ok: true, ...payload });
+
+  const etag = buildConfigEtag(session.orgId, payload);
+  const responseHeaders = new Headers({
+    "Cache-Control": `private, max-age=${FINANCIAL_CONFIG_TTL_SEC}, stale-while-revalidate=${FINANCIAL_CONFIG_SWR_SEC}`,
+    ETag: etag,
+    Vary: "Cookie",
+  });
+
+  const ifNoneMatch = req.headers.get("if-none-match");
+  if (!refresh && ifNoneMatch && ifNoneMatch === etag) {
+    return new NextResponse(null, { status: 304, headers: responseHeaders });
+  }
+
+  return NextResponse.json({ ok: true, ...payload }, { headers: responseHeaders });
 }
 
 export async function POST(req: Request) {
@@ -257,6 +301,9 @@ export async function POST(req: Request) {
     }
   });
 
-  const payload = await loadFinancialConfig(session.orgId);
+  revalidateTag(`financial-config:${session.orgId}`, { expire: 0 });
+  revalidateTag(`financial-impact:${session.orgId}`, { expire: 0 });
+
+  const payload = await getFinancialConfig(session.orgId, { refresh: true });
   return NextResponse.json({ ok: true, ...payload });
 }

app/api/financial/impact/route.ts

@@ -2,7 +2,11 @@ import { NextResponse } from "next/server";
 import type { NextRequest } from "next/server";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
-import { computeFinancialImpact } from "@/lib/financial/impact";
+import {
+  FINANCIAL_IMPACT_SWR_SEC,
+  FINANCIAL_IMPACT_TTL_SEC,
+  getFinancialImpactCached,
+} from "@/lib/financial/cache";
 
 const RANGE_MS: Record<string, number> = {
   "24h": 24 * 60 * 60 * 1000,
@@ -50,22 +54,31 @@ export async function GET(req: NextRequest) {
   }
 
   const url = new URL(req.url);
+  const refresh = url.searchParams.get("refresh") === "1";
   const { start, end } = pickRange(req);
   const machineId = url.searchParams.get("machineId") ?? undefined;
   const location = url.searchParams.get("location") ?? undefined;
   const sku = url.searchParams.get("sku") ?? undefined;
   const currency = url.searchParams.get("currency") ?? undefined;
 
-  const result = await computeFinancialImpact({
+  const result = await getFinancialImpactCached(
-    orgId: session.orgId,
+    {
-    start,
+      orgId: session.orgId,
-    end,
+      start,
-    machineId,
+      end,
-    location,
+      machineId,
-    sku,
+      location,
-    currency,
+      sku,
-    includeEvents: false,
+      currency,
+      includeEvents: false,
+    },
+    { refresh }
+  );
+
+  const responseHeaders = new Headers({
+    "Cache-Control": `private, max-age=${FINANCIAL_IMPACT_TTL_SEC}, stale-while-revalidate=${FINANCIAL_IMPACT_SWR_SEC}`,
+    Vary: "Cookie",
   });
 
-  return NextResponse.json({ ok: true, ...result });
+  return NextResponse.json({ ok: true, ...result }, { headers: responseHeaders });
 }

app/api/ingest/cycle/route.ts

@@ -33,6 +33,48 @@ function unwrapEnvelope(raw: unknown) {
   };
 }
 
+function asNumber(value: unknown) {
+  if (typeof value === "number" && Number.isFinite(value)) return value;
+  if (typeof value === "string" && value.trim() !== "") {
+    const parsed = Number(value);
+    return Number.isFinite(parsed) ? parsed : undefined;
+  }
+  return undefined;
+}
+
+function normalizeCycleInput(raw: unknown): Record<string, unknown> | null {
+  const row = asRecord(raw);
+  if (!row) return null;
+  const data = asRecord(row.data);
+
+  const fromRowOrData = (keys: string[]) => {
+    for (const key of keys) {
+      if (row[key] !== undefined) return row[key];
+      if (data && data[key] !== undefined) return data[key];
+    }
+    return undefined;
+  };
+
+  return {
+    ...row,
+    actual_cycle_time: fromRowOrData(["actual_cycle_time", "actualCycleTime", "actual_cycle", "actual"]),
+    theoretical_cycle_time: fromRowOrData([
+      "theoretical_cycle_time",
+      "theoreticalCycleTime",
+      "cycleTime",
+      "cycle_time",
+      "ideal",
+    ]),
+    cycle_count: fromRowOrData(["cycle_count", "cycleCount"]),
+    work_order_id: fromRowOrData(["work_order_id", "workOrderId"]),
+    good_delta: fromRowOrData(["good_delta", "goodDelta"]),
+    scrap_delta: fromRowOrData(["scrap_delta", "scrapDelta", "scrap_total"]),
+    timestamp: fromRowOrData(["timestamp", "tsMs"]),
+    ts: fromRowOrData(["ts", "tsMs"]),
+    event_timestamp: fromRowOrData(["event_timestamp", "eventTimestamp"]),
+  };
+}
+
 const numberFromAny = z.preprocess((value) => {
   if (typeof value === "number") return value;
   if (typeof value === "string" && value.trim() !== "") return Number(value);
@@ -87,15 +129,22 @@ export async function POST(req: Request) {
     return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
   }
 
-  const cycleList = Array.isArray(cyclesRaw) ? cyclesRaw : [cyclesRaw];
+  const cycleList = (Array.isArray(cyclesRaw) ? cyclesRaw : [cyclesRaw])
+    .map((row) => normalizeCycleInput(row))
+    .filter((row): row is Record<string, unknown> => !!row);
+
+  if (!cycleList.length) {
+    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+  }
+
   const parsedCycles = z.array(cycleSchema).safeParse(cycleList);
   if (!parsedCycles.success) {
     return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
   }
 
   const fallbackTsMs =
-    (typeof bodyRecord.tsMs === "number" && bodyRecord.tsMs) ||
+    asNumber(bodyRecord.tsMs) ||
-    (typeof bodyRecord.tsDevice === "number" && bodyRecord.tsDevice) ||
+    asNumber(bodyRecord.tsDevice) ||
     undefined;
 
   const rows = parsedCycles.data.map((data) => {

app/api/ingest/event/route.ts

@@ -4,6 +4,14 @@ 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 ?? "")
@@ -30,6 +38,8 @@ const CANON_TYPE: Record<string, string> = {
   "microparo": "microstop",
   "micro-paro": "microstop",
   "down": "stop",
+  "downtime-acknowledged": "downtime-acknowledged",
+  "scrap-manual-entry": "scrap-manual-entry",
 };
 
 const ALLOWED_TYPES = new Set([
@@ -42,6 +52,8 @@ const ALLOWED_TYPES = new Set([
   "quality-spike",
   "performance-degradation",
   "predictive-oee-decline",
+  "downtime-acknowledged",
+  "scrap-manual-entry",
 ]);
 
 const machineIdSchema = z.string().uuid();
@@ -58,6 +70,153 @@ function clampText(value: unknown, maxLen: number) {
   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 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 });
@@ -103,8 +262,11 @@ export async function POST(req: Request) {
   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 },
+    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(
@@ -129,6 +291,8 @@ export async function POST(req: Request) {
       continue;
     }
     const evData = asRecord(evRecord.data) ?? {};
+    const evReason = asRecord(evRecord.reason) ?? asRecord(evData.reason);
+    const evDowntime = asRecord(evRecord.downtime) ?? asRecord(evData.downtime);
 
     const rawType = evRecord.eventType ?? evRecord.anomaly_type ?? evRecord.topic ?? bodyRecord.topic ?? "";
     const typ0 = normalizeType(rawType);
@@ -211,6 +375,8 @@ export async function POST(req: Request) {
     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;
 
     const activeWorkOrder = asRecord(evRecord.activeWorkOrder);
     const dataActiveWorkOrder = asRecord(evData.activeWorkOrder);
@@ -244,8 +410,127 @@ export async function POST(req: Request) {
 
     created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
 
+    if (evReason) {
+      const inferredKind: ReasonCatalogKind =
+        String(evReason.type ?? "").toLowerCase() === "scrap" || finalType === "scrap-manual-entry"
+          ? "scrap"
+          : "downtime";
+      const resolved = resolveReason(evReason, inferredKind, reasonCatalog, reasonCatalog.version);
+
+      if (resolved.reasonCode) {
+        const reasonId =
+          clampText(evReason.reasonId, 128) ??
+          (inferredKind === "downtime"
+            ? `evt:${machine.id}:downtime:${clampText(evReason.incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id}`
+            : `evt:${machine.id}:scrap:${clampText(evReason.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(evReason.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(evReason.incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id;
+          const durationSeconds =
+            numberFrom(evDowntime?.durationSeconds) ??
+            numberFrom(evData.stoppage_duration_seconds) ??
+            numberFrom(evData.stop_duration_seconds) ??
+            null;
+          const episodeEndTsMs =
+            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(evReason.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(evReason.scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+            update: {
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText(evReason.scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+          });
+        }
+      }
+    }
+
     try {
-      await evaluateAlertsForEvent(row.id);
+      if (row.eventType !== "downtime-acknowledged" && row.eventType !== "scrap-manual-entry") {
+        await evaluateAlertsForEvent(row.id);
+      }
     } catch (err) {
       console.error("[alerts] evaluation failed", err);
     }

app/api/ingest/kpi/route.ts

@@ -4,6 +4,7 @@ import { prisma } from "@/lib/prisma";
 import { getMachineAuth } from "@/lib/machineAuthCache";
 import { normalizeSnapshotV1 } from "@/lib/contracts/v1";
 import { toJsonValue } from "@/lib/prismaJson";
+import { logLine } from "@/lib/logger";
 
 function getClientIp(req: Request) {
   const xf = req.headers.get("x-forwarded-for");
@@ -21,11 +22,68 @@ function parseSeqToBigInt(seq: unknown): bigint | null {
   return null;
 }
 
+function asRecord(value: unknown): Record<string, unknown> | null {
+  if (!value || typeof value !== "object" || Array.isArray(value)) return null;
+  return value as Record<string, unknown>;
+}
+
+function readPath(root: unknown, path: string[]): unknown {
+  let current = root;
+  for (const key of path) {
+    const record = asRecord(current);
+    if (!record) return undefined;
+    current = record[key];
+  }
+  return current;
+}
+
+function collectQualityTrace(params: {
+  rawBody: unknown;
+  normalizedKpis: Record<string, unknown> | null;
+  persistedQuality: number | null;
+  machineId: string;
+  rowId: string;
+}) {
+  const { rawBody, normalizedKpis, persistedQuality, machineId, rowId } = params;
+  const candidates = [
+    "kpis.quality",
+    "payload.kpis.quality",
+    "kpi_snapshot.quality",
+    "quality",
+    "payload.quality",
+  ] as const;
+
+  const rawQualityCandidates: Record<string, { type: string; value: unknown }> = {};
+  for (const path of candidates) {
+    const value = readPath(rawBody, path.split("."));
+    rawQualityCandidates[path] = {
+      type: value === null ? "null" : typeof value,
+      value,
+    };
+  }
+
+  const normalizedQuality = normalizedKpis?.quality;
+  return {
+    machineId,
+    rowId,
+    rawQualityCandidates,
+    normalizedQuality: {
+      type: normalizedQuality === null ? "null" : typeof normalizedQuality,
+      value: normalizedQuality ?? null,
+    },
+    persistedQuality: {
+      type: persistedQuality === null ? "null" : typeof persistedQuality,
+      value: persistedQuality,
+    },
+  };
+}
+
 export async function POST(req: Request) {
   const endpoint = "/api/ingest/kpi";
   const startedAt = Date.now();
   const ip = getClientIp(req);
   const userAgent = req.headers.get("user-agent");
+  const traceEnabled = process.env.TRACE_KPI_INGEST === "1" || req.headers.get("x-debug-ingest") === "1";
 
   let rawBody: unknown = null;
   let orgId: string | null = null;
@@ -182,11 +240,33 @@ export async function POST(req: Request) {
       },
     });
 
+    const trace = collectQualityTrace({
+      rawBody,
+      normalizedKpis: asRecord(k),
+      persistedQuality: row.quality ?? null,
+      machineId: machine.id,
+      rowId: row.id,
+    });
+    if (traceEnabled) {
+      logLine("ingest.kpi.trace", {
+        endpoint,
+        machineId: machine.id,
+        orgId,
+        schemaVersion,
+        seq: seq != null ? seq.toString() : null,
+        ip,
+        userAgent,
+        trace,
+        rawBody: toJsonValue(rawBody),
+      });
+    }
+
     return NextResponse.json({
       ok: true,
       id: row.id,
       tsDevice: row.ts,
       tsServer: row.tsServer,
+      trace: traceEnabled ? trace : undefined,
     });
   } catch (err: unknown) {
     const msg = err instanceof Error ? err.message : "Unknown error";

app/api/machines/[machineId]/route.ts

@@ -1,9 +1,11 @@
 import { NextResponse } from "next/server";
 import type { NextRequest } from "next/server";
+import { Prisma } from "@prisma/client";
 import { z } from "zod";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
 import { normalizeEvent } from "@/lib/events/normalizeEvent";
+import { invalidateMachineAuth } from "@/lib/machineAuthCache";
 
 const machineIdSchema = z.string().uuid();
 
@@ -29,10 +31,63 @@ function isPlainObject(value: unknown): value is Record<string, unknown> {
 }
 
 function parseNumber(value: string | null, fallback: number) {
+  if (value == null || value === "") return fallback;
   const parsed = Number(value);
   return Number.isFinite(parsed) ? parsed : fallback;
 }
 
+type MachineFkReference = {
+  tableName: string;
+  columnName: string;
+  deleteRule: string;
+};
+
+function quoteIdent(identifier: string) {
+  return `"${identifier.replace(/"/g, "\"\"")}"`;
+}
+
+async function cleanupMachineReferences(machineId: string) {
+  const refs = await prisma.$queryRaw<MachineFkReference[]>`
+    SELECT DISTINCT
+      tc.table_name AS "tableName",
+      kcu.column_name AS "columnName",
+      rc.delete_rule AS "deleteRule"
+    FROM information_schema.table_constraints tc
+    JOIN information_schema.key_column_usage kcu
+      ON tc.constraint_name = kcu.constraint_name
+     AND tc.table_schema = kcu.table_schema
+    JOIN information_schema.referential_constraints rc
+      ON tc.constraint_name = rc.constraint_name
+     AND tc.table_schema = rc.constraint_schema
+    WHERE tc.constraint_type = 'FOREIGN KEY'
+      AND tc.table_schema = 'public'
+      AND rc.unique_constraint_schema = 'public'
+      AND rc.unique_constraint_name IN (
+        SELECT constraint_name
+        FROM information_schema.table_constraints
+        WHERE table_schema = 'public'
+          AND table_name = 'Machine'
+          AND constraint_type IN ('PRIMARY KEY', 'UNIQUE')
+      )
+  `;
+
+  for (const ref of refs) {
+    if (ref.tableName === "Machine") continue;
+    const table = quoteIdent(ref.tableName);
+    const column = quoteIdent(ref.columnName);
+    const rule = String(ref.deleteRule ?? "").toUpperCase();
+
+    if (rule === "CASCADE") continue;
+
+    if (rule === "SET NULL") {
+      await prisma.$executeRawUnsafe(`UPDATE ${table} SET ${column} = NULL WHERE ${column} = $1`, machineId);
+      continue;
+    }
+
+    await prisma.$executeRawUnsafe(`DELETE FROM ${table} WHERE ${column} = $1`, machineId);
+  }
+}
+
 export async function GET(req: NextRequest, { params }: { params: Promise<{ machineId: string }> }) {
   const session = await requireSession();
   if (!session) {
@@ -158,25 +213,15 @@ export async function GET(req: NextRequest, { params }: { params: Promise<{ mach
 
   const eventWindowStart = new Date(Date.now() - eventsWindowSec * 1000);
   const criticalSeverities = ["critical", "error", "high"];
-  const eventWhere = {
+  const eventWhereBase = {
     orgId: session.orgId,
     machineId,
     ts: { gte: eventWindowStart },
-    eventType: { in: Array.from(ALLOWED_EVENT_TYPES) },
-    ...(eventsMode === "critical"
-      ? {
-          OR: [
-            { eventType: "macrostop" },
-            { requiresAck: true },
-            { severity: { in: criticalSeverities } },
-          ],
-        }
-      : {}),
   };
 
   const [rawEvents, eventsCountAll] = await Promise.all([
     prisma.machineEvent.findMany({
-      where: eventWhere,
+      where: eventWhereBase,
       orderBy: { ts: "desc" },
       take: eventsOnly ? 300 : 120,
       select: {
@@ -192,15 +237,29 @@ export async function GET(req: NextRequest, { params }: { params: Promise<{ mach
         workOrderId: true,
       },
     }),
-    prisma.machineEvent.count({ where: eventWhere }),
+    prisma.machineEvent.count({ where: eventWhereBase }),
   ]);
 
   const normalized = rawEvents.map((row) =>
     normalizeEvent(row, { microMultiplier: stoppageMultiplier, macroMultiplier: macroStoppageMultiplier })
   );
 
+  const allowed = normalized.filter((event) => ALLOWED_EVENT_TYPES.has(event.eventType));
+  const criticalEventTypes = new Set(["macrostop", "microstop", "slow-cycle", "offline", "error"]);
+  const filtered =
+    eventsMode === "critical"
+      ? allowed.filter((event) => {
+          const severity = String(event.severity ?? "").toLowerCase();
+          return (
+            criticalEventTypes.has(event.eventType) ||
+            event.requiresAck === true ||
+            criticalSeverities.includes(severity)
+          );
+        })
+      : allowed;
+
   const seen = new Set<string>();
-  const deduped = normalized.filter((event) => {
+  const deduped = filtered.filter((event) => {
     const key = `${event.eventType}-${event.ts ?? ""}-${event.title}`;
     if (seen.has(key)) return false;
     seen.add(key);
@@ -249,25 +308,185 @@ export async function DELETE(_req: Request, { params }: { params: Promise<{ mach
     return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
   }
 
-  const result = await prisma.$transaction(async (tx) => {
+  for (let attempt = 0; attempt < 3; attempt += 1) {
-    await tx.machineCycle.deleteMany({
+    try {
-      where: {
+      if (attempt === 0) {
+        // Revoke credentials first in a committed write so ingest auth fails immediately.
+        const revoked = await prisma.machine.updateMany({
+          where: {
+            id: machineId,
+            orgId: session.orgId,
+          },
+          data: {
+            apiKey: null,
+          },
+        });
+
+        if (revoked.count === 0) {
+          return NextResponse.json({ ok: false, error: "Machine not found" }, { status: 404 });
+        }
+
+        invalidateMachineAuth(machineId);
+      }
+
+      // Avoid long interactive transactions on very large history tables (P2028 timeout).
+      // This sequence is idempotent and safe to retry because apiKey is revoked first.
+      await prisma.machineCycle.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineHeartbeat.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineKpiSnapshot.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineEvent.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineWorkOrder.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineSettings.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.settingsAudit.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.alertNotification.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineFinancialOverride.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.reasonEntry.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.downtimeAction.updateMany({
+        where: {
+          machineId,
+        },
+        data: {
+          machineId: null,
+        },
+      });
+
+      const result = await prisma.machine.deleteMany({
+        where: {
+          id: machineId,
+          orgId: session.orgId,
+        },
+      });
+
+      if (result.count === 0) {
+        return NextResponse.json({ ok: false, error: "Machine not found" }, { status: 404 });
+      }
+
+      invalidateMachineAuth(machineId);
+      return NextResponse.json({ ok: true });
+    } catch (err: unknown) {
+      const code = err instanceof Prisma.PrismaClientKnownRequestError ? err.code : undefined;
+      const message = err instanceof Error ? err.message : String(err);
+      console.error("DELETE /api/machines/[machineId] failed", {
         machineId,
         orgId: session.orgId,
-      },
+        attempt,
-    });
+        code,
+        message,
+      });
 
-    return tx.machine.deleteMany({
+      if (code === "P2003") {
-      where: {
+        if (attempt < 2) {
-        id: machineId,
+          try {
-        orgId: session.orgId,
+            await cleanupMachineReferences(machineId);
-      },
+          } catch (cleanupErr: unknown) {
-    });
+            const cleanupMessage = cleanupErr instanceof Error ? cleanupErr.message : String(cleanupErr);
-  });
+            console.error("DELETE /api/machines/[machineId] cleanup failed", {
+              machineId,
+              orgId: session.orgId,
+              attempt,
+              cleanupMessage,
+            });
+          }
+          await new Promise((resolve) => setTimeout(resolve, (attempt + 1) * 150));
+          continue;
+        }
 
-  if (result.count === 0) {
+        return NextResponse.json(
-    return NextResponse.json({ ok: false, error: "Machine not found" }, { status: 404 });
+          {
+            ok: false,
+            error: "Machine has dependent records and could not be removed",
+            code,
+          },
+          { status: 409 }
+        );
+      }
+
+      if (code === "P2022") {
+        return NextResponse.json(
+          {
+            ok: false,
+            error: "Server schema is out of date for machine delete",
+            code,
+          },
+          { status: 500 }
+        );
+      }
+
+      if (code === "P2028") {
+        return NextResponse.json(
+          {
+            ok: false,
+            error: "Delete timed out while removing machine history",
+            code,
+          },
+          { status: 503 }
+        );
+      }
+
+      if (code) {
+        return NextResponse.json(
+          {
+            ok: false,
+            error: "Delete failed due to database error",
+            code,
+          },
+          { status: 500 }
+        );
+      }
+
+      return NextResponse.json({ ok: false, error: "Delete failed" }, { status: 500 });
+    }
   }
 
-  return NextResponse.json({ ok: true });
+  return NextResponse.json({ ok: false, error: "Delete failed", code: "DELETE_RETRY_EXHAUSTED" }, { status: 500 });
 }

app/api/machines/route.ts

@@ -1,11 +1,25 @@
 import { NextResponse } from "next/server";
 import { randomBytes } from "crypto";
 import { prisma } from "@/lib/prisma";
-import { cookies } from "next/headers";
 import { generatePairingCode } from "@/lib/pairingCode";
 import { z } from "zod";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, formatServerTiming, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+import { requireSession } from "@/lib/auth/requireSession";
+import {
+  fetchLatestHeartbeats,
+  fetchLatestKpis,
+  fetchMachineBase,
+  mergeMachineOverviewRows,
+} from "@/lib/machines/withLatest";
 
-const COOKIE_NAME = "mis_session";
+let machinesColdStart = true;
+
+function getColdStartInfo() {
+  const coldStart = machinesColdStart;
+  machinesColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
 
 const createMachineSchema = z.object({
   name: z.string().trim().min(1).max(80),
@@ -13,72 +27,66 @@ const createMachineSchema = z.object({
   location: z.string().trim().max(80).optional(),
 });
 
-async function requireSession() {
+export async function GET(req: Request) {
-  const sessionId = (await cookies()).get(COOKIE_NAME)?.value;
+  const perfEnabled = PERF_LOGS_ENABLED;
-  if (!sessionId) return null;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+  const { coldStart, uptimeMs } = getColdStartInfo();
+  const url = new URL(req.url);
+  const includeKpi = url.searchParams.get("includeKpi") === "1";
 
-  const session = await prisma.session.findFirst({
+  const authStart = nowMs();
-    where: { id: sessionId, revokedAt: null, expiresAt: { gt: new Date() } },
-    include: { org: true, user: true },
-  });
-
-  if (!session || !session.user?.isActive || !session.user?.emailVerifiedAt) {
-    return null;
-  }
-
-  return session;
-}
-
-export async function GET() {
   const session = await requireSession();
+  if (perfEnabled) timings.auth = elapsedMs(authStart);
   if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
 
-  const machines = await prisma.machine.findMany({
+  const preQueryStart = nowMs();
-    where: { orgId: session.orgId },
+  const machinesStart = nowMs();
-    orderBy: { createdAt: "desc" },
+  if (perfEnabled) timings.preQuery = elapsedMs(preQueryStart);
-    select: {
+  const machines = await fetchMachineBase(session.orgId);
-      id: true,
+  if (perfEnabled) timings.machinesQuery = elapsedMs(machinesStart);
-      name: true,
-      code: true,
-      location: true,
-      createdAt: true,
-      updatedAt: true,
-      heartbeats: {
-        orderBy: { tsServer: "desc" },
-        take: 1,
-        select: { ts: true, tsServer: true, status: true, message: true, ip: true, fwVersion: true },
-      },
-      kpiSnapshots: {
-        orderBy: { ts: "desc" },
-        take: 1,
-        select: {
-          ts: true,
-          oee: true,
-          availability: true,
-          performance: true,
-          quality: true,
-          workOrderId: true,
-          sku: true,
-          good: true,
-          scrap: true,
-          target: true,
-          cycleTime: true,
-        },
-      },
-    },
-  });
 
+  const heartbeatStart = nowMs();
+  const machineIds = machines.map((machine) => machine.id);
+  const heartbeats = await fetchLatestHeartbeats(session.orgId, machineIds);
+  if (perfEnabled) timings.heartbeatsQuery = elapsedMs(heartbeatStart);
+
+  let kpis: Awaited<ReturnType<typeof fetchLatestKpis>> = [];
+  if (includeKpi) {
+    const kpiStart = nowMs();
+    kpis = await fetchLatestKpis(session.orgId, machineIds);
+    if (perfEnabled) timings.kpiQuery = elapsedMs(kpiStart);
+  }
+
+  const postQueryStart = nowMs();
 
   // flatten latest heartbeat for UI convenience
-  const out = machines.map((m) => ({
+  const out = mergeMachineOverviewRows({
-    ...m,
+    machines,
-    latestHeartbeat: m.heartbeats[0] ?? null,
+    heartbeats,
-    latestKpi: m.kpiSnapshots[0] ?? null,
+    kpis,
-    heartbeats: undefined,
+    includeKpi,
-    kpiSnapshots: undefined,
+  });
-  }));
 
-  return NextResponse.json({ ok: true, machines: out });
+  const payload = { ok: true, machines: out };
+
+  const responseHeaders = new Headers();
+  if (perfEnabled) {
+    timings.postQuery = elapsedMs(postQueryStart);
+    timings.total = elapsedMs(totalStart);
+    responseHeaders.set("Server-Timing", formatServerTiming(timings));
+    const payloadBytes = Buffer.byteLength(JSON.stringify(payload));
+    logLine("perf.machines.api", {
+      orgId: session.orgId,
+      coldStart,
+      uptimeMs,
+      timings,
+      counts: { machines: out.length },
+      payloadBytes,
+    });
+  }
+
+  return NextResponse.json(payload, { headers: responseHeaders });
 }
 
 export async function POST(req: Request) {

app/api/overview/route.ts

@@ -4,23 +4,72 @@ import { createHash } from "crypto";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
 import { getOverviewData } from "@/lib/overview/getOverviewData";
+import { getOverviewSummary } from "@/lib/overview/getOverviewSummary";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, formatServerTiming, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+
+let overviewColdStart = true;
+
+function getColdStartInfo() {
+  const coldStart = overviewColdStart;
+  overviewColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
 
 function toMs(value?: Date | null) {
   return value ? value.getTime() : 0;
 }
 
 export async function GET(req: NextRequest) {
+  const perfEnabled = PERF_LOGS_ENABLED;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+  const { coldStart, uptimeMs } = getColdStartInfo();
+
+  const authStart = nowMs();
   const session = await requireSession();
+  if (perfEnabled) timings.auth = elapsedMs(authStart);
   if (!session) {
     return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
   }
 
   const url = new URL(req.url);
+  const detail = url.searchParams.get("detail") === "1";
+
+  if (!detail) {
+    const summaryStart = nowMs();
+    const { machines: machineRows } = await getOverviewSummary({ orgId: session.orgId });
+    if (perfEnabled) timings.summary = elapsedMs(summaryStart);
+
+    const payload = { ok: true, machines: machineRows, events: [] };
+    const responseHeaders = new Headers();
+    if (perfEnabled) {
+      timings.total = elapsedMs(totalStart);
+      responseHeaders.set("Server-Timing", formatServerTiming(timings));
+      const payloadBytes = Buffer.byteLength(JSON.stringify(payload));
+      logLine("perf.overview.api", {
+        orgId: session.orgId,
+        detail: false,
+        coldStart,
+        uptimeMs,
+        timings,
+        counts: { machines: machineRows.length, events: 0 },
+        payloadBytes,
+      });
+    }
+
+    return NextResponse.json(payload, { headers: responseHeaders });
+  }
+
+  const preQueryStart = nowMs();
   const eventsMode = url.searchParams.get("events") ?? "critical";
   const eventsWindowSecRaw = Number(url.searchParams.get("eventsWindowSec") ?? "21600");
   const eventsWindowSec = Number.isFinite(eventsWindowSecRaw) ? eventsWindowSecRaw : 21600;
   const eventMachinesRaw = Number(url.searchParams.get("eventMachines") ?? "6");
   const eventMachines = Number.isFinite(eventMachinesRaw) ? Math.max(1, eventMachinesRaw) : 6;
+  if (perfEnabled) timings.preQuery = elapsedMs(preQueryStart);
+
+  const aggStart = nowMs();
   const [machineAgg, heartbeatAgg, kpiAgg, eventAgg, orgSettings] = await Promise.all([
     prisma.machine.aggregate({
       where: { orgId: session.orgId },
@@ -43,6 +92,7 @@ export async function GET(req: NextRequest) {
       select: { updatedAt: true, stoppageMultiplier: true, macroStoppageMultiplier: true },
     }),
   ]);
+  if (perfEnabled) timings.agg = elapsedMs(aggStart);
 
   const lastModifiedMs = Math.max(
     toMs(machineAgg._max.updatedAt),
@@ -86,6 +136,7 @@ export async function GET(req: NextRequest) {
     }
   }
 
+  const dataStart = nowMs();
   const { machines: machineRows, events } = await getOverviewData({
     orgId: session.orgId,
     eventsMode,
@@ -93,9 +144,29 @@ export async function GET(req: NextRequest) {
     eventMachines,
     orgSettings,
   });
+  if (perfEnabled) timings.data = elapsedMs(dataStart);
 
-  return NextResponse.json(
+  const postQueryStart = nowMs();
-    { ok: true, machines: machineRows, events },
+
-    { headers: responseHeaders }
+  const payload = { ok: true, machines: machineRows, events };
-  );
+  if (perfEnabled) {
+    timings.postQuery = elapsedMs(postQueryStart);
+    timings.total = elapsedMs(totalStart);
+    responseHeaders.set("Server-Timing", formatServerTiming(timings));
+    const payloadBytes = Buffer.byteLength(JSON.stringify(payload));
+    logLine("perf.overview.api", {
+      orgId: session.orgId,
+      detail: true,
+      coldStart,
+      uptimeMs,
+      eventsMode,
+      eventsWindowSec,
+      eventMachines,
+      timings,
+      counts: { machines: machineRows.length, events: events.length },
+      payloadBytes,
+    });
+  }
+
+  return NextResponse.json(payload, { headers: responseHeaders });
 }

app/api/reasons/catalog/route.ts

@@ -0,0 +1,48 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import {
+  flattenReasonCatalog,
+  loadFallbackReasonCatalog,
+  normalizeReasonCatalog,
+  type ReasonCatalogKind,
+} from "@/lib/reasonCatalog";
+
+function asKind(value: string | null): ReasonCatalogKind | null {
+  const kind = String(value ?? "").toLowerCase();
+  if (kind === "downtime" || kind === "scrap") return kind;
+  return null;
+}
+
+export async function GET(req: Request) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const url = new URL(req.url);
+  const kind = asKind(url.searchParams.get("kind"));
+  if (!kind) {
+    return NextResponse.json({ ok: false, error: "Invalid kind (downtime|scrap)" }, { status: 400 });
+  }
+
+  const orgSettings = await prisma.orgSettings.findUnique({
+    where: { orgId: session.orgId },
+    select: { defaultsJson: true },
+  });
+  const defaultsJson =
+    orgSettings?.defaultsJson && typeof orgSettings.defaultsJson === "object" && !Array.isArray(orgSettings.defaultsJson)
+      ? (orgSettings.defaultsJson as Record<string, unknown>)
+      : {};
+  const settingsCatalog = normalizeReasonCatalog(defaultsJson.reasonCatalog ?? defaultsJson.reasonCatalogData);
+  const fallbackCatalog = await loadFallbackReasonCatalog();
+  const catalog = settingsCatalog ?? fallbackCatalog;
+  const rows = flattenReasonCatalog(catalog, kind);
+
+  return NextResponse.json({
+    ok: true,
+    source: settingsCatalog ? "settings" : "fallback",
+    kind,
+    catalogVersion: catalog.version,
+    categories: catalog[kind],
+    rows,
+  });
+}

app/api/reports/filters/route.ts

@@ -2,6 +2,16 @@ import { NextResponse } from "next/server";
 import type { NextRequest } from "next/server";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, formatServerTiming, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+
+let reportsFiltersColdStart = true;
+
+function getColdStartInfo() {
+  const coldStart = reportsFiltersColdStart;
+  reportsFiltersColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
 
 const RANGE_MS: Record<string, number> = {
   "24h": 24 * 60 * 60 * 1000,
@@ -33,10 +43,19 @@ function pickRange(req: NextRequest) {
 }
 
 export async function GET(req: NextRequest) {
+  const perfEnabled = PERF_LOGS_ENABLED;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+  const { coldStart, uptimeMs } = getColdStartInfo();
+
+  const authStart = nowMs();
   const session = await requireSession();
+  if (perfEnabled) timings.auth = elapsedMs(authStart);
   if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
 
+  const preQueryStart = nowMs();
   const url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "24h";
   const machineId = url.searchParams.get("machineId") ?? undefined;
   const { start, end } = pickRange(req);
 
@@ -46,20 +65,51 @@ export async function GET(req: NextRequest) {
     ts: { gte: start, lte: end },
   };
 
+  if (perfEnabled) timings.preQuery = elapsedMs(preQueryStart);
+
+  const workOrdersStart = nowMs();
   const workOrderRows = await prisma.machineCycle.findMany({
     where: { ...baseWhere, workOrderId: { not: null } },
     distinct: ["workOrderId"],
     select: { workOrderId: true },
   });
+  if (perfEnabled) timings.workOrders = elapsedMs(workOrdersStart);
 
+  const skuStart = nowMs();
   const skuRows = await prisma.machineCycle.findMany({
     where: { ...baseWhere, sku: { not: null } },
     distinct: ["sku"],
     select: { sku: true },
   });
+  if (perfEnabled) timings.skus = elapsedMs(skuStart);
+
+  const postQueryStart = nowMs();
 
   const workOrders = workOrderRows.map((r) => r.workOrderId).filter(Boolean) as string[];
   const skus = skuRows.map((r) => r.sku).filter(Boolean) as string[];
 
-  return NextResponse.json({ ok: true, workOrders, skus });
+  const payload = { ok: true, workOrders, skus };
+
+  const responseHeaders = new Headers();
+  if (perfEnabled) {
+    timings.postQuery = elapsedMs(postQueryStart);
+    timings.total = elapsedMs(totalStart);
+    responseHeaders.set("Server-Timing", formatServerTiming(timings));
+    const payloadBytes = Buffer.byteLength(JSON.stringify(payload));
+    logLine("perf.reports.filters", {
+      orgId: session.orgId,
+      coldStart,
+      uptimeMs,
+      range,
+      machineId,
+      timings,
+      rowCounts: {
+        workOrderRows: workOrderRows.length,
+        skuRows: skuRows.length,
+      },
+      payloadBytes,
+    });
+  }
+
+  return NextResponse.json(payload, { headers: responseHeaders });
 }

app/api/reports/route.ts

@@ -2,6 +2,16 @@ import { NextResponse } from "next/server";
 import type { NextRequest } from "next/server";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, formatServerTiming, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+
+let reportsColdStart = true;
+
+function getColdStartInfo() {
+  const coldStart = reportsColdStart;
+  reportsColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
 
 const RANGE_MS: Record<string, number> = {
   "24h": 24 * 60 * 60 * 1000,
@@ -37,10 +47,19 @@ function safeNum(v: unknown) {
 }
 
 export async function GET(req: NextRequest) {
+  const perfEnabled = PERF_LOGS_ENABLED;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+  const { coldStart, uptimeMs } = getColdStartInfo();
+
+  const authStart = nowMs();
   const session = await requireSession();
+  if (perfEnabled) timings.auth = elapsedMs(authStart);
   if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
 
+  const preQueryStart = nowMs();
   const url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "24h";
   const machineId = url.searchParams.get("machineId") ?? undefined;
   const { start, end } = pickRange(req);
   const workOrderId = url.searchParams.get("workOrderId") ?? undefined;
@@ -52,6 +71,9 @@ export async function GET(req: NextRequest) {
     ...(sku ? { sku } : {}),
   };
 
+  if (perfEnabled) timings.preQuery = elapsedMs(preQueryStart);
+
+  const kpiStart = nowMs();
   const kpiRows = await prisma.machineKpiSnapshot.findMany({
     where: { ...baseWhere, ts: { gte: start, lte: end } },
     orderBy: { ts: "asc" },
@@ -67,6 +89,7 @@ export async function GET(req: NextRequest) {
       machineId: true,
     },
   });
+  if (perfEnabled) timings.kpiRows = elapsedMs(kpiStart);
 
   let oeeSum = 0;
   let oeeCount = 0;
@@ -96,10 +119,12 @@ export async function GET(req: NextRequest) {
     }
   }
 
+  const cyclesStart = nowMs();
   const cycles = await prisma.machineCycle.findMany({
     where: { ...baseWhere, ts: { gte: start, lte: end } },
     select: { goodDelta: true, scrapDelta: true },
   });
+  if (perfEnabled) timings.cycles = elapsedMs(cyclesStart);
 
   let goodTotal = 0;
   let scrapTotal = 0;
@@ -109,6 +134,7 @@ export async function GET(req: NextRequest) {
     if (safeNum(c.scrapDelta) != null) scrapTotal += Number(c.scrapDelta);
   }
 
+  const kpiAggStart = nowMs();
   const kpiAgg = await prisma.machineKpiSnapshot.groupBy({
     by: ["machineId"],
     where: { ...baseWhere, ts: { gte: start, lte: end } },
@@ -116,6 +142,7 @@ export async function GET(req: NextRequest) {
     _min: { good: true, scrap: true },
     _count: { _all: true },
   });
+  if (perfEnabled) timings.kpiAgg = elapsedMs(kpiAggStart);
 
   let targetTotal = 0;
   if (goodTotal === 0 && scrapTotal === 0) {
@@ -151,10 +178,12 @@ export async function GET(req: NextRequest) {
     if (maxTarget != null) targetTotal += maxTarget;
   }
 
+  const eventsStart = nowMs();
   const events = await prisma.machineEvent.findMany({
     where: { ...baseWhere, ts: { gte: start, lte: end } },
     select: { eventType: true, data: true },
   });
+  if (perfEnabled) timings.events = elapsedMs(eventsStart);
 
   let macrostopSec = 0;
   let microstopSec = 0;
@@ -223,10 +252,12 @@ export async function GET(req: NextRequest) {
       trend.scrapRate.push({ t, v: (scrap / (good + scrap)) * 100 });
     }
   }
+  const cycleRowsStart = nowMs();
   const cycleRows = await prisma.machineCycle.findMany({
     where: { ...baseWhere, ts: { gte: start, lte: end } },
     select: { actualCycleTime: true },
   });
+  if (perfEnabled) timings.cycleRows = elapsedMs(cycleRowsStart);
 
   const values = cycleRows
     .map((c) => Number(c.actualCycleTime))
@@ -310,10 +341,14 @@ export async function GET(req: NextRequest) {
   const scrapBySku = new Map<string, number>();
   const scrapByWo = new Map<string, number>();
 
+  const scrapRowsStart = nowMs();
   const scrapRows = await prisma.machineCycle.findMany({
     where: { ...baseWhere, ts: { gte: start, lte: end } },
     select: { sku: true, workOrderId: true, scrapDelta: true },
   });
+  if (perfEnabled) timings.scrapRows = elapsedMs(scrapRowsStart);
+
+  const postQueryStart = nowMs();
 
   for (const row of scrapRows) {
     const scrap = safeNum(row.scrapDelta);
@@ -340,20 +375,20 @@ export async function GET(req: NextRequest) {
 
 
 
-  return NextResponse.json({
+  const payload = {
     ok: true,
     summary: {
-    oeeAvg,
+      oeeAvg,
-    availabilityAvg,
+      availabilityAvg,
-    performanceAvg,
+      performanceAvg,
-    qualityAvg,
+      qualityAvg,
-    goodTotal,
+      goodTotal,
-    scrapTotal,
+      scrapTotal,
-    targetTotal,
+      targetTotal,
-    scrapRate,
+      scrapRate,
-    topScrapSku,
+      topScrapSku,
-    topScrapWorkOrder,
+      topScrapWorkOrder,
-  },
+    },
 
     downtime: {
       macrostopSec,
@@ -365,9 +400,36 @@ export async function GET(req: NextRequest) {
     },
     trend,
     insights,
-    distribution: { 
+    distribution: {
-      cycleTime: cycleTimeBins 
+      cycleTime: cycleTimeBins,
     },
+  };
 
-  });
+  const responseHeaders = new Headers();
+  if (perfEnabled) {
+    timings.postQuery = elapsedMs(postQueryStart);
+    timings.total = elapsedMs(totalStart);
+    responseHeaders.set("Server-Timing", formatServerTiming(timings));
+    const payloadBytes = Buffer.byteLength(JSON.stringify(payload));
+    logLine("perf.reports.api", {
+      orgId: session.orgId,
+      coldStart,
+      uptimeMs,
+      range,
+      machineId,
+      workOrderId,
+      sku,
+      timings,
+      rowCounts: {
+        kpiRows: kpiRows.length,
+        cycles: cycles.length,
+        events: events.length,
+        cycleRows: cycleRows.length,
+        scrapRows: scrapRows.length,
+      },
+      payloadBytes,
+    });
+  }
+
+  return NextResponse.json(payload, { headers: responseHeaders });
 }

app/api/settings/machines/[machineId]/route.ts

@@ -14,8 +14,10 @@ import {
   validateDefaults,
   validateShiftFields,
   validateShiftSchedule,
+  validateShiftOverrides,
   validateThresholds,
 } from "@/lib/settings";
+import { loadFallbackReasonCatalog, normalizeReasonCatalog, type ReasonCatalog } from "@/lib/reasonCatalog";
 import { publishSettingsUpdate } from "@/lib/mqtt";
 import { z } from "zod";
 
@@ -44,6 +46,24 @@ function pickAllowedOverrides(raw: unknown) {
   return out;
 }
 
+function withReasonCatalog<T extends Record<string, unknown>>(payload: T, fallbackCatalog: ReasonCatalog) {
+  const base = (isPlainObject(payload) ? { ...payload } : {}) as T;
+  const defaults = isPlainObject(base.defaults) ? base.defaults : {};
+  const parsed =
+    normalizeReasonCatalog(base.reasonCatalog) ??
+    normalizeReasonCatalog(base.reasonCatalogData) ??
+    normalizeReasonCatalog(defaults.reasonCatalog) ??
+    normalizeReasonCatalog(defaults.reasonCatalogData) ??
+    fallbackCatalog;
+
+  return {
+    ...base,
+    reasonCatalog: parsed,
+    reasonCatalogData: parsed,
+    reasonCatalogVersion: Number(parsed.version || 1),
+  };
+}
+
 async function ensureOrgSettings(
   tx: Prisma.TransactionClient,
   orgId: string,
@@ -144,6 +164,7 @@ export async function GET(
     if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
     orgId = machine.orgId;
   }
+  const fallbackCatalog = await loadFallbackReasonCatalog();
 
   const { settings, overrides } = await prisma.$transaction(async (tx) => {
     const orgSettings = await ensureOrgSettings(tx, orgId as string, userId);
@@ -154,9 +175,15 @@ export async function GET(
       select: { overridesJson: true },
     });
 
-    const orgPayload = buildSettingsPayload(orgSettings.settings, orgSettings.shifts ?? []);
+    const orgPayload = withReasonCatalog(
+      buildSettingsPayload(orgSettings.settings, orgSettings.shifts ?? []),
+      fallbackCatalog
+    );
     const rawOverrides = pickAllowedOverrides(machineSettings?.overridesJson ?? {});
-    const effective = deepMerge(orgPayload, rawOverrides);
+    const effective = withReasonCatalog(
+      deepMerge(orgPayload, rawOverrides) as Record<string, unknown>,
+      fallbackCatalog
+    );
 
     return { settings: { org: orgPayload, effective }, overrides: rawOverrides };
   });
@@ -242,6 +269,14 @@ export async function PUT(
     return NextResponse.json({ ok: false, error: shiftValidation.error }, { status: 400 });
   }
 
+  const overridesResult =
+    patch?.shiftSchedule?.overrides !== undefined
+      ? validateShiftOverrides(patch.shiftSchedule.overrides)
+      : ({ ok: true, overrides: undefined } as const);
+  if (!overridesResult.ok) {
+    return NextResponse.json({ ok: false, error: overridesResult.error }, { status: 400 });
+  }
+
   const thresholdsValidation = validateThresholds(patch?.thresholds);
   if (!thresholdsValidation.ok) {
     return NextResponse.json({ ok: false, error: thresholdsValidation.error }, { status: 400 });
@@ -275,6 +310,12 @@ export async function PUT(
       ...patch,
       shiftSchedule: {
         ...patch.shiftSchedule,
+        overrides:
+          patch.shiftSchedule.overrides !== undefined
+            ? overridesResult.overrides === null
+              ? null
+              : overridesResult.overrides
+            : patch.shiftSchedule.overrides,
         shiftChangeCompensationMin:
           patch.shiftSchedule.shiftChangeCompensationMin !== undefined
             ? Number(patch.shiftSchedule.shiftChangeCompensationMin)
@@ -372,9 +413,16 @@ export async function PUT(
       },
     });
 
-    const orgPayload = buildSettingsPayload(orgSettings.settings, orgSettings.shifts ?? []);
+    const fallbackCatalog = await loadFallbackReasonCatalog();
+    const orgPayload = withReasonCatalog(
+      buildSettingsPayload(orgSettings.settings, orgSettings.shifts ?? []),
+      fallbackCatalog
+    );
     const overrides = pickAllowedOverrides(saved.overridesJson ?? {});
-    const effective = deepMerge(orgPayload, overrides);
+    const effective = withReasonCatalog(
+      deepMerge(orgPayload, overrides) as Record<string, unknown>,
+      fallbackCatalog
+    );
 
     return {
       orgPayload,

app/api/settings/route.ts

@@ -1,4 +1,7 @@
 import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { createHash } from "crypto";
+import { revalidateTag, unstable_cache } from "next/cache";
 import { Prisma } from "@prisma/client";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
@@ -13,8 +16,10 @@ import {
   validateDefaults,
   validateShiftFields,
   validateShiftSchedule,
+  validateShiftOverrides,
   validateThresholds,
 } from "@/lib/settings";
+import { loadFallbackReasonCatalog, normalizeReasonCatalog, type ReasonCatalog } from "@/lib/reasonCatalog";
 import { publishSettingsUpdate } from "@/lib/mqtt";
 import { z } from "zod";
 
@@ -34,6 +39,24 @@ function canManageSettings(role?: string | null) {
   return role === "OWNER" || role === "ADMIN";
 }
 
+function withReasonCatalog<T extends Record<string, unknown>>(payload: T, fallbackCatalog: ReasonCatalog) {
+  const base = (isPlainObject(payload) ? { ...payload } : {}) as T;
+  const defaults = isPlainObject(base.defaults) ? base.defaults : {};
+  const parsed =
+    normalizeReasonCatalog(base.reasonCatalog) ??
+    normalizeReasonCatalog(base.reasonCatalogData) ??
+    normalizeReasonCatalog(defaults.reasonCatalog) ??
+    normalizeReasonCatalog(defaults.reasonCatalogData) ??
+    fallbackCatalog;
+
+  return {
+    ...base,
+    reasonCatalog: parsed,
+    reasonCatalogData: parsed,
+    reasonCatalogVersion: Number(parsed.version || 1),
+  };
+}
+
 const settingsPayloadSchema = z
   .object({
     source: z.string().trim().max(40).optional(),
@@ -43,10 +66,14 @@ const settingsPayloadSchema = z
     thresholds: z.any().optional(),
     alerts: z.any().optional(),
     defaults: z.any().optional(),
+    reasonCatalog: z.any().optional(),
     version: z.union([z.number(), z.string()]).optional(),
   })
   .passthrough();
 
+const SETTINGS_TTL_SEC = 10;
+const SETTINGS_SWR_SEC = 30;
+
 async function ensureOrgSettings(tx: Prisma.TransactionClient, orgId: string, userId: string) {
   let settings = await tx.orgSettings.findUnique({
     where: { orgId },
@@ -111,24 +138,56 @@ async function ensureOrgSettings(tx: Prisma.TransactionClient, orgId: string, us
   return { settings, shifts };
 }
 
-export async function GET() {
+async function loadSettingsPayload(orgId: string, userId: string) {
+  const loaded = await prisma.$transaction(async (tx) => {
+    const found = await ensureOrgSettings(tx, orgId, userId);
+    if (!found?.settings) throw new Error("SETTINGS_NOT_FOUND");
+    return found;
+  });
+
+  const fallbackCatalog = await loadFallbackReasonCatalog();
+  const payload = withReasonCatalog(buildSettingsPayload(loaded.settings, loaded.shifts ?? []), fallbackCatalog);
+  const defaultsRaw = isPlainObject(loaded.settings.defaultsJson) ? (loaded.settings.defaultsJson as any) : {};
+  const modulesRaw = isPlainObject(defaultsRaw.modules) ? defaultsRaw.modules : {};
+  const modules = { screenlessMode: modulesRaw.screenlessMode === true };
+
+  return { payload, modules };
+}
+
+async function loadSettingsCached(orgId: string, userId: string) {
+  const cached = unstable_cache(
+    () => loadSettingsPayload(orgId, userId),
+    ["settings", orgId],
+    { revalidate: SETTINGS_TTL_SEC, tags: [`settings:${orgId}`] }
+  );
+  return cached();
+}
+
+export async function GET(req: NextRequest) {
   const session = await requireSession();
   if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
 
   try {
-    const loaded = await prisma.$transaction(async (tx) => {
+    const url = new URL(req.url);
-      const found = await ensureOrgSettings(tx, session.orgId, session.userId);
+    const refresh = url.searchParams.get("refresh") === "1";
-      if (!found?.settings) throw new Error("SETTINGS_NOT_FOUND");
+    const { payload, modules } = refresh
-      return found;
+      ? await loadSettingsPayload(session.orgId, session.userId)
+      : await loadSettingsCached(session.orgId, session.userId);
+
+    const version = payload.version ?? 0;
+    const etag = `W/"${createHash("sha1").update(`${session.orgId}:${version}`).digest("hex")}"`;
+    const responseHeaders = new Headers({
+      "Cache-Control": `private, max-age=${SETTINGS_TTL_SEC}, stale-while-revalidate=${SETTINGS_SWR_SEC}`,
+      ETag: etag,
+      Vary: "Cookie",
     });
 
-    const payload = buildSettingsPayload(loaded.settings, loaded.shifts ?? []);
+    const ifNoneMatch = req.headers.get("if-none-match");
+    if (!refresh && ifNoneMatch && ifNoneMatch === etag) {
+      return new NextResponse(null, { status: 304, headers: responseHeaders });
+    }
 
-    const defaultsRaw = isPlainObject(loaded.settings.defaultsJson) ? (loaded.settings.defaultsJson as any) : {};
+    return NextResponse.json({ ok: true, settings: { ...payload, modules } }, { headers: responseHeaders });
-    const modulesRaw = isPlainObject(defaultsRaw.modules) ? defaultsRaw.modules : {};
-    const modules = { screenlessMode: modulesRaw.screenlessMode === true };
-
-    return NextResponse.json({ ok: true, settings: { ...payload, modules } });
 
   } catch (err) {
     console.error("[settings GET] failed", err);
@@ -162,6 +221,7 @@ export async function PUT(req: Request) {
     const thresholds = parsed.data.thresholds;
     const alerts = parsed.data.alerts;
     const defaults = parsed.data.defaults;
+    const reasonCatalogRaw = parsed.data.reasonCatalog;
     const expectedVersion = parsed.data.version;
     const modules = parsed.data.modules;
 
@@ -173,6 +233,7 @@ export async function PUT(req: Request) {
       thresholds === undefined &&
       alerts === undefined &&
       defaults === undefined &&
+      reasonCatalogRaw === undefined &&
       modules === undefined
 
     ) {
@@ -191,6 +252,13 @@ export async function PUT(req: Request) {
     if (defaults !== undefined && !isPlainObject(defaults)) {
       return NextResponse.json({ ok: false, error: "defaults must be an object" }, { status: 400 });
     }
+    const nextReasonCatalog =
+      reasonCatalogRaw === undefined || reasonCatalogRaw === null
+        ? reasonCatalogRaw
+        : normalizeReasonCatalog(reasonCatalogRaw);
+    if (reasonCatalogRaw !== undefined && reasonCatalogRaw !== null && !nextReasonCatalog) {
+      return NextResponse.json({ ok: false, error: "reasonCatalog must be a valid catalog payload" }, { status: 400 });
+    }
     if (modules !== undefined && !isPlainObject(modules)) {
       return NextResponse.json({ ok: false, error: "Invalid modules payload" }, { status: 400 });
     }
@@ -210,6 +278,14 @@ export async function PUT(req: Request) {
       return NextResponse.json({ ok: false, error: shiftValidation.error }, { status: 400 });
     }
 
+    const overridesResult =
+      shiftSchedule?.overrides !== undefined
+        ? validateShiftOverrides(shiftSchedule.overrides)
+        : ({ ok: true, overrides: undefined } as const);
+    if (!overridesResult.ok) {
+      return NextResponse.json({ ok: false, error: overridesResult.error }, { status: 400 });
+    }
+
     const thresholdsValidation = validateThresholds(thresholds);
     if (!thresholdsValidation.ok) {
       return NextResponse.json({ ok: false, error: thresholdsValidation.error }, { status: 400 });
@@ -257,12 +333,22 @@ export async function PUT(req: Request) {
         : { ...currentModulesRaw, screenlessMode };
 
     // Write defaultsJson if either defaults changed OR modules changed
-    const shouldWriteDefaultsJson = !!nextDefaultsCore || screenlessMode !== undefined;
+    const shouldWriteDefaultsJson =
+      !!nextDefaultsCore || screenlessMode !== undefined || reasonCatalogRaw !== undefined;
 
     const nextDefaultsJson = shouldWriteDefaultsJson
       ? { ...(nextDefaultsCore ?? normalizeDefaults(currentDefaultsRaw)), modules: nextModules }
       : undefined;
 
+    if (nextDefaultsJson && reasonCatalogRaw !== undefined) {
+      const defaultsTarget = nextDefaultsJson as Record<string, unknown>;
+      if (nextReasonCatalog === null) {
+        delete defaultsTarget.reasonCatalog;
+      } else if (nextReasonCatalog) {
+        defaultsTarget.reasonCatalog = nextReasonCatalog;
+      }
+    }
+
 
     const updateData = stripUndefined({
       timezone: timezone !== undefined ? String(timezone) : undefined,
@@ -272,6 +358,12 @@ export async function PUT(req: Request) {
           : undefined,
       lunchBreakMin:
         shiftSchedule?.lunchBreakMin !== undefined ? Number(shiftSchedule.lunchBreakMin) : undefined,
+      shiftScheduleOverridesJson:
+        shiftSchedule?.overrides !== undefined
+          ? overridesResult.overrides === null
+            ? null
+            : overridesResult.overrides
+          : undefined,
       stoppageMultiplier:
         thresholds?.stoppageMultiplier !== undefined ? Number(thresholds.stoppageMultiplier) : undefined,
       macroStoppageMultiplier:
@@ -373,6 +465,8 @@ export async function PUT(req: Request) {
     const modulesRaw = isPlainObject(defaultsRaw.modules) ? defaultsRaw.modules : {};
     const modulesOut = { screenlessMode: modulesRaw.screenlessMode === true };
 
+    revalidateTag(`settings:${session.orgId}`, { expire: 0 });
+
     return NextResponse.json({ ok: true, settings: { ...payload, modules: modulesOut } });
 
   } catch (err) {

app/global-error.tsx

@@ -0,0 +1,37 @@
+"use client";
+
+export default function GlobalError({
+  error,
+  reset,
+}: {
+  error: Error & { digest?: string };
+  reset: () => void;
+}) {
+  return (
+    <html lang="en">
+      <body style={{ margin: 0, fontFamily: "system-ui, sans-serif", background: "#0a0a0a", color: "#e5e5e5", minHeight: "100vh", display: "flex", alignItems: "center", justifyContent: "center" }}>
+        <div style={{ textAlign: "center", padding: "2rem", maxWidth: "28rem" }}>
+          <h1 style={{ fontSize: "1.25rem", fontWeight: 600, marginBottom: "0.5rem" }}>Something went wrong</h1>
+          <p style={{ fontSize: "0.875rem", color: "#a3a3a3", marginBottom: "1.5rem" }}>
+            An unexpected error occurred. Please try again.
+          </p>
+          <button
+            type="button"
+            onClick={() => reset()}
+            style={{
+              padding: "0.5rem 1rem",
+              fontSize: "0.875rem",
+              borderRadius: "0.5rem",
+              border: "1px solid rgba(255,255,255,0.2)",
+              background: "rgba(255,255,255,0.05)",
+              color: "#e5e5e5",
+              cursor: "pointer",
+            }}
+          >
+            Try again
+          </button>
+        </div>
+      </body>
+    </html>
+  );
+}

app/invite/[token]/page.tsx

@@ -3,14 +3,14 @@ import { redirect } from "next/navigation";
 import { prisma } from "@/lib/prisma";
 import InviteAcceptForm from "./InviteAcceptForm";
 
-export default async function InvitePage({ params }: { params: { token: string } | Promise<{ token: string }> }) {
+export default async function InvitePage({ params }: { params: Promise<{ token: string }> }) {
   const session = (await cookies()).get("mis_session")?.value;
   if (session) {
     redirect("/machines");
   }
 
-  const resolvedParams = await Promise.resolve(params);
+  const { token: rawToken } = await params;
-  const token = String(resolvedParams?.token || "").trim().toLowerCase();
+  const token = String(rawToken || "").trim().toLowerCase();
   let invite = null;
   let error: string | null = null;
 

app/layout.tsx

@@ -1,11 +1,14 @@
 import type { Metadata } from "next";
 import { cookies } from "next/headers";
 import "./globals.css";
+import { prisma } from "@/lib/prisma";
 
-export const metadata: Metadata = {
+export async function generateMetadata(): Promise<Metadata> {
-  title: "MIS Control Tower",
+  return {
-  description: "MaliounTech Industrial Suite",
+    title: "MIS Control Tower",
-};
+    description: "MaliounTech Industrial Suite",
+  };
+}
 
 export default async function RootLayout({ children }: { children: React.ReactNode }) {
   const cookieJar = await cookies();

app/login/page.tsx

@@ -6,13 +6,14 @@ import LoginForm from "./LoginForm"; // adjust path if needed
 export default async function LoginPage({
   searchParams,
 }: {
-  searchParams?: { next?: string };
+  searchParams?: Promise<{ next?: string }>;
 }) {
   const session = (await cookies()).get("mis_session")?.value;
 
   // If already logged in, send to next or machines
   if (session) {
-    const next = searchParams?.next || "/machines";
+    const params = searchParams ? await searchParams : {};
+    const next = params?.next || "/machines";
     redirect(next);
   }
 

components/downtime/DowntimePageClient.tsx

@@ -80,6 +80,24 @@ type ApiDowntimeEventsRes = {
   events?: ApiDowntimeEvent[];
 };
 
+type ApiReasonCatalogRow = {
+  kind: "downtime" | "scrap";
+  categoryId: string;
+  categoryLabel: string;
+  detailId: string;
+  detailLabel: string;
+  reasonCode: string;
+  reasonLabel: string;
+};
+
+type ApiReasonCatalogRes = {
+  ok: boolean;
+  error?: string;
+  kind?: "downtime" | "scrap";
+  catalogVersion?: number;
+  rows?: ApiReasonCatalogRow[];
+};
+
 function fmtDT(iso: string | null) {
   if (!iso) return "—";
   const d = new Date(iso);
@@ -1155,6 +1173,8 @@ export default function DowntimePageClient() {
   const [eventsRes, setEventsRes] = useState<ApiDowntimeEventsRes | null>(null);
   const [eventsLoading, setEventsLoading] = useState(false);
   const [eventsErr, setEventsErr] = useState<string | null>(null);
+  const [catalogRows, setCatalogRows] = useState<ApiReasonCatalogRow[]>([]);
+  const [catalogErr, setCatalogErr] = useState<string | null>(null);
 
   const [eventsLimit, setEventsLimit] = useState<number>(200);
   const [eventsBefore, setEventsBefore] = useState<string | null>(null);
@@ -1251,6 +1271,41 @@ export default function DowntimePageClient() {
       ac.abort();
     };
   }, [range, machineId]);
+
+  useEffect(() => {
+    let alive = true;
+    const ac = new AbortController();
+
+    async function run() {
+      setCatalogErr(null);
+      try {
+        const res = await fetch("/api/reasons/catalog?kind=downtime", {
+          cache: "no-cache",
+          credentials: "include",
+          signal: ac.signal,
+        });
+        const json = (await res.json().catch(() => ({}))) as ApiReasonCatalogRes;
+        if (!alive) return;
+        if (!res.ok || json.ok === false) {
+          setCatalogRows([]);
+          setCatalogErr(json.error ?? "Failed to load reason catalog");
+          return;
+        }
+        setCatalogRows(Array.isArray(json.rows) ? json.rows : []);
+      } catch (err: unknown) {
+        if (!alive) return;
+        setCatalogRows([]);
+        setCatalogErr(err instanceof Error ? err.message : "Network error");
+      }
+    }
+
+    run();
+    return () => {
+      alive = false;
+      ac.abort();
+    };
+  }, []);
+
     useEffect(() => {
         let alive = true;
         const ac = new AbortController();
@@ -1308,6 +1363,29 @@ export default function DowntimePageClient() {
     return metricRowsAll.filter((r) => r.reasonCode === reasonCode);
   }, [metricRowsAll, reasonCode]);
 
+  const selectedReasonLabel = useMemo(() => {
+    if (!reasonCode) return null;
+    const fromMetrics = metricRowsAll.find((row) => row.reasonCode === reasonCode)?.reasonLabel;
+    if (fromMetrics) return fromMetrics;
+    const fromCatalog = catalogRows.find((row) => row.reasonCode === reasonCode)?.reasonLabel;
+    return fromCatalog ?? reasonCode;
+  }, [catalogRows, metricRowsAll, reasonCode]);
+
+  const catalogByCategory = useMemo(() => {
+    const grouped = new Map<string, { categoryLabel: string; rows: ApiReasonCatalogRow[] }>();
+    for (const row of catalogRows) {
+      const key = row.categoryId;
+      const slot = grouped.get(key) ?? { categoryLabel: row.categoryLabel, rows: [] };
+      slot.rows.push(row);
+      grouped.set(key, slot);
+    }
+    return [...grouped.entries()].map(([categoryId, value]) => ({
+      categoryId,
+      categoryLabel: value.categoryLabel,
+      rows: value.rows,
+    }));
+  }, [catalogRows]);
+
   const totalMinutes = pareto?.totalMinutesLost ?? 0;
   const totalStops = useMemo(
     () => baseRows.reduce((acc, r) => acc + (r.count ?? 0), 0),
@@ -1365,6 +1443,7 @@ const filteredEvents = useMemo(() => {
       e.machineName ?? "",
       e.reasonLabel ?? "",
       e.reasonCode ?? "",
+      e.reasonText ?? "",
       e.workOrderId ?? "",
       e.episodeId ?? "",
     ]
@@ -1467,7 +1546,7 @@ const estImpactMxn = rate > 0 ? totalDowntimeMin * rate : 0;
       )}
       {reasonCode ? (
         <span className="inline-flex items-center gap-2 rounded-full border border-white/10 bg-white/5 px-3 py-1 text-xs text-white">
-          Reason: {reasonCode}
+          Reason: {selectedReasonLabel ?? reasonCode}
           <button
             className="rounded-full border border-white/10 bg-black/20 px-2 py-0.5 text-[11px] text-zinc-200 hover:bg-white/10"
             onClick={() => setParams({ reasonCode: null })}
@@ -1805,7 +1884,7 @@ const estImpactMxn = rate > 0 ? totalDowntimeMin * rate : 0;
                 className="mt-4 h-[360px] rounded-3xl border border-white/10 bg-black/30 p-4 backdrop-blur"
                 style={{ boxShadow: "var(--app-chart-shadow)" }}
               >
-                <ResponsiveContainer width="100%" height="100%">
+                <ResponsiveContainer width="100%" height="100%" minHeight={200}>
                   <ComposedChart
                     data={heroData}
                     onClick={(st: any) => {
@@ -1883,6 +1962,45 @@ const estImpactMxn = rate > 0 ? totalDowntimeMin * rate : 0;
                 </div>
               </div>
 
+              <div className="mt-4 rounded-2xl border border-white/10 bg-black/20 p-3">
+                <div className="text-xs font-semibold text-white">Downtime reason menu</div>
+                <div className="mt-1 text-[11px] text-zinc-400">
+                  From settings or `downtime_menu.md` fallback
+                </div>
+                {catalogErr ? (
+                  <div className="mt-2 text-[11px] text-rose-300">{catalogErr}</div>
+                ) : null}
+                <div className="mt-3 max-h-[180px] space-y-2 overflow-y-auto no-scrollbar pr-1">
+                  {catalogByCategory.map((group) => (
+                    <div key={group.categoryId} className="rounded-xl border border-white/10 bg-white/5 p-2">
+                      <div className="mb-1 text-[11px] font-semibold text-zinc-300">{group.categoryLabel}</div>
+                      <div className="flex flex-wrap gap-1.5">
+                        {group.rows.map((option) => {
+                          const active = reasonCode === option.reasonCode;
+                          return (
+                            <button
+                              key={option.reasonCode}
+                              onClick={() => setParams({ reasonCode: option.reasonCode })}
+                              className={cn(
+                                "rounded-lg border px-2 py-1 text-[11px]",
+                                active
+                                  ? "border-emerald-500/40 bg-emerald-500/15 text-emerald-200"
+                                  : "border-white/10 bg-black/20 text-zinc-300 hover:bg-white/10"
+                              )}
+                            >
+                              {option.detailLabel}
+                            </button>
+                          );
+                        })}
+                      </div>
+                    </div>
+                  ))}
+                  {!catalogErr && catalogByCategory.length === 0 ? (
+                    <div className="text-[11px] text-zinc-500">No reason menu available.</div>
+                  ) : null}
+                </div>
+              </div>
+
               <div className="mt-4 max-h-[360px] overflow-y-auto no-scrollbar rounded-2xl border border-white/10 bg-black/20">
                 <div className="grid grid-cols-12 gap-2 border-b border-white/10 px-4 py-3 text-[11px] text-zinc-500">
                   <div className="col-span-8">Reason</div>
@@ -2162,6 +2280,9 @@ const estImpactMxn = rate > 0 ? totalDowntimeMin * rate : 0;
                             <td className="px-4 py-3">
                             <div className="truncate text-white">{e.reasonLabel}</div>
                             <div className="mt-1 text-[11px] text-zinc-500">{e.reasonCode}</div>
+                            {e.reasonText && e.reasonText !== e.reasonLabel ? (
+                              <div className="mt-1 text-[11px] text-zinc-400">{e.reasonText}</div>
+                            ) : null}
                             </td>
                             <td className="px-4 py-3 text-zinc-200">{e.workOrderId ?? "—"}</td>
                             <td className="px-4 py-3 text-right text-white">

components/layout/AppShell.tsx

@@ -3,6 +3,7 @@
 import { useEffect, useState } from "react";
 import { Menu } from "lucide-react";
 import { Sidebar } from "@/components/layout/Sidebar";
+import { RouteAudit } from "@/components/perf/RouteAudit";
 import { UtilityControls } from "@/components/layout/UtilityControls";
 import { useI18n } from "@/lib/i18n/useI18n";
 
@@ -31,6 +32,7 @@ export function AppShell({
 
   return (
     <div className="h-screen overflow-hidden bg-black text-white">
+      <RouteAudit />
       <div className="flex h-full">
         <Sidebar />
         <div className="flex h-full flex-1 flex-col">

components/layout/Sidebar.tsx

@@ -2,12 +2,14 @@
 
 import Link from "next/link";
 import { usePathname, useRouter } from "next/navigation";
-import { useEffect, useMemo, useState } from "react";
+import { useEffect, useMemo, useState, useTransition } from "react";
-import { BarChart3, Bell, DollarSign, LayoutGrid, LogOut, Settings, Wrench, X } from "lucide-react";
+import { BarChart3, Bell, DollarSign, LayoutGrid, Loader2, LogOut, Settings, Wrench, X } from "lucide-react";
 import type { LucideIcon } from "lucide-react";
 import { useI18n } from "@/lib/i18n/useI18n";
 import { useScreenlessMode } from "@/lib/ui/screenlessMode";
 
+const PERF_ENABLED = process.env.NEXT_PUBLIC_PERF_LOGS === "1";
+const NAV_MARK_KEY = "perf_nav_start";
 
 type NavItem = {
   href: string;
@@ -38,6 +40,8 @@ export function Sidebar({ variant = "desktop", onNavigate, onClose }: SidebarPro
   const router = useRouter();
   const { t } = useI18n();
   const { screenlessMode } = useScreenlessMode();
+  const [isPending, startTransition] = useTransition();
+  const [pendingHref, setPendingHref] = useState<string | null>(null);
   const [me, setMe] = useState<{
     user?: { name?: string | null; email?: string | null };
     org?: { name?: string | null };
@@ -93,13 +97,33 @@ export function Sidebar({ variant = "desktop", onNavigate, onClose }: SidebarPro
     }
   }, [screenlessMode, pathname, router]);
 
-
-
   useEffect(() => {
-    visibleItems.forEach((it) => {
+    if (!pendingHref) return;
-      router.prefetch(it.href);
+    if (pathname === pendingHref || pathname.startsWith(`${pendingHref}/`)) {
-    });
+      setPendingHref(null);
-  }, [router, visibleItems]);
+    } else if (!isPending) {
+      setPendingHref(null);
+    }
+  }, [pathname, pendingHref, isPending]);
+
+  const markNavStart = (href: string) => {
+    if (!PERF_ENABLED) return;
+    try {
+      sessionStorage.setItem(
+        NAV_MARK_KEY,
+        JSON.stringify({
+          href,
+          from: pathname,
+          ts: Date.now(),
+        })
+      );
+    } catch {
+      // ignore
+    }
+  };
+
+  // Prefetch disabled: Next.js 16 has RSC prefetch bugs that can cause 404 on
+  // client-side navigation (see e.g. vercel/next.js#85374). Use fresh fetch on click.
   const shellClass = [
     "relative z-20 flex flex-col border-r border-white/10 bg-black/40 shrink-0",
     variant === "desktop" ? "hidden md:flex h-screen w-64" : "flex h-full w-72 max-w-[85vw]",
@@ -126,23 +150,53 @@ export function Sidebar({ variant = "desktop", onNavigate, onClose }: SidebarPro
 
       <nav className="px-3 py-2 flex-1 space-y-1">
         {visibleItems.map((it) => {
-          const active = pathname === it.href || pathname.startsWith(it.href + "/");
+          const isCurrent = pathname === it.href;
+          const active = isCurrent || pathname.startsWith(it.href + "/");
+          const isPendingItem = isPending && pendingHref === it.href;
+          const navLocked = isPending;
           const Icon = it.icon;
           return (
             <Link
               key={it.href}
               href={it.href}
-              onMouseEnter={() => router.prefetch(it.href)}
+              prefetch={false}
-              onClick={onNavigate}
+              aria-disabled={navLocked}
+              onClick={(event) => {
+                if (
+                  navLocked ||
+                  event.defaultPrevented ||
+                  event.button !== 0 ||
+                  event.metaKey ||
+                  event.altKey ||
+                  event.ctrlKey ||
+                  event.shiftKey
+                ) {
+                  return;
+                }
+                if (isCurrent) {
+                  onNavigate?.();
+                  return;
+                }
+                event.preventDefault();
+                markNavStart(it.href);
+                setPendingHref(it.href);
+                startTransition(() => {
+                  router.push(it.href);
+                });
+                onNavigate?.();
+              }}
               className={[
                 "flex items-center gap-3 rounded-xl px-3 py-2 text-sm transition",
                 active
                   ? "bg-emerald-500/15 text-emerald-300 border border-emerald-500/20"
                   : "text-zinc-300 hover:bg-white/5 hover:text-white",
+                navLocked ? "pointer-events-none" : "",
+                navLocked && !isPendingItem ? "opacity-60" : "",
               ].join(" ")}
             >
               <Icon className="h-4 w-4" />
               <span>{t(it.labelKey)}</span>
+              {isPendingItem ? <Loader2 className="ml-auto h-4 w-4 animate-spin text-emerald-300" /> : null}
             </Link>
           );
         })}

components/perf/RouteAudit.tsx

@@ -0,0 +1,68 @@
+"use client";
+
+import { useEffect } from "react";
+import { usePathname, useSearchParams } from "next/navigation";
+
+const PERF_ENABLED = process.env.NEXT_PUBLIC_PERF_LOGS === "1";
+const STORAGE_KEY = "perf_nav_start";
+
+type NavMark = {
+  href?: string;
+  from?: string;
+  ts: number;
+};
+
+function readNavMark(): NavMark | null {
+  try {
+    const raw = sessionStorage.getItem(STORAGE_KEY);
+    if (!raw) return null;
+    const parsed = JSON.parse(raw) as NavMark;
+    if (!parsed || typeof parsed.ts !== "number") return null;
+    return parsed;
+  } catch {
+    return null;
+  }
+}
+
+function clearNavMark() {
+  try {
+    sessionStorage.removeItem(STORAGE_KEY);
+  } catch {
+    // ignore
+  }
+}
+
+export function RouteAudit() {
+  const pathname = usePathname();
+  const searchParams = useSearchParams();
+
+  useEffect(() => {
+    if (!PERF_ENABLED) return;
+
+    const params = searchParams?.toString();
+    const to = params ? `${pathname}?${params}` : pathname;
+    const mark = readNavMark();
+    if (!mark) return;
+
+    const durationMs = Date.now() - mark.ts;
+    const payload = {
+      from: mark.from ?? "",
+      to,
+      href: mark.href ?? "",
+      durationMs,
+      startedAt: mark.ts,
+    };
+
+    console.info("[perf.nav]", payload);
+    fetch("/api/debug/perf", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({ event: "nav", data: payload }),
+      keepalive: true,
+    }).catch(() => {});
+
+    clearNavMark();
+  }, [pathname, searchParams]);
+
+  return null;
+}

dictionary_en_es.md

@@ -333,6 +333,20 @@ Main KPIs remain English in ES-MX (OEE, KPI, SKU, AVAILABILITY, PERFORMANCE, QUA
 | settings.shiftCompLabel | Shift change compensation (min) | Compensación por cambio de turno (min) |
 | settings.lunchBreakLabel | Lunch break (min) | Comida (min) |
 | settings.shift.defaultName | Shift {index} | Turno {index} |
+| settings.shiftOverrides.title | Day-specific shifts | Turnos por día |
+| settings.shiftOverrides.subtitle | Optional overrides for individual days. | Sobrescrituras opcionales por día. |
+| settings.shiftOverrides.useDefault | Use default | Usar predeterminado |
+| settings.shiftOverrides.customize | Customize | Personalizar |
+| settings.shiftOverrides.inherits | Uses default shift schedule. | Usa el horario de turnos predeterminado. |
+| settings.shiftOverrides.dayOff | Day off (no shifts) | Día libre (sin turnos) |
+| settings.shiftOverrides.clear | Clear shifts | Borrar turnos |
+| settings.shiftOverrides.mon | Monday | Lunes |
+| settings.shiftOverrides.tue | Tuesday | Martes |
+| settings.shiftOverrides.wed | Wednesday | Miércoles |
+| settings.shiftOverrides.thu | Thursday | Jueves |
+| settings.shiftOverrides.fri | Friday | Viernes |
+| settings.shiftOverrides.sat | Saturday | Sábado |
+| settings.shiftOverrides.sun | Sunday | Domingo |
 | settings.thresholds | Alert thresholds | Umbrales de alertas |
 | settings.thresholdsSubtitle | Tune production health alerts. | Ajusta alertas de salud de producción. |
 | settings.thresholds.appliesAll | Applies to all machines | Aplica a todas las máquinas |

downtime_menu.md

@@ -0,0 +1,264 @@
+Downtime
+
+Material / Falta de material
+Material / Material incorrecto
+Material / Material contaminado
+Material / Atasco de material
+Material / Cambio de material
+Material / Otro
+
+Proceso / Temperatura fuera de rango
+Proceso / Parámetros incorrectos
+Proceso / Ajuste de proceso
+Proceso / Arranque o estabilización
+Proceso / Proceso inestable
+Proceso / Otro
+
+Calidad / Inspección de calidad
+Calidad / Defecto detectado
+Calidad / Espera de liberación
+Calidad / Rechazo de producción
+Calidad / Validación de primera pieza
+Calidad / Otro
+
+Seguridad / Paro de seguridad
+Seguridad / Guarda o puerta abierta
+Seguridad / Sensor de seguridad activado
+Seguridad / Bloqueo y etiquetado
+Seguridad / Reset de seguridad
+Seguridad / Otro
+
+Molde / Cambio de molde
+Molde / Ajuste de molde
+Molde / Limpieza de molde
+Molde / Falla de molde
+Molde / Problema de expulsión
+Molde / Otro
+
+Máquina / Alarma de máquina
+Máquina / Falla eléctrica
+Máquina / Falla mecánica
+Máquina / Falla neumática o hidráulica
+Máquina / Reinicio de máquina
+Máquina / Otro
+
+Automatización / Falla de robot
+Automatización / Falla de sensor
+Automatización / Pérdida de comunicación
+Automatización / Atasco de pieza
+Automatización / Reset de celda
+Automatización / Otro
+
+Operación / Falta de operador
+Operación / Error de operación
+Operación / Cambio de turno
+Operación / Espera de apoyo
+Operación / Limpieza o ajuste
+Operación / Otro
+
+Servicios / Falta de energía
+Servicios / Baja presión de aire
+Servicios / Falta de agua o enfriamiento
+Servicios / Falla de red o comunicación
+Servicios / Utilidad fuera de rango
+Servicios / Otro
+
+Scrap
+
+Material / Material incorrecto
+Material / Material contaminado
+Material / Humedad de material
+Material / Mezcla incorrecta
+Material / Color incorrecto
+Material / Otro
+
+Proceso / Parámetros incorrectos
+Proceso / Temperatura incorrecta
+Proceso / Presión incorrecta
+Proceso / Tiempo incorrecto
+Proceso / Proceso inestable
+Proceso / Otro
+
+Calidad / Defecto visual
+Calidad / Defecto dimensional
+Calidad / No cumple especificación
+Calidad / Defecto detectado en inspección
+Calidad / Pieza no liberada
+Calidad / Otro
+
+Molde / Rebaba
+Molde / Falta de llenado
+Molde / Problema de expulsión
+Molde / Desalineación
+Molde / Daño de molde
+Molde / Otro
+
+Manipulación / Pieza golpeada
+Manipulación / Pieza rayada
+Manipulación / Pieza deformada
+Manipulación / Daño por robot
+Manipulación / Daño por operador
+Manipulación / Otro
+
+
+Already implemented in node-red side:
+
+### Summary
+Implementaremos captura obligatoria de razón en pantalla táctil para microstop, macrostop y scrap (no para slow-cycle en v1), usando un selector breadcrumb en español de **2 niveles**.  
+La taxonomía vendrá de **Control Tower settings** con **fallback a caché local**.  
+La razón seleccionada viajará a Control Tower **enriqueciendo el payload actual de event** (/api/ingest/event).  
+Para macrostops con refrescos periódicos, pediremos razón **una sola vez por incidente**.
+
+### Key Changes
+- **Catálogo de razones (backend settings + cache local)**
+  - Extender el flujo de Apply settings + update UI para aceptar y persistir (memory + file context) un catálogo versionado:
+    - reasonCatalog.downtime (árbol 2 niveles)
+    - reasonCatalog.scrap (árbol 2 niveles)
+  - Enviar al UI un nuevo topic (reasonCatalogData) para hidratar selector.
+  - Si CT no responde catálogo, usar última versión en caché local; no bloquear operación.
+
+- **UI táctil (breadcrumb)**
+  - Reusar UI global de anomalías + Home para abrir modal de razón con botones touch-first (mínimo 64px de alto, grid compacto).
+  - Breadcrumb de 2 pasos:
+    - Paso 1: categoría
+    - Paso 2: subrazón
+  - **Micro/Macro**: al presionar ACK, primero abrir selector de razón; al confirmar, enviar submit + ACK.
+  - **Scrap**: después de capturar cantidad (numpad), abrir selector de razón scrap antes de confirmar envío final.
+  - Evitar prompts repetidos en macro refresh usando incidentKey en frontend/backend (once per incident).
+
+- **Mensajería Node-RED (interfaces nuevas)**
+  - Nuevos mensajes desde UI:
+    - topic: "anomaly-reason-submit" con { event_id, incidentKey, reasonPath, reasonText, reasonType: "downtime" }
+    - action: "scrap-entry-with-reason" con { id, scrap, reasonPath, reasonText, reasonType: "scrap" }
+  - Mantener compatibilidad con rutas actuales (acknowledge-anomaly, scrap-entry) durante transición v1.
+  - Enriquecer eventos enviados por outbox con campos de razón:
+    - event.reason = { type, categoryId, categoryLabel, detailId, detailLabel, catalogVersion, incidentKey }
+
+- **Persistencia local y trazabilidad**
+  - Guardar razón en anomaly_events sin migración (v1) dentro de data_json y/o notes al momento de submit.
+  - Para scrap, persistir razón junto con evento outbox y opcionalmente en work_orders flujo de actualización si ya existe payload contextual.
+  - No usar stop_events en v1 (tabla existe pero hoy no está integrada al pipeline activo).
+
+### API / Interface Additions
+- **Settings contract (Control Tower -> Edge)**: agregar bloque reasonCatalog con árboles downtime y scrap, y version.
+- **Edge event payload (Edge -> Control Tower)**: agregar objeto reason dentro de event cuando aplique.
+- **Node-RED UI topics/actions nuevos**:
+  - reasonCatalogData
+  - anomaly-reason-submit
+  - scrap-entry-with-reason
+
+### Test Plan
+- **Catalog + fallback**
+  - Con catálogo remoto disponible: UI muestra opciones correctas en español.
+  - Sin catálogo remoto: UI usa caché local previa y sigue operando.
+- **Downtime reason flow**
+  - Microstop: ACK obliga razón, envía 1 evento con razón, actualiza estado local.
+  - Macrostop refrescado: solo primer ACK del incidente solicita razón; refrescos posteriores no repiten prompt.
+- **Scrap reason flow**
+  - Scrap manual: cantidad + razón obligatoria, persistencia local correcta y outbox event enriquecido.
+- **Outbox / CT integration**
+  - outbox_messages para msg_type=event incluye event.reason con shape esperado.
+  - Retries no pierden razón (payload intacto tras reintentos).
+- **UX touch**
+  - Botones utilizables en raspi touch (tap error bajo, sin overflow en 1280x800).
+  - Breadcrumb claro y navegable (atrás/adelante) sin bloquear otras pantallas fuera del modal.
+
+### Assumptions
+- Control Tower aceptará el enriquecimiento de event.reason en el endpoint actual /api/ingest/event.
+- El catálogo remoto será entregado desde settings de máquina/org y versionado.
+- En v1 no se requiere migración SQL; razón local se serializa en campos existentes.
+- slow-cycle permanece informativo sin razón obligatoria (según decisión actual)
+
+
+
+Click-Through Runbook (what to test on screen)
+Trigger a macrostop or microstop alert.
+Tap Acknowledge on anomaly panel/popup.
+Confirm downtime reason modal appears (Paso 1 category).
+Pick category -> confirm step 2 (subreason) appears.
+Pick subreason.
+Confirm:
+alert is removed
+no re-prompt on same macro incident refresh (incidentKey once-per-incident)
+event is queued as type=event to /api/ingest/event
+event payload includes both event.reason and event.downtime.
+Open scrap modal from Home.
+Enter scrap qty and submit.
+Confirm scrap reason modal appears (Paso 1 -> Paso 2).
+Pick subreason and submit.
+Confirm:
+work_orders.scrap_parts updates
+event is queued as type=event
+payload includes event.reason and event.downtime: null.
+Exact JSON sent to CT (POST /api/ingest/event)
+This is the HTTP body from outbox publisher (payload_json envelope).
+
+A) Downtime reason acknowledgment event
+{
+  "schemaVersion": "1.0",
+  "machineId": "M-EDGE-01",
+  "tsMs": 1710001234567,
+  "seq": "901",
+  "type": "event",
+  "payload": {
+    "event": {
+      "tsMs": 1710001234567,
+      "eventType": "downtime-acknowledged",
+      "anomalyType": "macrostop",
+      "eventId": 1710001112222,
+      "incidentKey": "macrostop:WO-100:1710000000000",
+      "reason": {
+        "type": "downtime",
+        "categoryId": "mecanico",
+        "categoryLabel": "Mecanico",
+        "detailId": "hidraulico",
+        "detailLabel": "Hidraulico",
+        "reasonText": "Mecanico > Hidraulico",
+        "catalogVersion": 3,
+        "incidentKey": "macrostop:WO-100:1710000000000"
+      },
+      "downtime": {
+        "incidentKey": "macrostop:WO-100:1710000000000",
+        "eventId": 1710001112222,
+        "anomalyType": "macrostop",
+        "acknowledgedAtMs": 1710001234567,
+        "reason": {
+          "type": "downtime",
+          "categoryId": "mecanico",
+          "categoryLabel": "Mecanico",
+          "detailId": "hidraulico",
+          "detailLabel": "Hidraulico",
+          "reasonText": "Mecanico > Hidraulico",
+          "catalogVersion": 3,
+          "incidentKey": "macrostop:WO-100:1710000000000"
+        }
+      }
+    }
+  }
+}
+B) Scrap manual entry with reason
+{
+  "schemaVersion": "1.0",
+  "machineId": "M-EDGE-01",
+  "tsMs": 1776472069609,
+  "seq": "902",
+  "type": "event",
+  "payload": {
+    "event": {
+      "tsMs": 1776472069609,
+      "eventType": "scrap-manual-entry",
+      "workOrderId": "WO-100",
+      "scrapDelta": 4,
+      "source": "home-ui",
+      "reason": {
+        "type": "scrap",
+        "categoryId": "calidad",
+        "categoryLabel": "Calidad",
+        "detailId": "rebaba",
+        "detailLabel": "Rebaba",
+        "reasonText": "Calidad > Rebaba",
+        "catalogVersion": 3
+      }
+    }
+  }
+}

lib/alerts/engine.ts

@@ -46,6 +46,19 @@ function readBool(value: unknown) {
   return value === true;
 }
 
+function normalizeStatus(value?: string | null) {
+  if (!value) return null;
+  const raw = value.trim().toLowerCase();
+  if (!raw) return null;
+  if (raw === "in_progress" || raw === "in-progress" || raw === "open" || raw === "activa" || raw === "activo") {
+    return "active";
+  }
+  if (raw === "resuelta" || raw === "resuelto" || raw === "closed" || raw === "ended" || raw === "done") {
+    return "resolved";
+  }
+  return raw;
+}
+
 function extractDurationSec(raw: unknown): number | null {
   const payload = asRecord(raw);
   if (!payload) return null;
@@ -302,10 +315,11 @@ export async function evaluateAlertsForEvent(eventId: string) {
   const alertId = readString(payload?.alert_id ?? inner?.alert_id);
   const isUpdate = readBool(payload?.is_update ?? inner?.is_update);
   const isAutoAck = readBool(payload?.is_auto_ack ?? inner?.is_auto_ack);
+  const status = normalizeStatus(readString(payload?.status ?? inner?.status));
   const lastCycleTs = readNumber(payload?.last_cycle_timestamp ?? inner?.last_cycle_timestamp);
   const theoreticalSec = readNumber(payload?.theoretical_cycle_time ?? inner?.theoretical_cycle_time);
   if (isAutoAck) return;
-  if (isUpdate && !(rule.repeatMinutes && rule.repeatMinutes > 0)) return;
+  if (isUpdate && status !== "resolved") return;
   if ((eventType === "microstop" || eventType === "macrostop") && theoreticalSec && lastCycleTs == null) {
     return;
   }
@@ -345,9 +359,11 @@ export async function evaluateAlertsForEvent(eventId: string) {
         const key = `${channel}:${recipient.userId ?? recipient.contactId ?? recipient.email ?? recipient.phone ?? ""}`;
         if (delivered.has(key)) continue;
 
+        const statusKey = status === "resolved" ? "resolved" : "active";
+        const ruleKey = `${rule.id}:${statusKey}`;
         const allowed = await shouldSendNotification({
           eventIds: notificationEventIds,
-          ruleId: rule.id,
+          ruleId: ruleKey,
           role: roleName,
           channel,
           contactId: recipient.contactId,
@@ -376,7 +392,7 @@ export async function evaluateAlertsForEvent(eventId: string) {
             machineId: event.machineId,
             eventId: event.id,
             eventType,
-            ruleId: rule.id,
+            ruleId: ruleKey,
             role: roleName,
             channel,
             contactId: recipient.contactId,
@@ -391,7 +407,7 @@ export async function evaluateAlertsForEvent(eventId: string) {
             machineId: event.machineId,
             eventId: event.id,
             eventType,
-            ruleId: rule.id,
+            ruleId: ruleKey,
             role: roleName,
             channel,
             contactId: recipient.contactId,

lib/alerts/getAlertsInboxData.ts

@@ -1,3 +1,4 @@
+import { normalizeShiftOverrides } from "@/lib/settings";
 import { prisma } from "@/lib/prisma";
 
 const RANGE_MS: Record<string, number> = {
@@ -21,6 +22,26 @@ type AlertsInboxParams = {
   limit?: number;
 };
 
+type AlertsInboxEvent = {
+  id: string;
+  ts: Date;
+  eventType: string;
+  severity: string;
+  title: string;
+  description?: string | null;
+  machineId: string;
+  machineName?: string | null;
+  location?: string | null;
+  workOrderId?: string | null;
+  sku?: string | null;
+  durationSec?: number | null;
+  status?: string | null;
+  shift?: string | null;
+  alertId?: string | null;
+  isUpdate?: boolean;
+  isAutoAck?: boolean;
+};
+
 function pickRange(range: string, start?: Date | null, end?: Date | null) {
   const now = new Date();
   if (range === "custom") {
@@ -50,6 +71,19 @@ function safeBool(value: unknown) {
   return value === true;
 }
 
+function normalizeStatus(value?: string | null) {
+  if (!value) return null;
+  const raw = value.trim().toLowerCase();
+  if (!raw) return null;
+  if (raw === "in_progress" || raw === "in-progress" || raw === "open" || raw === "activa" || raw === "activo") {
+    return "active";
+  }
+  if (raw === "resuelta" || raw === "resuelto" || raw === "closed" || raw === "ended" || raw === "done") {
+    return "resolved";
+  }
+  return raw;
+}
+
 function parsePayload(raw: unknown) {
   let parsed: unknown = raw;
   if (typeof raw === "string") {
@@ -131,17 +165,54 @@ function getLocalMinutes(ts: Date, timeZone: string) {
   }
 }
 
+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 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()];
+  }
+}
+
+type ShiftLike = {
+  name: string;
+  startTime?: string | null;
+  endTime?: string | null;
+  start?: string | null;
+  end?: string | null;
+  enabled?: boolean;
+};
+
 function resolveShift(
-  shifts: Array<{ name: string; startTime: string; endTime: string; enabled?: boolean }>,
+  shifts: ShiftLike[],
+  overrides: Record<string, ShiftLike[]> | undefined,
   ts: Date,
   timeZone: string
 ) {
-  if (!shifts.length) return null;
+  const dayKey = getLocalDayKey(ts, timeZone);
+  const dayOverrides = overrides?.[dayKey];
+  const activeShifts = dayOverrides ?? shifts;
+  if (!activeShifts.length) return null;
   const nowMin = getLocalMinutes(ts, timeZone);
-  for (const shift of shifts) {
+  for (const shift of activeShifts) {
     if (shift.enabled === false) continue;
-    const start = parseTimeMinutes(shift.startTime);
+    const start = parseTimeMinutes(shift.startTime ?? shift.start ?? null);
-    const end = parseTimeMinutes(shift.endTime);
+    const end = parseTimeMinutes(shift.endTime ?? shift.end ?? null);
     if (start == null || end == null) continue;
     if (start <= end) {
       if (nowMin >= start && nowMin < end) return shift.name;
@@ -152,6 +223,34 @@ function resolveShift(
   return null;
 }
 
+function collapseAlertEvents(events: AlertsInboxEvent[]) {
+  const byAlert = new Map<string, AlertsInboxEvent>();
+  const passthrough: AlertsInboxEvent[] = [];
+
+  for (const ev of events) {
+    if (!ev.alertId) {
+      passthrough.push(ev);
+      continue;
+    }
+    const statusKey = ev.status === "resolved" ? "resolved" : "active";
+    const key = `${ev.alertId}:${statusKey}`;
+    const existing = byAlert.get(key);
+    if (!existing) {
+      byAlert.set(key, ev);
+      continue;
+    }
+    const pickNewest = statusKey === "resolved";
+    const shouldReplace = pickNewest
+      ? ev.ts.getTime() > existing.ts.getTime()
+      : ev.ts.getTime() < existing.ts.getTime();
+    if (shouldReplace) byAlert.set(key, ev);
+  }
+
+  const combined = [...passthrough, ...byAlert.values()];
+  combined.sort((a, b) => b.ts.getTime() - a.ts.getTime());
+  return combined;
+}
+
 export async function getAlertsInboxData(params: AlertsInboxParams) {
   const {
     orgId,
@@ -213,12 +312,13 @@ export async function getAlertsInboxData(params: AlertsInboxParams) {
     }),
     prisma.orgSettings.findUnique({
       where: { orgId },
-      select: { timezone: true },
+      select: { timezone: true, shiftScheduleOverridesJson: true },
     }),
   ]);
 
   const timeZone = settings?.timezone || "UTC";
-  const mapped = [];
+  const shiftOverrides = normalizeShiftOverrides(settings?.shiftScheduleOverridesJson);
+  const mapped: AlertsInboxEvent[] = [];
 
   for (const ev of events) {
     const { payload, inner } = parsePayload(ev.data);
@@ -227,10 +327,10 @@ export async function getAlertsInboxData(params: AlertsInboxParams) {
     const isAutoAck = safeBool(payload?.is_auto_ack ?? inner?.is_auto_ack);
     if (!includeUpdates && (isUpdate || isAutoAck)) continue;
 
-    const shiftName = resolveShift(shifts, ev.ts, timeZone);
+    const shiftName = resolveShift(shifts, shiftOverrides, ev.ts, timeZone);
     if (normalizedShift && shiftName !== normalizedShift) continue;
 
-    const statusLabel = rawStatus ? rawStatus.toLowerCase() : "unknown";
+    const statusLabel = normalizeStatus(rawStatus) ?? "unknown";
     if (normalizedStatus && statusLabel !== normalizedStatus) continue;
 
     mapped.push({
@@ -254,8 +354,10 @@ export async function getAlertsInboxData(params: AlertsInboxParams) {
     });
   }
 
+  const finalEvents = includeUpdates ? mapped : collapseAlertEvents(mapped);
+
   return {
     range: { range: picked.range, start: picked.start, end: picked.end },
-    events: mapped,
+    events: finalEvents,
   };
 }

lib/auth/requireSession.ts

@@ -1,43 +1,98 @@
 import { cookies } from "next/headers";
 import { prisma } from "@/lib/prisma";
+import { logLine } from "@/lib/logger";
 
 const COOKIE_NAME = "mis_session";
+const SESSION_CACHE_TTL_MS = 30000;
+const LAST_SEEN_TTL_MS = 300000;
 
-export async function requireSession() {
+type SessionPayload = {
-  const jar = await cookies();
+  sessionId: string;
-  const sessionId = jar.get(COOKIE_NAME)?.value;
+  userId: string;
-  if (!sessionId) return null;
+  orgId: string;
+};
 
-  const session = await prisma.session.findFirst({
+type CachedSession = {
-    where: {
+  value: SessionPayload;
-      id: sessionId,
+  expiresAt: number;
-      revokedAt: null,
+};
-      expiresAt: { gt: new Date() },
-    },
-    include: {
-      user: {
-        select: { isActive: true, emailVerifiedAt: true },
-      },
-    },
-  });
 
-  if (!session) return null;
+const sessionCache = new Map<string, CachedSession>();
+const lastSeenCache = new Map<string, number>();
 
-  if (!session.user?.isActive || !session.user?.emailVerifiedAt) {
+function readCache(sessionId: string, now: number) {
-    await prisma.session
+  const cached = sessionCache.get(sessionId);
-      .update({ where: { id: session.id }, data: { revokedAt: new Date() } })
+  if (!cached) return null;
-      .catch(() => {});
+  if (cached.expiresAt <= now) {
+    sessionCache.delete(sessionId);
+    return null;
+  }
+  return cached.value;
+}
+
+function writeCache(sessionId: string, value: SessionPayload, now: number) {
+  sessionCache.set(sessionId, { value, expiresAt: now + SESSION_CACHE_TTL_MS });
+}
+
+function shouldUpdateLastSeen(sessionId: string, now: number) {
+  const last = lastSeenCache.get(sessionId) ?? 0;
+  if (now - last < LAST_SEEN_TTL_MS) return false;
+  lastSeenCache.set(sessionId, now);
+  return true;
+}
+
+export async function requireSession() {
+  try {
+    const jar = await cookies();
+    const sessionId = jar.get(COOKIE_NAME)?.value;
+    if (!sessionId) return null;
+
+    const now = Date.now();
+    const cached = readCache(sessionId, now);
+    if (cached) return cached;
+
+    const session = await prisma.session.findFirst({
+      where: {
+        id: sessionId,
+        revokedAt: null,
+        expiresAt: { gt: new Date() },
+      },
+      include: {
+        user: {
+          select: { isActive: true, emailVerifiedAt: true },
+        },
+      },
+    });
+
+    if (!session) return null;
+
+    if (!session.user?.isActive || !session.user?.emailVerifiedAt) {
+      void prisma.session
+        .update({ where: { id: session.id }, data: { revokedAt: new Date() } })
+        .catch(() => {});
+      sessionCache.delete(sessionId);
+      lastSeenCache.delete(sessionId);
+      return null;
+    }
+
+    if (shouldUpdateLastSeen(sessionId, now)) {
+      void prisma.session
+        .update({ where: { id: session.id }, data: { lastSeenAt: new Date() } })
+        .catch(() => {});
+    }
+
+    const payload = {
+      sessionId: session.id,
+      userId: session.userId,
+      orgId: session.orgId,
+    };
+    writeCache(sessionId, payload, now);
+    return payload;
+  } catch (err) {
+    const message = err instanceof Error ? err.message : String(err);
+    const stack = err instanceof Error ? err.stack : undefined;
+    logLine("requireSession.error", { message, stack });
+    console.error("[requireSession]", err);
     return null;
   }
-
-  // Optional: update lastSeenAt (useful later)
-  await prisma.session
-    .update({ where: { id: session.id }, data: { lastSeenAt: new Date() } })
-    .catch(() => {});
-
-  return {
-    sessionId: session.id,
-    userId: session.userId,
-    orgId: session.orgId,
-  };
 }

lib/financial/cache.ts

@@ -0,0 +1,63 @@
+import { unstable_cache } from "next/cache";
+import { prisma } from "@/lib/prisma";
+import { computeFinancialImpact, type FinancialImpactParams } from "@/lib/financial/impact";
+
+export const FINANCIAL_CONFIG_TTL_SEC = 15;
+export const FINANCIAL_CONFIG_SWR_SEC = 45;
+export const FINANCIAL_IMPACT_TTL_SEC = 10;
+export const FINANCIAL_IMPACT_SWR_SEC = 30;
+
+async function loadFinancialConfig(orgId: string) {
+  const [org, locations, machines, products] = await Promise.all([
+    prisma.orgFinancialProfile.findUnique({ where: { orgId } }),
+    prisma.locationFinancialOverride.findMany({ where: { orgId }, orderBy: { location: "asc" } }),
+    prisma.machineFinancialOverride.findMany({ where: { orgId }, orderBy: { createdAt: "desc" } }),
+    prisma.productCostOverride.findMany({ where: { orgId }, orderBy: { sku: "asc" } }),
+  ]);
+
+  return { org, locations, machines, products };
+}
+
+export type FinancialConfigPayload = Awaited<ReturnType<typeof loadFinancialConfig>>;
+
+export async function getFinancialConfig(orgId: string, options?: { refresh?: boolean }) {
+  if (options?.refresh) {
+    return loadFinancialConfig(orgId);
+  }
+
+  const cached = unstable_cache(
+    () => loadFinancialConfig(orgId),
+    ["financial-config", orgId],
+    { revalidate: FINANCIAL_CONFIG_TTL_SEC, tags: [`financial-config:${orgId}`] }
+  );
+  return cached();
+}
+
+export async function getFinancialImpactCached(
+  params: FinancialImpactParams,
+  options?: { refresh?: boolean }
+) {
+  if (options?.refresh) {
+    return computeFinancialImpact(params);
+  }
+
+  const keyParts = [
+    "financial-impact",
+    params.orgId,
+    String(params.start.getTime()),
+    String(params.end.getTime()),
+    params.machineId ?? "",
+    params.location ?? "",
+    params.sku ?? "",
+    params.currency ?? "",
+    params.includeEvents ? "1" : "0",
+  ];
+
+  const cached = unstable_cache(
+    () => computeFinancialImpact(params),
+    keyParts,
+    { revalidate: FINANCIAL_IMPACT_TTL_SEC, tags: [`financial-impact:${params.orgId}`] }
+  );
+
+  return cached();
+}

lib/i18n/en.json

@@ -395,10 +395,24 @@
   "settings.minutes": "minutes",
   "settings.shiftHint": "Max 3 shifts, HH:mm",
   "settings.shiftTo": "to",
-  "settings.shiftCompLabel": "Shift change compensation (min)",
+  "settings.shiftCompLabel": "Shift change compensation (min)",
-  "settings.lunchBreakLabel": "Lunch break (min)",
+  "settings.lunchBreakLabel": "Lunch break (min)",
-  "settings.shift.defaultName": "Shift {index}",
+  "settings.shift.defaultName": "Shift {index}",
-  "settings.thresholds": "Alert thresholds",
+  "settings.shiftOverrides.title": "Day-specific shifts",
+  "settings.shiftOverrides.subtitle": "Optional overrides for individual days.",
+  "settings.shiftOverrides.useDefault": "Use default",
+  "settings.shiftOverrides.customize": "Customize",
+  "settings.shiftOverrides.inherits": "Uses default shift schedule.",
+  "settings.shiftOverrides.dayOff": "Day off (no shifts)",
+  "settings.shiftOverrides.clear": "Clear shifts",
+  "settings.shiftOverrides.mon": "Monday",
+  "settings.shiftOverrides.tue": "Tuesday",
+  "settings.shiftOverrides.wed": "Wednesday",
+  "settings.shiftOverrides.thu": "Thursday",
+  "settings.shiftOverrides.fri": "Friday",
+  "settings.shiftOverrides.sat": "Saturday",
+  "settings.shiftOverrides.sun": "Sunday",
+  "settings.thresholds": "Alert thresholds",
   "settings.thresholdsSubtitle": "Tune production health alerts.",
   "settings.thresholds.appliesAll": "Applies to all machines",
   "settings.thresholds.oee": "OEE alert threshold",
@@ -453,11 +467,12 @@
   "financial.title": "Financial Impact",
   "financial.subtitle": "Translate downtime, slow cycles, and scrap into money.",
   "financial.ownerOnly": "Financial impact is available only to owners.",
-  "financial.costsMoved": "Cost settings are now in",
+  "financial.costsMoved": "Cost settings are now in",
-  "financial.costsMovedLink": "Settings -> Financial",
+  "financial.costsMovedLink": "Settings -> Financial",
-  "financial.export.html": "HTML",
+  "financial.export.html": "HTML",
-  "financial.export.csv": "CSV",
+  "financial.export.csv": "CSV",
-  "financial.totalLoss": "Total Loss",
+  "financial.refresh": "Refresh",
+  "financial.totalLoss": "Total Loss",
   "financial.currencyLabel": "Currency: {currency}",
   "financial.noImpact": "No impact data yet.",
   "financial.chart.title": "Lost Money Over Time",

lib/i18n/es-MX.json

@@ -395,10 +395,24 @@
   "settings.minutes": "minutos",
   "settings.shiftHint": "Máx 3 turnos, HH:mm",
   "settings.shiftTo": "a",
-  "settings.shiftCompLabel": "Compensación por cambio de turno (min)",
+  "settings.shiftCompLabel": "Compensación por cambio de turno (min)",
-  "settings.lunchBreakLabel": "Comida (min)",
+  "settings.lunchBreakLabel": "Comida (min)",
-  "settings.shift.defaultName": "Turno {index}",
+  "settings.shift.defaultName": "Turno {index}",
-  "settings.thresholds": "Umbrales de alertas",
+  "settings.shiftOverrides.title": "Turnos por día",
+  "settings.shiftOverrides.subtitle": "Sobrescrituras opcionales por día.",
+  "settings.shiftOverrides.useDefault": "Usar predeterminado",
+  "settings.shiftOverrides.customize": "Personalizar",
+  "settings.shiftOverrides.inherits": "Usa el horario de turnos predeterminado.",
+  "settings.shiftOverrides.dayOff": "Día libre (sin turnos)",
+  "settings.shiftOverrides.clear": "Borrar turnos",
+  "settings.shiftOverrides.mon": "Lunes",
+  "settings.shiftOverrides.tue": "Martes",
+  "settings.shiftOverrides.wed": "Miércoles",
+  "settings.shiftOverrides.thu": "Jueves",
+  "settings.shiftOverrides.fri": "Viernes",
+  "settings.shiftOverrides.sat": "Sábado",
+  "settings.shiftOverrides.sun": "Domingo",
+  "settings.thresholds": "Umbrales de alertas",
   "settings.thresholdsSubtitle": "Ajusta alertas de salud de producción.",
   "settings.thresholds.appliesAll": "Aplica a todas las máquinas",
   "settings.thresholds.oee": "Umbral de alerta OEE",
@@ -453,11 +467,12 @@
   "financial.title": "Impacto financiero",
   "financial.subtitle": "Convierte paros, ciclos lentos y scrap en dinero.",
   "financial.ownerOnly": "El impacto financiero solo está disponible para propietarios.",
-  "financial.costsMoved": "Los costos ahora están en",
+  "financial.costsMoved": "Los costos ahora están en",
-  "financial.costsMovedLink": "Configuración -> Finanzas",
+  "financial.costsMovedLink": "Configuración -> Finanzas",
-  "financial.export.html": "HTML",
+  "financial.export.html": "HTML",
-  "financial.export.csv": "CSV",
+  "financial.export.csv": "CSV",
-  "financial.totalLoss": "Pérdida total",
+  "financial.refresh": "Actualizar",
+  "financial.totalLoss": "Pérdida total",
   "financial.currencyLabel": "Moneda: {currency}",
   "financial.noImpact": "Sin datos de impacto.",
   "financial.chart.title": "Pérdida de dinero en el tiempo",

lib/i18n/useI18n.ts

@@ -7,6 +7,7 @@ const LOCALE_COOKIE = "mis_locale";
 const LOCALE_EVENT = "mis-locale-change";
 
 function readCookieLocale(): Locale | null {
+  if (typeof document === "undefined") return null;
   const match = document.cookie
     .split(";")
     .map((part) => part.trim())
@@ -18,6 +19,7 @@ function readCookieLocale(): Locale | null {
 }
 
 function readLocale(): Locale {
+  if (typeof document === "undefined") return defaultLocale;
   const docLang = document.documentElement.getAttribute("lang");
   if (docLang === "es-MX" || docLang === "en") return docLang;
   return readCookieLocale() ?? defaultLocale;

lib/logger.ts

@@ -3,6 +3,10 @@ import path from "path";
 
 const LOG_PATH = process.env.LOG_FILE || "/tmp/mis-control-tower.log";
 
+export function getLogPath() {
+  return LOG_PATH;
+}
+
 export function logLine(event: string, data: Record<string, unknown> = {}) {
   const line = JSON.stringify({
     ts: new Date().toISOString(),

lib/machineAuthCache.ts

@@ -2,7 +2,7 @@ import { prisma } from "@/lib/prisma";
 
 type MachineAuth = { id: string; orgId: string };
 
-const TTL_MS = 60_000;
+const TTL_MS = 10_000;
 const MAX_SIZE = 1000;
 const cache = new Map<string, { value: MachineAuth; expiresAt: number }>();
 
@@ -36,3 +36,12 @@ export async function getMachineAuth(machineId: string, apiKey: string) {
   cache.set(key, { value: machine, expiresAt: now + TTL_MS });
   return machine;
 }
+
+export function invalidateMachineAuth(machineId: string) {
+  const prefix = `${machineId}:`;
+  for (const key of cache.keys()) {
+    if (key.startsWith(prefix)) {
+      cache.delete(key);
+    }
+  }
+}

lib/machines/withLatest.ts

@@ -0,0 +1,113 @@
+import { prisma } from "@/lib/prisma";
+import type { OverviewMachineRow } from "@/lib/overview/types";
+
+type MachineBaseRow = Pick<
+  OverviewMachineRow,
+  "id" | "name" | "code" | "location" | "createdAt" | "updatedAt"
+>;
+
+type LatestHeartbeatRow = {
+  machineId: string;
+  ts: Date;
+  tsServer: Date | null;
+  status: string;
+  message?: string | null;
+  ip?: string | null;
+  fwVersion?: string | null;
+};
+
+type LatestKpiRow = {
+  machineId: string;
+  ts: Date;
+  oee?: number | null;
+  availability?: number | null;
+  performance?: number | null;
+  quality?: number | null;
+  workOrderId?: string | null;
+  sku?: string | null;
+  good?: number | null;
+  scrap?: number | null;
+  target?: number | null;
+  cycleTime?: number | null;
+};
+
+export async function fetchMachineBase(orgId: string): Promise<MachineBaseRow[]> {
+  return prisma.machine.findMany({
+    where: { orgId },
+    orderBy: { createdAt: "desc" },
+    select: {
+      id: true,
+      name: true,
+      code: true,
+      location: true,
+      createdAt: true,
+      updatedAt: true,
+    },
+  });
+}
+
+export async function fetchLatestHeartbeats(
+  orgId: string,
+  machineIds: string[]
+): Promise<LatestHeartbeatRow[]> {
+  if (!machineIds.length) return [];
+  return prisma.machineHeartbeat.findMany({
+    where: { orgId, machineId: { in: machineIds } },
+    orderBy: [{ machineId: "asc" }, { tsServer: "desc" }],
+    distinct: ["machineId"],
+    select: {
+      machineId: true,
+      ts: true,
+      tsServer: true,
+      status: true,
+      message: true,
+      ip: true,
+      fwVersion: true,
+    },
+  });
+}
+
+export async function fetchLatestKpis(
+  orgId: string,
+  machineIds: string[]
+): Promise<LatestKpiRow[]> {
+  if (!machineIds.length) return [];
+  return prisma.machineKpiSnapshot.findMany({
+    where: { orgId, machineId: { in: machineIds } },
+    orderBy: [{ machineId: "asc" }, { ts: "desc" }],
+    distinct: ["machineId"],
+    select: {
+      machineId: true,
+      ts: true,
+      oee: true,
+      availability: true,
+      performance: true,
+      quality: true,
+      workOrderId: true,
+      sku: true,
+      good: true,
+      scrap: true,
+      target: true,
+      cycleTime: true,
+    },
+  });
+}
+
+export function mergeMachineOverviewRows(params: {
+  machines: MachineBaseRow[];
+  heartbeats: LatestHeartbeatRow[];
+  kpis?: LatestKpiRow[];
+  includeKpi?: boolean;
+}): OverviewMachineRow[] {
+  const { machines, heartbeats, kpis = [], includeKpi = false } = params;
+  const heartbeatMap = new Map(heartbeats.map((row) => [row.machineId, row]));
+  const kpiMap = new Map(kpis.map((row) => [row.machineId, row]));
+
+  return machines.map((machine) => ({
+    ...machine,
+    latestHeartbeat: (heartbeatMap.get(machine.id) ?? null) as OverviewMachineRow["latestHeartbeat"],
+    latestKpi: includeKpi ? (kpiMap.get(machine.id) ?? null) : null,
+    heartbeats: undefined,
+    kpiSnapshots: undefined,
+  }));
+}

lib/overview/getOverviewData.ts

@@ -1,5 +1,14 @@
 import { prisma } from "@/lib/prisma";
 import { normalizeEvent } from "@/lib/events/normalizeEvent";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+import type { OverviewEventRow, OverviewMachineRow } from "@/lib/overview/types";
+import {
+  fetchLatestHeartbeats,
+  fetchLatestKpis,
+  fetchMachineBase,
+  mergeMachineOverviewRows,
+} from "@/lib/machines/withLatest";
 
 const ALLOWED_TYPES = new Set([
   "slow-cycle",
@@ -37,157 +46,169 @@ export async function getOverviewData({
   eventsWindowSec = 21600,
   eventMachines = 6,
   orgSettings,
-}: OverviewParams) {
+}: OverviewParams): Promise<{ machines: OverviewMachineRow[]; events: OverviewEventRow[] }> {
-  const machines = await prisma.machine.findMany({
+  const perfEnabled = PERF_LOGS_ENABLED;
-    where: { orgId },
+  const timings: Record<string, number> = {};
-    orderBy: { createdAt: "desc" },
+  const totalStart = nowMs();
-    select: {
+
-      id: true,
+  try {
-      name: true,
+    const machinesStart = nowMs();
-      code: true,
+    const machines = await fetchMachineBase(orgId);
-      location: true,
+    if (perfEnabled) timings.machinesQuery = elapsedMs(machinesStart);
-      createdAt: true,
+
-      updatedAt: true,
+    const heartbeatStart = nowMs();
-      heartbeats: {
+    const machineIds = machines.map((machine) => machine.id);
-        orderBy: { tsServer: "desc" },
+    const heartbeats = await fetchLatestHeartbeats(orgId, machineIds);
-        take: 1,
+    if (perfEnabled) timings.heartbeatsQuery = elapsedMs(heartbeatStart);
-        select: { ts: true, tsServer: true, status: true, message: true, ip: true, fwVersion: true },
+
-      },
+    const kpiStart = nowMs();
-      kpiSnapshots: {
+    const kpis = await fetchLatestKpis(orgId, machineIds);
-        orderBy: { ts: "desc" },
+    if (perfEnabled) timings.kpiQuery = elapsedMs(kpiStart);
-        take: 1,
+
-        select: {
+    const machineRows: OverviewMachineRow[] = mergeMachineOverviewRows({
-          ts: true,
+      machines,
-          oee: true,
+      heartbeats,
-          availability: true,
+      kpis,
-          performance: true,
+      includeKpi: true,
-          quality: true,
+    });
-          workOrderId: true,
+
-          sku: true,
+    const safeEventMachines = Number.isFinite(eventMachines) ? Math.max(1, Math.floor(eventMachines)) : 6;
-          good: true,
+    const safeWindowSec = Number.isFinite(eventsWindowSec) ? eventsWindowSec : 21600;
-          scrap: true,
+
-          target: true,
+    const topMachines = machineRows
-          cycleTime: true,
+      .slice()
+      .sort((a, b) => {
+        const at = heartbeatTime(a.latestHeartbeat);
+        const bt = heartbeatTime(b.latestHeartbeat);
+        const atMs = at ? at.getTime() : 0;
+        const btMs = bt ? bt.getTime() : 0;
+        return btMs - atMs;
+      })
+      .slice(0, safeEventMachines);
+
+    const targetIds = topMachines.map((m) => m.id);
+
+    let events: OverviewEventRow[] = [];
+
+    if (targetIds.length) {
+      let settings = orgSettings ?? null;
+      if (!settings) {
+        const settingsStart = nowMs();
+        settings = await prisma.orgSettings.findUnique({
+          where: { orgId },
+          select: { stoppageMultiplier: true, macroStoppageMultiplier: true },
+        });
+        if (perfEnabled) timings.orgSettingsQuery = elapsedMs(settingsStart);
+      }
+
+      const microMultiplier = Number(settings?.stoppageMultiplier ?? 1.5);
+      const macroMultiplier = Math.max(microMultiplier, Number(settings?.macroStoppageMultiplier ?? 5));
+      const windowStart = new Date(Date.now() - Math.max(0, safeWindowSec) * 1000);
+
+      const eventsStart = nowMs();
+      const rawEvents = await prisma.machineEvent.findMany({
+        where: {
+          orgId,
+          machineId: { in: targetIds },
+          ts: { gte: windowStart },
         },
-      },
+        orderBy: { ts: "desc" },
-    },
+        take: Math.min(300, Math.max(60, targetIds.length * 40)),
-  });
+        select: {
+          id: true,
+          ts: true,
+          topic: true,
+          eventType: true,
+          severity: true,
+          title: true,
+          description: true,
+          requiresAck: true,
+          data: true,
+          workOrderId: true,
+          machineId: true,
+          machine: { select: { name: true } },
+        },
+      });
+      if (perfEnabled) timings.eventsQuery = elapsedMs(eventsStart);
 
-  const machineRows = machines.map((m) => ({
+      const normalizeStart = nowMs();
-    ...m,
+      const normalized = rawEvents
-    latestHeartbeat: m.heartbeats[0] ?? null,
+        .map((row) => ({
-    latestKpi: m.kpiSnapshots[0] ?? null,
+          ...normalizeEvent(row, { microMultiplier, macroMultiplier }),
-    heartbeats: undefined,
+          machineId: row.machineId,
-    kpiSnapshots: undefined,
+          machineName: row.machine?.name ?? null,
-  }));
+          source: "ingested" as const,
+        }))
+        .filter((event) => event.ts);
+      if (perfEnabled) timings.eventsNormalize = elapsedMs(normalizeStart);
 
-  const safeEventMachines = Number.isFinite(eventMachines) ? Math.max(1, Math.floor(eventMachines)) : 6;
+      const filterStart = nowMs();
-  const safeWindowSec = Number.isFinite(eventsWindowSec) ? eventsWindowSec : 21600;
+      const allowed = normalized.filter((event) => ALLOWED_TYPES.has(event.eventType));
+      const isCritical = (event: (typeof allowed)[number]) => {
+        const severity = String(event.severity ?? "").toLowerCase();
+        return (
+          event.eventType === "macrostop" ||
+          event.requiresAck === true ||
+          severity === "critical" ||
+          severity === "error" ||
+          severity === "high"
+        );
+      };
 
-  const topMachines = machineRows
+      const filtered = eventsMode === "critical" ? allowed.filter(isCritical) : allowed;
-    .slice()
-    .sort((a, b) => {
-      const at = heartbeatTime(a.latestHeartbeat);
-      const bt = heartbeatTime(b.latestHeartbeat);
-      const atMs = at ? at.getTime() : 0;
-      const btMs = bt ? bt.getTime() : 0;
-      return btMs - atMs;
-    })
-    .slice(0, safeEventMachines);
 
-  const targetIds = topMachines.map((m) => m.id);
+      const seen = new Set<string>();
+      const deduped = filtered.filter((event) => {
+        const key = `${event.machineId}-${event.eventType}-${event.ts ?? ""}-${event.title}`;
+        if (seen.has(key)) return false;
+        seen.add(key);
+        return true;
+      });
 
-  let events = [] as Array<{
+      deduped.sort((a, b) => {
-    id: string;
+        const at = a.ts ? a.ts.getTime() : 0;
-    ts: Date | null;
+        const bt = b.ts ? b.ts.getTime() : 0;
-    topic: string;
+        return bt - at;
-    eventType: string;
+      });
-    severity: string;
-    title: string;
-    description?: string | null;
-    requiresAck: boolean;
-    workOrderId?: string | null;
-    machineId: string;
-    machineName?: string | null;
-    source: "ingested";
-  }>;
 
-  if (targetIds.length) {
+      events = deduped.slice(0, 30);
-    let settings = orgSettings ?? null;
+      if (perfEnabled) timings.eventsFilter = elapsedMs(filterStart);
-    if (!settings) {
+    }
-      settings = await prisma.orgSettings.findUnique({
+
-        where: { orgId },
+    if (perfEnabled) {
-        select: { stoppageMultiplier: true, macroStoppageMultiplier: true },
+      timings.total = elapsedMs(totalStart);
+      logLine("perf.overview.getOverviewData", {
+        orgId,
+        eventsMode,
+        eventsWindowSec,
+        eventMachines,
+        timings,
+        counts: {
+          machines: machineRows.length,
+          events: events.length,
+          targetMachines: targetIds.length,
+        },
       });
     }
 
-    const microMultiplier = Number(settings?.stoppageMultiplier ?? 1.5);
+    return { machines: machineRows, events };
-    const macroMultiplier = Math.max(microMultiplier, Number(settings?.macroStoppageMultiplier ?? 5));
+  } catch (err) {
-    const windowStart = new Date(Date.now() - Math.max(0, safeWindowSec) * 1000);
+    const message = err instanceof Error ? err.message : String(err);
-
+    const stack = err instanceof Error ? err.stack : undefined;
-    const rawEvents = await prisma.machineEvent.findMany({
+    if (perfEnabled) {
-      where: {
+      timings.total = elapsedMs(totalStart);
+      logLine("perf.overview.getOverviewData.error", {
         orgId,
-        machineId: { in: targetIds },
+        eventsMode,
-        ts: { gte: windowStart },
+        eventsWindowSec,
-      },
+        eventMachines,
-      orderBy: { ts: "desc" },
+        timings,
-      take: Math.min(300, Math.max(60, targetIds.length * 40)),
+        message,
-      select: {
+        stack,
-        id: true,
+      });
-        ts: true,
+    }
-        topic: true,
+    logLine("getOverviewData.error", { message, stack });
-        eventType: true,
+    console.error("[getOverviewData]", err);
-        severity: true,
+    return { machines: [], events: [] };
-        title: true,
-        description: true,
-        requiresAck: true,
-        data: true,
-        workOrderId: true,
-        machineId: true,
-        machine: { select: { name: true } },
-      },
-    });
-
-    const normalized = rawEvents
-      .map((row) => ({
-        ...normalizeEvent(row, { microMultiplier, macroMultiplier }),
-        machineId: row.machineId,
-        machineName: row.machine?.name ?? null,
-        source: "ingested" as const,
-      }))
-      .filter((event) => event.ts);
-
-    const allowed = normalized.filter((event) => ALLOWED_TYPES.has(event.eventType));
-    const isCritical = (event: (typeof allowed)[number]) => {
-      const severity = String(event.severity ?? "").toLowerCase();
-      return (
-        event.eventType === "macrostop" ||
-        event.requiresAck === true ||
-        severity === "critical" ||
-        severity === "error" ||
-        severity === "high"
-      );
-    };
-
-    const filtered = eventsMode === "critical" ? allowed.filter(isCritical) : allowed;
-
-    const seen = new Set<string>();
-    const deduped = filtered.filter((event) => {
-      const key = `${event.machineId}-${event.eventType}-${event.ts ?? ""}-${event.title}`;
-      if (seen.has(key)) return false;
-      seen.add(key);
-      return true;
-    });
-
-    deduped.sort((a, b) => {
-      const at = a.ts ? a.ts.getTime() : 0;
-      const bt = b.ts ? b.ts.getTime() : 0;
-      return bt - at;
-    });
-
-    events = deduped.slice(0, 30);
   }
-
-  return { machines: machineRows, events };
 }

lib/overview/getOverviewSummary.ts

@@ -0,0 +1,102 @@
+import { logLine } from "@/lib/logger";
+import { elapsedMs, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+import type { OverviewMachineRow } from "@/lib/overview/types";
+import {
+  fetchLatestHeartbeats,
+  fetchMachineBase,
+  mergeMachineOverviewRows,
+} from "@/lib/machines/withLatest";
+
+type OverviewSummaryParams = {
+  orgId: string;
+};
+
+const SUMMARY_CACHE_TTL_MS = 10000;
+const summaryCache = new Map<string, { value: OverviewMachineRow[]; expiresAt: number; cachedAt: number }>();
+const summaryInFlight = new Map<string, Promise<{ machines: OverviewMachineRow[] }>>();
+
+export async function getOverviewSummary({
+  orgId,
+}: OverviewSummaryParams): Promise<{ machines: OverviewMachineRow[] }> {
+  const now = Date.now();
+  const cached = summaryCache.get(orgId);
+  if (cached && cached.expiresAt > now) {
+    if (PERF_LOGS_ENABLED) {
+      logLine("perf.overview.summary", {
+        orgId,
+        cached: true,
+        timings: { total: 0 },
+        ageMs: now - cached.cachedAt,
+        counts: { machines: cached.value.length },
+      });
+    }
+    return { machines: cached.value };
+  }
+
+  const inFlight = summaryInFlight.get(orgId);
+  if (inFlight) return inFlight;
+
+  const promise = fetchOverviewSummary({ orgId })
+    .then((result) => {
+      summaryCache.set(orgId, {
+        value: result.machines,
+        cachedAt: now,
+        expiresAt: now + SUMMARY_CACHE_TTL_MS,
+      });
+      summaryInFlight.delete(orgId);
+      return result;
+    })
+    .catch((err) => {
+      summaryInFlight.delete(orgId);
+      throw err;
+    });
+
+  summaryInFlight.set(orgId, promise);
+  return promise;
+}
+
+async function fetchOverviewSummary({
+  orgId,
+}: OverviewSummaryParams): Promise<{ machines: OverviewMachineRow[] }> {
+  const perfEnabled = PERF_LOGS_ENABLED;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+
+  try {
+    const machinesStart = nowMs();
+    const machines = await fetchMachineBase(orgId);
+    if (perfEnabled) timings.machinesQuery = elapsedMs(machinesStart);
+
+    const heartbeatStart = nowMs();
+    const machineIds = machines.map((machine) => machine.id);
+    const heartbeats = await fetchLatestHeartbeats(orgId, machineIds);
+    if (perfEnabled) timings.heartbeatsQuery = elapsedMs(heartbeatStart);
+
+    const machineRows: OverviewMachineRow[] = mergeMachineOverviewRows({
+      machines,
+      heartbeats,
+      includeKpi: false,
+    });
+
+    if (perfEnabled) {
+      timings.total = elapsedMs(totalStart);
+      logLine("perf.overview.summary", {
+        orgId,
+        timings,
+        counts: { machines: machineRows.length },
+      });
+    }
+
+    return { machines: machineRows };
+  } catch (err) {
+    const message = err instanceof Error ? err.message : String(err);
+    const stack = err instanceof Error ? err.stack : undefined;
+    if (perfEnabled) {
+      timings.total = elapsedMs(totalStart);
+      logLine("perf.overview.summary.error", { orgId, timings, message, stack });
+    }
+    logLine("getOverviewSummary.error", { message, stack });
+    console.error("[getOverviewSummary]", err);
+    return { machines: [] };
+  }
+}

lib/overview/types.ts

@@ -0,0 +1,51 @@
+export type OverviewLatestHeartbeat = {
+  ts: Date;
+  tsServer?: Date | null;
+  status: string;
+  message?: string | null;
+  ip?: string | null;
+  fwVersion?: string | null;
+};
+
+export type OverviewLatestKpi = {
+  ts: Date;
+  oee?: number | null;
+  availability?: number | null;
+  performance?: number | null;
+  quality?: number | null;
+  workOrderId?: string | null;
+  sku?: string | null;
+  good?: number | null;
+  scrap?: number | null;
+  target?: number | null;
+  cycleTime?: number | null;
+};
+
+export type OverviewMachineRow = {
+  id: string;
+  name: string;
+  code?: string | null;
+  location?: string | null;
+  createdAt: Date;
+  updatedAt: Date;
+  latestHeartbeat: OverviewLatestHeartbeat | null;
+  latestKpi: OverviewLatestKpi | null;
+  heartbeats?: undefined;
+  kpiSnapshots?: undefined;
+};
+
+export type OverviewEventRow = {
+  id: string;
+  ts: Date | null;
+  topic: string;
+  eventType: string;
+  severity: string;
+  title: string;
+  description?: string | null;
+  requiresAck: boolean;
+  workOrderId?: string | null;
+  machineId: string;
+  machineName?: string | null;
+  source: "ingested";
+};
+

lib/perf/serverTiming.ts

@@ -0,0 +1,18 @@
+import { performance } from "perf_hooks";
+
+export const PERF_LOGS_ENABLED = process.env.PERF_LOGS === "1";
+
+export function nowMs() {
+  return performance.now();
+}
+
+export function elapsedMs(startMs: number) {
+  return Math.round((performance.now() - startMs) * 100) / 100;
+}
+
+export function formatServerTiming(entries: Record<string, number>) {
+  return Object.entries(entries)
+    .filter(([, value]) => Number.isFinite(value))
+    .map(([name, value]) => `${name};dur=${value.toFixed(1)}`)
+    .join(", ");
+}

lib/reasonCatalog.ts

@@ -0,0 +1,200 @@
+import { readFile } from "fs/promises";
+import path from "path";
+
+type AnyRecord = Record<string, unknown>;
+
+export type ReasonCatalogKind = "downtime" | "scrap";
+
+export type ReasonCatalogDetail = {
+  id: string;
+  label: string;
+};
+
+export type ReasonCatalogCategory = {
+  id: string;
+  label: string;
+  details: ReasonCatalogDetail[];
+};
+
+export type ReasonCatalog = {
+  version: number;
+  downtime: ReasonCatalogCategory[];
+  scrap: ReasonCatalogCategory[];
+};
+
+function isPlainObject(value: unknown): value is AnyRecord {
+  return !!value && typeof value === "object" && !Array.isArray(value);
+}
+
+function canonicalId(input: unknown, fallback = "item") {
+  const text = String(input ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+  return text || fallback;
+}
+
+function buildReasonCode(categoryId: string, detailId: string) {
+  return `${canonicalId(categoryId)}__${canonicalId(detailId)}`.toUpperCase();
+}
+
+function toCategory(raw: unknown): ReasonCatalogCategory | null {
+  if (!isPlainObject(raw)) return null;
+  const labelRaw = String(raw.label ?? "").trim();
+  if (!labelRaw) return null;
+  const idRaw = String(raw.id ?? "").trim() || canonicalId(labelRaw, "category");
+  const detailsRaw =
+    (Array.isArray(raw.details) && raw.details) ||
+    (Array.isArray(raw.children) && raw.children) ||
+    (Array.isArray(raw.items) && raw.items) ||
+    [];
+
+  const details: ReasonCatalogDetail[] = [];
+  for (const detailRaw of detailsRaw) {
+    if (!isPlainObject(detailRaw)) continue;
+    const detailLabel = String(detailRaw.label ?? "").trim();
+    if (!detailLabel) continue;
+    const detailId = String(detailRaw.id ?? "").trim() || canonicalId(detailLabel, "detail");
+    details.push({ id: detailId, label: detailLabel });
+  }
+
+  if (!details.length) return null;
+  return { id: idRaw, label: labelRaw, details };
+}
+
+function normalizeKind(raw: unknown): ReasonCatalogCategory[] {
+  const arr =
+    (Array.isArray(raw) && raw) ||
+    (isPlainObject(raw) && Array.isArray(raw.categories) && raw.categories) ||
+    [];
+  const out: ReasonCatalogCategory[] = [];
+  for (const candidate of arr) {
+    const parsed = toCategory(candidate);
+    if (parsed) out.push(parsed);
+  }
+  return out;
+}
+
+export function normalizeReasonCatalog(raw: unknown): ReasonCatalog | null {
+  if (!isPlainObject(raw)) return null;
+  const downtime = normalizeKind(raw.downtime);
+  const scrap = normalizeKind(raw.scrap);
+  if (!downtime.length && !scrap.length) return null;
+  const versionNum = Number(raw.version);
+  const version = Number.isFinite(versionNum) ? Math.max(1, Math.trunc(versionNum)) : 1;
+  return {
+    version,
+    downtime,
+    scrap,
+  };
+}
+
+export function parseReasonCatalogMarkdown(markdown: string): ReasonCatalog {
+  const lines = markdown
+    .split(/\r?\n/)
+    .map((line) => line.trim())
+    .filter(Boolean);
+
+  const buckets: Record<ReasonCatalogKind, Map<string, ReasonCatalogCategory>> = {
+    downtime: new Map(),
+    scrap: new Map(),
+  };
+  let activeKind: ReasonCatalogKind = "downtime";
+
+  for (const line of lines) {
+    const lowered = line.toLowerCase();
+    if (lowered === "downtime") {
+      activeKind = "downtime";
+      continue;
+    }
+    if (lowered === "scrap") {
+      activeKind = "scrap";
+      continue;
+    }
+
+    const slash = line.indexOf("/");
+    if (slash < 1 || slash === line.length - 1) continue;
+
+    const categoryLabel = line.slice(0, slash).trim();
+    const detailLabel = line.slice(slash + 1).trim();
+    if (!categoryLabel || !detailLabel) continue;
+
+    const categoryId = canonicalId(categoryLabel, "category");
+    const detailId = canonicalId(detailLabel, "detail");
+
+    const existing =
+      buckets[activeKind].get(categoryId) ?? {
+        id: categoryId,
+        label: categoryLabel,
+        details: [] as ReasonCatalogDetail[],
+      };
+    if (!existing.details.some((d) => d.id === detailId)) {
+      existing.details.push({ id: detailId, label: detailLabel });
+    }
+    buckets[activeKind].set(categoryId, existing);
+  }
+
+  return {
+    version: 1,
+    downtime: [...buckets.downtime.values()],
+    scrap: [...buckets.scrap.values()],
+  };
+}
+
+let catalogPromise: Promise<ReasonCatalog> | null = null;
+
+export async function loadFallbackReasonCatalog() {
+  if (!catalogPromise) {
+    catalogPromise = readFile(path.join(process.cwd(), "downtime_menu.md"), "utf8")
+      .then((raw) => parseReasonCatalogMarkdown(raw))
+      .catch(() => ({ version: 1, downtime: [], scrap: [] }));
+  }
+  return catalogPromise;
+}
+
+export function flattenReasonCatalog(catalog: ReasonCatalog, kind: ReasonCatalogKind) {
+  return (catalog[kind] ?? []).flatMap((category) =>
+    category.details.map((detail) => ({
+      kind,
+      categoryId: category.id,
+      categoryLabel: category.label,
+      detailId: detail.id,
+      detailLabel: detail.label,
+      reasonCode: buildReasonCode(category.id, detail.id),
+      reasonLabel: `${category.label} > ${detail.label}`,
+    }))
+  );
+}
+
+export function findCatalogReason(
+  catalog: ReasonCatalog | null | undefined,
+  kind: ReasonCatalogKind,
+  categoryId: unknown,
+  detailId: unknown
+) {
+  if (!catalog) return null;
+  const catId = canonicalId(categoryId, "");
+  const detId = canonicalId(detailId, "");
+  if (!catId || !detId) return null;
+  const category = (catalog[kind] ?? []).find((c) => canonicalId(c.id, "") === catId);
+  if (!category) return null;
+  const detail = category.details.find((d) => canonicalId(d.id, "") === detId);
+  if (!detail) return null;
+  return {
+    categoryId: category.id,
+    categoryLabel: category.label,
+    detailId: detail.id,
+    detailLabel: detail.label,
+    reasonCode: buildReasonCode(category.id, detail.id),
+    reasonLabel: `${category.label} > ${detail.label}`,
+  };
+}
+
+export function toReasonCode(categoryId: unknown, detailId: unknown) {
+  const cat = canonicalId(categoryId, "");
+  const det = canonicalId(detailId, "");
+  if (!cat || !det) return null;
+  return buildReasonCode(cat, det);
+}

lib/settings.ts

@@ -18,6 +18,9 @@ export const DEFAULT_SHIFT = {
   end: "15:00",
 };
 
+export const SHIFT_OVERRIDE_DAYS = ["mon", "tue", "wed", "thu", "fri", "sat", "sun"] as const;
+export type ShiftOverrideDay = (typeof SHIFT_OVERRIDE_DAYS)[number];
+
 type AnyRecord = Record<string, unknown>;
 
 function isPlainObject(value: unknown): value is AnyRecord {
@@ -40,6 +43,7 @@ type SettingsRow = {
   timezone: string;
   shiftChangeCompMin?: number | null;
   lunchBreakMin?: number | null;
+  shiftScheduleOverridesJson?: unknown;
   stoppageMultiplier?: number | null;
   macroStoppageMultiplier?: number | null;
   oeeAlertThresholdPct?: number | null;
@@ -59,6 +63,13 @@ type ShiftRow = {
   sortOrder?: number | null;
 };
 
+type ShiftOverridePayload = {
+  name: string;
+  start: string;
+  end: string;
+  enabled: boolean;
+};
+
 export function buildSettingsPayload(settings: SettingsRow, shifts: ShiftRow[]) {
   const ordered = [...(shifts ?? [])].sort((a, b) => (a.sortOrder ?? 0) - (b.sortOrder ?? 0));
   const mappedShifts = ordered.map((s, idx) => ({
@@ -67,6 +78,13 @@ export function buildSettingsPayload(settings: SettingsRow, shifts: ShiftRow[])
     end: s.endTime,
     enabled: s.enabled !== false,
   }));
+  const overrides = normalizeShiftOverrides(settings.shiftScheduleOverridesJson);
+
+  const defaults = normalizeDefaults(settings.defaultsJson);
+  const reasonCatalog =
+    isPlainObject(settings.defaultsJson) && "reasonCatalog" in settings.defaultsJson
+      ? (settings.defaultsJson as AnyRecord).reasonCatalog
+      : null;
 
   return {
     orgId: settings.orgId,
@@ -74,6 +92,7 @@ export function buildSettingsPayload(settings: SettingsRow, shifts: ShiftRow[])
     timezone: settings.timezone,
     shiftSchedule: {
       shifts: mappedShifts,
+      overrides: overrides && Object.keys(overrides).length ? overrides : undefined,
       shiftChangeCompensationMin: settings.shiftChangeCompMin,
       lunchBreakMin: settings.lunchBreakMin,
     },
@@ -85,7 +104,10 @@ export function buildSettingsPayload(settings: SettingsRow, shifts: ShiftRow[])
       qualitySpikeDeltaPct: settings.qualitySpikeDeltaPct,
     },
     alerts: normalizeAlerts(settings.alertsJson),
-    defaults: normalizeDefaults(settings.defaultsJson),
+    defaults,
+    reasonCatalog: reasonCatalog ?? undefined,
+    reasonCatalogData: reasonCatalog ?? undefined,
+    reasonCatalogVersion: Number((reasonCatalog as AnyRecord | null)?.version ?? 1),
     updatedAt: settings.updatedAt,
     updatedBy: settings.updatedBy,
   };
@@ -169,6 +191,57 @@ export function validateShiftSchedule(shifts: unknown) {
   return { ok: true, shifts: normalized as NormalizedShift[] };
 }
 
+export function validateShiftOverrides(overrides: unknown) {
+  if (overrides === null) {
+    return { ok: true, overrides: null as Record<string, ShiftOverridePayload[]> | null } as const;
+  }
+  if (!isPlainObject(overrides)) {
+    return { ok: false, error: "shift overrides must be an object" } as const;
+  }
+
+  const normalized: Record<string, ShiftOverridePayload[]> = {};
+  for (const [key, value] of Object.entries(overrides)) {
+    if (!SHIFT_OVERRIDE_DAYS.includes(key as ShiftOverrideDay)) {
+      return { ok: false, error: `invalid shift override day: ${key}` } as const;
+    }
+    const shiftResult = validateShiftSchedule(value);
+    if (!shiftResult.ok) {
+      return { ok: false, error: `shift overrides ${key}: ${shiftResult.error}` } as const;
+    }
+    normalized[key] =
+      shiftResult.shifts?.map((s) => ({
+        name: s.name,
+        start: s.startTime,
+        end: s.endTime,
+        enabled: s.enabled !== false,
+      })) ?? [];
+  }
+
+  return { ok: true, overrides: normalized } as const;
+}
+
+export function normalizeShiftOverrides(raw: unknown) {
+  if (!isPlainObject(raw)) return undefined;
+  const out: Record<string, ShiftOverridePayload[]> = {};
+  for (const day of SHIFT_OVERRIDE_DAYS) {
+    const value = raw[day];
+    if (!Array.isArray(value)) continue;
+    const normalized = value
+      .map((entry, idx) => {
+        const record = isPlainObject(entry) ? entry : {};
+        const start = String(record.start ?? record.startTime ?? "").trim();
+        const end = String(record.end ?? record.endTime ?? "").trim();
+        if (!TIME_RE.test(start) || !TIME_RE.test(end)) return null;
+        const name = String(record.name ?? `Shift ${idx + 1}`).trim() || `Shift ${idx + 1}`;
+        const enabled = record.enabled !== false;
+        return { name, start, end, enabled };
+      })
+      .filter((entry): entry is ShiftOverridePayload => !!entry);
+    out[day] = normalized;
+  }
+  return out;
+}
+
 export function validateShiftFields(shiftChangeCompensationMin?: unknown, lunchBreakMin?: unknown) {
   if (shiftChangeCompensationMin != null) {
     const v = Number(shiftChangeCompensationMin);

middleware.ts

@@ -0,0 +1,41 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+
+const COOKIE_NAME = "mis_session";
+
+export function middleware(req: NextRequest) {
+  try {
+    const { pathname, search } = req.nextUrl;
+
+    if (
+      pathname.startsWith("/_next") ||
+      pathname.startsWith("/favicon") ||
+      pathname.startsWith("/public") ||
+      pathname === "/login" ||
+      pathname === "/signup" ||
+      pathname === "/logout" ||
+      pathname.startsWith("/invite") ||
+      pathname.startsWith("/api")
+    ) {
+      return NextResponse.next();
+    }
+
+    const sessionId = req.cookies.get(COOKIE_NAME)?.value;
+
+    if (!sessionId) {
+      const url = req.nextUrl.clone();
+      url.pathname = "/login";
+      url.searchParams.set("next", pathname + search);
+      return NextResponse.redirect(url);
+    }
+
+    return NextResponse.next();
+  } catch (err) {
+    console.error("[middleware]", err);
+    return NextResponse.next();
+  }
+}
+
+export const config = {
+  matcher: ["/((?!_next/static|_next/image).*)"],
+};

package.json

@@ -3,8 +3,8 @@
   "version": "0.1.0",
   "private": true,
   "scripts": {
-    "dev": "next dev",
+    "dev": "next dev --turbopack",
-    "build": "next build",
+    "build": "next build --webpack",
     "start": "next start",
     "lint": "eslint"
   },

prisma/migrations/20260310120000_add_shift_schedule_overrides/migration.sql

@@ -0,0 +1,2 @@
+-- AlterTable
+ALTER TABLE "org_settings" ADD COLUMN "shift_schedule_overrides_json" JSONB;

prisma/schema.prisma

@@ -146,6 +146,7 @@ model Machine {
 
   @@unique([orgId, name])
   @@index([orgId])
+  @@index([orgId, createdAt])
 }
 
 model MachineHeartbeat {
@@ -166,6 +167,7 @@ model MachineHeartbeat {
   machine Machine @relation(fields: [machineId], references: [id], onDelete: Cascade)
 
   @@index([orgId, machineId, ts])
+  @@index([orgId, machineId, tsServer])
 }
 
 model MachineKpiSnapshot {
@@ -310,6 +312,7 @@ model OrgSettings {
   timezone                String   @default("UTC")
   shiftChangeCompMin      Int      @default(10) @map("shift_change_comp_min")
   lunchBreakMin           Int      @default(30) @map("lunch_break_min")
+  shiftScheduleOverridesJson Json? @map("shift_schedule_overrides_json")
   stoppageMultiplier      Float    @default(1.5) @map("stoppage_multiplier")
   oeeAlertThresholdPct    Float    @default(90) @map("oee_alert_threshold_pct")
   macroStoppageMultiplier Float    @default(5) @map("macro_stoppage_multiplier")

rpi-case/.claude/skills/openscad/SKILL.md

@@ -0,0 +1,232 @@
+---
+name: openscad
+description: "Create and render OpenSCAD 3D models. Generate preview images from multiple angles, extract customizable parameters, validate syntax, and export STL files for 3D printing platforms like MakerWorld."
+---
+
+# OpenSCAD Skill
+
+Create, validate, and export OpenSCAD 3D models. Supports parameter customization, visual preview from multiple angles, and STL export for 3D printing platforms like MakerWorld.
+
+## Prerequisites
+
+OpenSCAD must be installed. Install via Homebrew:
+```bash
+brew install openscad
+```
+
+## Tools
+
+This skill provides several tools in the `tools/` directory:
+
+### Preview Generation
+```bash
+# Generate a single preview image
+./tools/preview.sh model.scad output.png [--camera=x,y,z,tx,ty,tz,dist] [--size=800x600]
+
+# Generate multi-angle preview (front, back, left, right, top, iso)
+./tools/multi-preview.sh model.scad output_dir/
+```
+
+### STL Export
+```bash
+# Export to STL for 3D printing
+./tools/export-stl.sh model.scad output.stl [-D 'param=value']
+```
+
+### Parameter Extraction
+```bash
+# Extract customizable parameters from an OpenSCAD file
+./tools/extract-params.sh model.scad
+```
+
+### Validation
+```bash
+# Check for syntax errors and warnings
+./tools/validate.sh model.scad
+```
+
+## Visual Validation (Required)
+
+**Always validate your OpenSCAD models visually after creating or modifying them.**
+
+After writing or editing any OpenSCAD file:
+
+1. **Generate multi-angle previews** using `multi-preview.sh`
+2. **View each generated image** using the `read` tool
+3. **Check for issues** from multiple perspectives:
+   - Front/back: Verify symmetry, features, and proportions
+   - Left/right: Check depth and side profiles
+   - Top: Ensure top features are correct
+   - Isometric: Overall shape validation
+4. **Iterate if needed**: If something looks wrong, fix the code and re-validate
+
+This catches issues that syntax validation alone cannot detect:
+- Inverted normals or inside-out geometry
+- Misaligned features or incorrect boolean operations
+- Proportions that don't match the intended design
+- Missing or floating geometry
+- Z-fighting or overlapping surfaces
+
+**Never deliver an OpenSCAD model without visually confirming it looks correct from multiple angles.**
+
+## Workflow
+
+### 1. Creating an OpenSCAD Model
+
+Write OpenSCAD code with customizable parameters at the top:
+
+```openscad
+// Customizable parameters
+wall_thickness = 2;        // [1:0.5:5] Wall thickness in mm
+width = 50;                // [20:100] Width in mm
+height = 30;               // [10:80] Height in mm
+rounded = true;            // Add rounded corners
+
+// Model code below
+module main_shape() {
+    if (rounded) {
+        minkowski() {
+            cube([width - 4, width - 4, height - 2]);
+            sphere(r = 2);
+        }
+    } else {
+        cube([width, width, height]);
+    }
+}
+
+difference() {
+    main_shape();
+    translate([wall_thickness, wall_thickness, wall_thickness])
+        scale([1 - 2*wall_thickness/width, 1 - 2*wall_thickness/width, 1])
+        main_shape();
+}
+```
+
+Parameter comment format:
+- `// [min:max]` - numeric range
+- `// [min:step:max]` - numeric range with step
+- `// [opt1, opt2, opt3]` - dropdown options
+- `// Description text` - plain description
+
+### 2. Validate the Model
+```bash
+./tools/validate.sh model.scad
+```
+
+### 3. Generate Previews
+
+Generate preview images to visually validate the model:
+```bash
+./tools/multi-preview.sh model.scad ./previews/
+```
+
+This creates PNG images from multiple angles. Use the `read` tool to view them.
+
+### 4. Export to STL
+```bash
+./tools/export-stl.sh model.scad output.stl
+# With custom parameters:
+./tools/export-stl.sh model.scad output.stl -D 'width=60' -D 'height=40'
+```
+
+## Camera Positions
+
+Common camera angles for previews:
+- **Isometric**: `--camera=0,0,0,45,0,45,200`
+- **Front**: `--camera=0,0,0,90,0,0,200`
+- **Top**: `--camera=0,0,0,0,0,0,200`
+- **Right**: `--camera=0,0,0,90,0,90,200`
+
+Format: `x,y,z,rotx,roty,rotz,distance`
+
+## MakerWorld Publishing
+
+For MakerWorld, you typically need:
+1. STL file(s) exported via `export-stl.sh`
+2. Preview images (at least one good isometric view)
+3. A description of customizable parameters
+
+Consider creating a `model.json` with metadata:
+```json
+{
+  "name": "Model Name",
+  "description": "Description for MakerWorld",
+  "parameters": [...],
+  "tags": ["functional", "container", "organizer"]
+}
+```
+
+## Example: Full Workflow
+
+```bash
+# 1. Create the model (write .scad file)
+
+# 2. Validate syntax
+./tools/validate.sh box.scad
+
+# 3. Generate multi-angle previews
+./tools/multi-preview.sh box.scad ./previews/
+
+# 4. IMPORTANT: View and validate ALL preview images
+#    Use the read tool on each PNG file to visually inspect:
+#    - previews/box_front.png
+#    - previews/box_back.png
+#    - previews/box_left.png
+#    - previews/box_right.png
+#    - previews/box_top.png
+#    - previews/box_iso.png
+#    Look for geometry issues, misalignments, or unexpected results.
+#    If anything looks wrong, go back to step 1 and fix it!
+
+# 5. Extract and review parameters
+./tools/extract-params.sh box.scad
+
+# 6. Export STL with default parameters
+./tools/export-stl.sh box.scad box.stl
+
+# 7. Export STL with custom parameters
+./tools/export-stl.sh box.scad box_large.stl -D 'width=80' -D 'height=60'
+```
+
+**Remember**: Never skip the visual validation step. Many issues (wrong dimensions, boolean operation errors, inverted geometry) are only visible when you actually look at the rendered model.
+
+## OpenSCAD Quick Reference
+
+### Basic Shapes
+```openscad
+cube([x, y, z]);
+sphere(r = radius);
+cylinder(h = height, r = radius);
+cylinder(h = height, r1 = bottom_r, r2 = top_r);  // cone
+```
+
+### Transformations
+```openscad
+translate([x, y, z]) object();
+rotate([rx, ry, rz]) object();
+scale([sx, sy, sz]) object();
+mirror([x, y, z]) object();
+```
+
+### Boolean Operations
+```openscad
+union() { a(); b(); }        // combine
+difference() { a(); b(); }   // subtract b from a
+intersection() { a(); b(); } // overlap only
+```
+
+### Advanced
+```openscad
+linear_extrude(height) 2d_shape();
+rotate_extrude() 2d_shape();
+hull() { objects(); }        // convex hull
+minkowski() { a(); b(); }    // minkowski sum (rounding)
+```
+
+### 2D Shapes
+```openscad
+circle(r = radius);
+square([x, y]);
+polygon(points = [[x1,y1], [x2,y2], ...]);
+text("string", size = 10);
+```

rpi-case/.claude/skills/openscad/examples/parametric_box.scad

@@ -0,0 +1,92 @@
+// Parametric Box with Lid
+// A customizable storage box for 3D printing
+
+// === Box Parameters ===
+width = 60;              // [20:200] Width in mm
+depth = 40;              // [20:200] Depth in mm
+height = 30;             // [10:150] Height in mm
+wall_thickness = 2;      // [1:0.5:5] Wall thickness in mm
+
+// === Lid Parameters ===
+include_lid = true;      // Include a separate lid
+lid_height = 8;          // [5:30] Lid height in mm
+lid_tolerance = 0.3;     // [0.1:0.1:0.8] Gap for lid fit
+
+// === Style Options ===
+corner_radius = 3;       // [0:10] Corner rounding radius
+add_grip = true;         // Add grip indents to lid
+
+// === Internal ===
+$fn = 32;                // Smoothness
+
+// Rounded box module
+module rounded_box(w, d, h, r) {
+    if (r > 0) {
+        hull() {
+            for (x = [r, w-r]) {
+                for (y = [r, d-r]) {
+                    translate([x, y, 0])
+                        cylinder(h = h, r = r);
+                }
+            }
+        }
+    } else {
+        cube([w, d, h]);
+    }
+}
+
+// Main box body
+module box_body() {
+    difference() {
+        rounded_box(width, depth, height, corner_radius);
+        
+        // Hollow inside
+        translate([wall_thickness, wall_thickness, wall_thickness])
+            rounded_box(
+                width - 2*wall_thickness,
+                depth - 2*wall_thickness,
+                height,  // Open top
+                max(0, corner_radius - wall_thickness)
+            );
+    }
+}
+
+// Lid
+module lid() {
+    inner_w = width - 2*wall_thickness - 2*lid_tolerance;
+    inner_d = depth - 2*wall_thickness - 2*lid_tolerance;
+    lip_height = lid_height * 0.6;
+    
+    difference() {
+        union() {
+            // Top cap
+            rounded_box(width, depth, wall_thickness, corner_radius);
+            
+            // Inner lip
+            translate([wall_thickness + lid_tolerance, wall_thickness + lid_tolerance, -lip_height + wall_thickness])
+                rounded_box(inner_w, inner_d, lip_height, max(0, corner_radius - wall_thickness));
+        }
+        
+        // Grip indents
+        if (add_grip) {
+            for (x = [width * 0.3, width * 0.7]) {
+                translate([x, -1, wall_thickness/2])
+                    rotate([-90, 0, 0])
+                    cylinder(h = 5, r = 3, $fn = 16);
+                translate([x, depth - 4, wall_thickness/2])
+                    rotate([-90, 0, 0])
+                    cylinder(h = 5, r = 3, $fn = 16);
+            }
+        }
+    }
+}
+
+// Render
+box_body();
+
+if (include_lid) {
+    // Position lid next to box for printing
+    translate([width + 10, 0, lid_height - wall_thickness])
+        rotate([180, 0, 0])
+        lid();
+}

rpi-case/.claude/skills/openscad/examples/phone_stand.scad

@@ -0,0 +1,95 @@
+// Adjustable Phone/Tablet Stand
+// Parametric stand with customizable angle and size
+
+// === Device Parameters ===
+device_width = 80;       // [50:200] Device width in mm
+device_thickness = 12;   // [6:20] Device thickness (with case)
+
+// === Stand Parameters ===  
+stand_angle = 65;        // [45:85] Viewing angle in degrees
+stand_depth = 80;        // [50:150] Base depth in mm
+stand_height = 100;      // [60:200] Back support height in mm
+
+// === Construction ===
+material_thickness = 4;  // [2:0.5:8] Material thickness
+slot_depth = 15;         // [10:30] How deep device sits in slot
+
+// === Features ===
+cable_hole = true;       // Add cable pass-through hole
+cable_diameter = 15;     // [8:25] Cable hole diameter
+add_feet = true;         // Add anti-slip feet
+
+// === Quality ===
+$fn = 48;
+
+module stand_profile() {
+    // 2D profile of the stand side
+    polygon([
+        [0, 0],                                          // Front bottom
+        [stand_depth, 0],                                // Back bottom
+        [stand_depth, material_thickness],               // Back bottom inner
+        [stand_depth - material_thickness, material_thickness], // Base top back
+        [slot_depth + material_thickness, material_thickness],  // Base top front (behind slot)
+        [slot_depth + material_thickness, slot_depth * tan(90 - stand_angle) + material_thickness], // Slot back
+        [material_thickness, slot_depth * tan(90 - stand_angle) + material_thickness + device_thickness / sin(stand_angle)], // Slot front top
+        [0, slot_depth * tan(90 - stand_angle) + material_thickness], // Front face bottom of slot
+        [0, 0]                                           // Close
+    ]);
+}
+
+module back_support() {
+    // Back angled support
+    translate([stand_depth - material_thickness, 0, material_thickness]) {
+        rotate([0, -90 + stand_angle, 0]) {
+            cube([stand_height, device_width, material_thickness]);
+        }
+    }
+}
+
+module cable_cutout() {
+    if (cable_hole) {
+        translate([stand_depth/2, device_width/2, -1])
+            cylinder(h = material_thickness + 2, d = cable_diameter);
+    }
+}
+
+module foot() {
+    cylinder(h = 2, d1 = 10, d2 = 8);
+}
+
+module stand() {
+    difference() {
+        union() {
+            // Left side
+            linear_extrude(material_thickness)
+                stand_profile();
+            
+            // Right side
+            translate([0, device_width - material_thickness, 0])
+                linear_extrude(material_thickness)
+                stand_profile();
+            
+            // Base plate
+            cube([stand_depth, device_width, material_thickness]);
+            
+            // Front lip
+            cube([material_thickness, device_width, slot_depth * tan(90 - stand_angle) + material_thickness]);
+            
+            // Back support
+            back_support();
+        }
+        
+        // Cable hole
+        cable_cutout();
+    }
+    
+    // Feet
+    if (add_feet) {
+        translate([10, 10, 0]) foot();
+        translate([10, device_width - 10, 0]) foot();
+        translate([stand_depth - 10, 10, 0]) foot();
+        translate([stand_depth - 10, device_width - 10, 0]) foot();
+    }
+}
+
+stand();

rpi-case/.claude/skills/openscad/tools/common.sh

@@ -0,0 +1,50 @@
+#!/bin/bash
+# Common utilities for OpenSCAD tools
+
+# Find OpenSCAD executable
+find_openscad() {
+    # Check common locations
+    if command -v openscad &> /dev/null; then
+        echo "openscad"
+        return 0
+    fi
+    
+    # macOS Application bundle
+    if [ -d "/Applications/OpenSCAD.app" ]; then
+        echo "/Applications/OpenSCAD.app/Contents/MacOS/OpenSCAD"
+        return 0
+    fi
+    
+    # Homebrew on Apple Silicon
+    if [ -x "/opt/homebrew/bin/openscad" ]; then
+        echo "/opt/homebrew/bin/openscad"
+        return 0
+    fi
+    
+    # Homebrew on Intel
+    if [ -x "/usr/local/bin/openscad" ]; then
+        echo "/usr/local/bin/openscad"
+        return 0
+    fi
+    
+    return 1
+}
+
+# Check if OpenSCAD is available
+check_openscad() {
+    OPENSCAD=$(find_openscad) || {
+        echo "Error: OpenSCAD not found!"
+        echo ""
+        echo "Install OpenSCAD using one of:"
+        echo "  brew install openscad"
+        echo "  Download from https://openscad.org/downloads.html"
+        exit 1
+    }
+    export OPENSCAD
+}
+
+# Get version info
+openscad_version() {
+    check_openscad
+    $OPENSCAD --version 2>&1
+}

rpi-case/.claude/skills/openscad/tools/export-stl.sh

@@ -0,0 +1,56 @@
+#!/bin/bash
+# Export OpenSCAD file to STL
+# Usage: export-stl.sh input.scad output.stl [-D 'var=value' ...]
+
+set -e
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+source "$SCRIPT_DIR/common.sh"
+
+check_openscad
+
+if [ $# -lt 2 ]; then
+    echo "Usage: $0 input.scad output.stl [-D 'var=value' ...]"
+    echo ""
+    echo "Examples:"
+    echo "  $0 box.scad box.stl"
+    echo "  $0 box.scad box_large.stl -D 'width=80' -D 'height=60'"
+    exit 1
+fi
+
+INPUT="$1"
+OUTPUT="$2"
+shift 2
+
+# Collect -D parameters
+DEFINES=()
+while [ $# -gt 0 ]; do
+    case "$1" in
+        -D)
+            shift
+            DEFINES+=("-D" "$1")
+            ;;
+        *)
+            echo "Unknown option: $1"
+            exit 1
+            ;;
+    esac
+    shift
+done
+
+# Ensure output directory exists
+mkdir -p "$(dirname "$OUTPUT")"
+
+echo "Exporting STL: $INPUT -> $OUTPUT"
+if [ ${#DEFINES[@]} -gt 0 ]; then
+    echo "Parameters: ${DEFINES[*]}"
+fi
+
+$OPENSCAD \
+    "${DEFINES[@]}" \
+    -o "$OUTPUT" \
+    "$INPUT"
+
+# Show file info
+SIZE=$(ls -lh "$OUTPUT" | awk '{print $5}')
+echo "STL exported: $OUTPUT ($SIZE)"

rpi-case/.claude/skills/openscad/tools/extract-params.sh

@@ -0,0 +1,147 @@
+#!/bin/bash
+# Extract customizable parameters from an OpenSCAD file
+# Usage: extract-params.sh input.scad [--json]
+#
+# Parses parameter declarations with special comments:
+#   param = value;           // [min:max] Description
+#   param = value;           // [min:step:max] Description  
+#   param = value;           // [opt1, opt2] Description
+#   param = value;           // Description only
+
+set -e
+
+if [ $# -lt 1 ]; then
+    echo "Usage: $0 input.scad [--json]"
+    exit 1
+fi
+
+INPUT="$1"
+JSON_OUTPUT=false
+
+if [ "$2" = "--json" ]; then
+    JSON_OUTPUT=true
+fi
+
+if [ ! -f "$INPUT" ]; then
+    echo "Error: File not found: $INPUT"
+    exit 1
+fi
+
+# Extract parameters using Python for better parsing
+extract_params() {
+    python3 -c '
+import sys
+import re
+
+filename = sys.argv[1]
+in_block = 0
+
+with open(filename, "r") as f:
+    for line in f:
+        # Track block depth (skip params inside modules/functions)
+        in_block += line.count("{") - line.count("}")
+        if in_block > 0:
+            continue
+            
+        # Match: varname = value; // comment
+        match = re.match(r"^\s*([a-zA-Z_][a-zA-Z0-9_]*)\s*=\s*([^;]+);\s*(?://\s*(.*))?", line)
+        if not match:
+            continue
+            
+        var_name = match.group(1)
+        value = match.group(2).strip()
+        comment = match.group(3) or ""
+        
+        # Determine type
+        if value in ("true", "false"):
+            var_type = "boolean"
+        elif re.match(r"^-?\d+$", value):
+            var_type = "integer"
+        elif re.match(r"^-?\d*\.?\d+$", value):
+            var_type = "number"
+        elif value.startswith("\"") and value.endswith("\""):
+            var_type = "string"
+            value = value[1:-1]  # Remove quotes
+        elif value.startswith("["):
+            var_type = "array"
+        else:
+            var_type = "expression"
+        
+        # Parse comment for range/options
+        range_val = ""
+        options_val = ""
+        description = comment
+        
+        range_match = re.match(r"\[([^\]]+)\]\s*(.*)", comment)
+        if range_match:
+            bracket_content = range_match.group(1)
+            description = range_match.group(2)
+            
+            # Check if numeric range (contains :) or options (contains ,)
+            if ":" in bracket_content and not "," in bracket_content:
+                range_val = bracket_content
+            else:
+                options_val = bracket_content
+        
+        # Output pipe-delimited
+        print(f"{var_name}|{value}|{var_type}|{range_val}|{options_val}|{description}")
+' "$INPUT"
+}
+
+if [ "$JSON_OUTPUT" = true ]; then
+    echo "["
+    first=true
+    while IFS='|' read -r name value type range options description; do
+        if [ "$first" = true ]; then
+            first=false
+        else
+            echo ","
+        fi
+        
+        # Escape quotes in values
+        value=$(echo "$value" | sed 's/"/\\"/g')
+        description=$(echo "$description" | sed 's/"/\\"/g')
+        
+        # Build JSON object
+        printf '  {\n'
+        printf '    "name": "%s",\n' "$name"
+        printf '    "value": "%s",\n' "$value"
+        printf '    "type": "%s"' "$type"
+        
+        if [ -n "$range" ]; then
+            printf ',\n    "range": "%s"' "$range"
+        fi
+        if [ -n "$options" ]; then
+            printf ',\n    "options": "%s"' "$options"
+        fi
+        if [ -n "$description" ]; then
+            printf ',\n    "description": "%s"' "$description"
+        fi
+        printf '\n  }'
+    done < <(extract_params)
+    echo ""
+    echo "]"
+else
+    echo "Parameters in: $INPUT"
+    echo "==============================================="
+    printf "%-20s %-15s %-10s %s\n" "NAME" "VALUE" "TYPE" "CONSTRAINT/DESC"
+    echo "-----------------------------------------------"
+    
+    while IFS='|' read -r name value type range options description; do
+        constraint=""
+        if [ -n "$range" ]; then
+            constraint="[$range]"
+        elif [ -n "$options" ]; then
+            constraint="[$options]"
+        fi
+        if [ -n "$description" ]; then
+            if [ -n "$constraint" ]; then
+                constraint="$constraint $description"
+            else
+                constraint="$description"
+            fi
+        fi
+        
+        printf "%-20s %-15s %-10s %s\n" "$name" "$value" "$type" "$constraint"
+    done < <(extract_params)
+fi

rpi-case/.claude/skills/openscad/tools/multi-preview.sh

@@ -0,0 +1,68 @@
+#!/bin/bash
+# Generate preview images from multiple angles
+# Usage: multi-preview.sh input.scad output_dir/ [-D 'var=value']
+
+set -e
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+source "$SCRIPT_DIR/common.sh"
+
+check_openscad
+
+if [ $# -lt 2 ]; then
+    echo "Usage: $0 input.scad output_dir/ [-D 'var=value' ...]"
+    exit 1
+fi
+
+INPUT="$1"
+OUTPUT_DIR="$2"
+shift 2
+
+# Collect -D parameters
+DEFINES=()
+while [ $# -gt 0 ]; do
+    case "$1" in
+        -D)
+            shift
+            DEFINES+=("-D" "$1")
+            ;;
+    esac
+    shift
+done
+
+mkdir -p "$OUTPUT_DIR"
+
+# Get base name without extension
+BASENAME=$(basename "$INPUT" .scad)
+
+echo "Generating multi-angle previews for: $INPUT"
+echo "Output directory: $OUTPUT_DIR"
+echo ""
+
+# Define angles as name:camera pairs
+# Camera format: translate_x,translate_y,translate_z,rot_x,rot_y,rot_z,distance
+ANGLES="iso:0,0,0,55,0,25,0
+front:0,0,0,90,0,0,0
+back:0,0,0,90,0,180,0
+left:0,0,0,90,0,90,0
+right:0,0,0,90,0,-90,0
+top:0,0,0,0,0,0,0"
+
+echo "$ANGLES" | while IFS=: read -r angle camera; do
+    output="$OUTPUT_DIR/${BASENAME}_${angle}.png"
+    
+    echo "  Rendering $angle view..."
+    $OPENSCAD \
+        --camera="$camera" \
+        --imgsize="800,600" \
+        --colorscheme="Tomorrow Night" \
+        --autocenter \
+        --viewall \
+        "${DEFINES[@]}" \
+        -o "$output" \
+        "$INPUT" 2>/dev/null
+done
+
+echo ""
+echo "Generated previews:"
+ls -la "$OUTPUT_DIR"/${BASENAME}_*.png

rpi-case/.claude/skills/openscad/tools/preview.sh

@@ -0,0 +1,74 @@
+#!/bin/bash
+# Generate a preview PNG from an OpenSCAD file
+# Usage: preview.sh input.scad output.png [options]
+#
+# Options:
+#   --camera=x,y,z,rx,ry,rz,dist  Camera position
+#   --size=WxH                     Image size (default: 800x600)
+#   -D 'var=value'                 Set parameter value
+
+set -e
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+source "$SCRIPT_DIR/common.sh"
+
+check_openscad
+
+if [ $# -lt 2 ]; then
+    echo "Usage: $0 input.scad output.png [--camera=...] [--size=WxH] [-D 'var=val']"
+    echo ""
+    echo "Camera format: x,y,z,rotx,roty,rotz,distance"
+    echo "Common cameras:"
+    echo "  Isometric: --camera=0,0,0,55,0,25,200"
+    echo "  Front:     --camera=0,0,0,90,0,0,200"
+    echo "  Top:       --camera=0,0,0,0,0,0,200"
+    exit 1
+fi
+
+INPUT="$1"
+OUTPUT="$2"
+shift 2
+
+# Defaults
+CAMERA="0,0,0,55,0,25,0"
+SIZE="800,600"
+DEFINES=()
+
+# Parse options
+while [ $# -gt 0 ]; do
+    case "$1" in
+        --camera=*)
+            CAMERA="${1#--camera=}"
+            ;;
+        --size=*)
+            SIZE="${1#--size=}"
+            SIZE="${SIZE/x/,}"
+            ;;
+        -D)
+            shift
+            DEFINES+=("-D" "$1")
+            ;;
+        *)
+            echo "Unknown option: $1"
+            exit 1
+            ;;
+    esac
+    shift
+done
+
+# Ensure output directory exists
+mkdir -p "$(dirname "$OUTPUT")"
+
+# Run OpenSCAD
+echo "Rendering preview: $INPUT -> $OUTPUT"
+$OPENSCAD \
+    --camera="$CAMERA" \
+    --imgsize="${SIZE}" \
+    --colorscheme="Tomorrow Night" \
+    --autocenter \
+    --viewall \
+    "${DEFINES[@]}" \
+    -o "$OUTPUT" \
+    "$INPUT"
+
+echo "Preview saved to: $OUTPUT"

rpi-case/.claude/skills/openscad/tools/render-with-params.sh

@@ -0,0 +1,91 @@
+#!/bin/bash
+# Render OpenSCAD with parameters from a JSON file
+# Usage: render-with-params.sh input.scad params.json output.stl|output.png
+
+set -e
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+source "$SCRIPT_DIR/common.sh"
+
+check_openscad
+
+if [ $# -lt 3 ]; then
+    echo "Usage: $0 input.scad params.json output.[stl|png]"
+    echo ""
+    echo "params.json format:"
+    echo '  {"width": 60, "height": 40, "include_lid": true}'
+    exit 1
+fi
+
+INPUT="$1"
+PARAMS_FILE="$2"
+OUTPUT="$3"
+
+if [ ! -f "$INPUT" ]; then
+    echo "Error: Input file not found: $INPUT"
+    exit 1
+fi
+
+if [ ! -f "$PARAMS_FILE" ]; then
+    echo "Error: Params file not found: $PARAMS_FILE"
+    exit 1
+fi
+
+# Build -D arguments from JSON
+DEFINES=()
+while IFS= read -r line; do
+    # Parse each key-value pair
+    key=$(echo "$line" | cut -d'=' -f1)
+    value=$(echo "$line" | cut -d'=' -f2-)
+    
+    if [ -n "$key" ]; then
+        DEFINES+=("-D" "$key=$value")
+    fi
+done < <(
+    # Use python or jq to parse JSON to key=value lines
+    if command -v python3 &> /dev/null; then
+        python3 -c "
+import json
+with open('$PARAMS_FILE') as f:
+    params = json.load(f)
+for k, v in params.items():
+    if isinstance(v, bool):
+        print(f'{k}={str(v).lower()}')
+    elif isinstance(v, str):
+        print(f'{k}=\"{v}\"')
+    else:
+        print(f'{k}={v}')
+"
+    elif command -v jq &> /dev/null; then
+        jq -r 'to_entries | .[] | "\(.key)=\(.value)"' "$PARAMS_FILE"
+    else
+        echo "Error: Requires python3 or jq to parse JSON"
+        exit 1
+    fi
+)
+
+echo "Rendering with parameters from: $PARAMS_FILE"
+echo "Parameters: ${DEFINES[*]}"
+
+# Determine output type and set appropriate options
+EXT="${OUTPUT##*.}"
+case "$EXT" in
+    stl|STL)
+        $OPENSCAD "${DEFINES[@]}" -o "$OUTPUT" "$INPUT"
+        ;;
+    png|PNG)
+        $OPENSCAD "${DEFINES[@]}" \
+            --camera="0,0,0,55,0,25,0" \
+            --imgsize="800,600" \
+            --colorscheme="Tomorrow Night" \
+            --autocenter --viewall \
+            -o "$OUTPUT" "$INPUT"
+        ;;
+    *)
+        echo "Unsupported output format: $EXT"
+        echo "Supported: stl, png"
+        exit 1
+        ;;
+esac
+
+echo "Output saved: $OUTPUT"

rpi-case/.claude/skills/openscad/tools/validate.sh

@@ -0,0 +1,46 @@
+#!/bin/bash
+# Validate an OpenSCAD file for syntax errors
+# Usage: validate.sh input.scad
+
+set -e
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+source "$SCRIPT_DIR/common.sh"
+
+check_openscad
+
+if [ $# -lt 1 ]; then
+    echo "Usage: $0 input.scad"
+    exit 1
+fi
+
+INPUT="$1"
+
+if [ ! -f "$INPUT" ]; then
+    echo "Error: File not found: $INPUT"
+    exit 1
+fi
+
+echo "Validating: $INPUT"
+
+# Create temp file for output
+TEMP_OUTPUT=$(mktemp /tmp/openscad_validate.XXXXXX.echo)
+trap "rm -f $TEMP_OUTPUT" EXIT
+
+# Run OpenSCAD with echo output (fastest way to check syntax)
+# Using --export-format=echo just parses and evaluates without rendering
+if $OPENSCAD -o "$TEMP_OUTPUT" --export-format=echo "$INPUT" 2>&1; then
+    echo "✓ Syntax OK"
+    
+    # Check for warnings in stderr
+    if [ -s "$TEMP_OUTPUT" ]; then
+        echo ""
+        echo "Echo output:"
+        cat "$TEMP_OUTPUT"
+    fi
+    
+    exit 0
+else
+    echo "✗ Validation failed"
+    exit 1
+fi

rpi-case/rpi5_industrial_case_001.scad

@@ -0,0 +1,289 @@
+// ============================================================
+// RPi5 Industrial Enclosure for Luckfox DHX-10.1" Touchscreen
+// Version: 001
+// ============================================================
+
+// ── SCREEN PARAMETERS ───────────────────────────────────────
+scr_w       = 236;      // screen outer width  (mm)
+scr_h       = 144;      // screen outer height (mm)
+scr_d       = 19;       // screen outer depth  (mm)
+scr_active_w = 222;     // active area width   (mm)  ← confirm
+scr_active_h = 130;     // active area height  (mm)  ← confirm
+scr_mount_x  = 75;      // screen M2.5 mount pattern X (mm) ← verify
+scr_mount_y  = 75;      // screen M2.5 mount pattern Y (mm) ← verify
+
+// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
+pi_w        = 85;       // Pi board width  (mm)
+pi_h        = 56;       // Pi board height (mm)
+pi_d        = 17;       // Pi board depth incl. tallest component (mm)
+pi_mnt_x    = 58;       // Pi mount hole pattern X (mm)
+pi_mnt_y    = 49;       // Pi mount hole pattern Y (mm)
+pi_standoff = 5;        // standoff height between screen rear and Pi (mm)
+// Pi offset from screen center (positive = up, right)
+pi_offset_x = 0;        // horizontal offset of Pi center from screen center
+pi_offset_y = 5;        // vertical offset upward from screen center
+
+// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
+wall        = 2.5;      // wall thickness (mm)
+chamfer     = 1.5;      // external edge chamfer (mm)
+recess      = 1.0;      // screen recess depth in front bezel (mm)
+gap         = 0.3;      // fit clearance between bezel and rear cover
+
+// ── VENT PARAMETERS ──────────────────────────────────────────
+vent_w      = 3;        // vent slot width  (mm)
+vent_l      = 20;       // vent slot length (mm)
+vent_sp     = 4;        // slot pitch (edge to edge) (mm)
+soc_vent_sz = 30;       // SoC vent zone size (mm sq)
+
+// ── CABLE GLAND PARAMETERS ───────────────────────────────────
+gland_count = 2;        // number of cable glands
+gland_dia   = 16.5;     // M16 clearance hole diameter (mm)
+gland_spacing = 40;     // spacing between gland centers (mm)
+
+// ── PEDESTAL PARAMETERS ──────────────────────────────────────
+ped_tilt    = 75;       // tilt angle from vertical (deg) — screen tilts back
+ped_depth   = 80;       // foot depth front-to-back (mm)
+ped_width   = 200;      // foot width (mm)
+ped_thick   = 6;        // foot plate thickness (mm)
+ped_brace_h = 30;       // height of triangular brace
+
+// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
+m3_dia      = 3.4;      // M3 clearance hole
+insert_dia  = 4.2;      // M3 heat-set insert OD
+insert_h    = 6;        // heat-set insert depth
+
+// ── DERIVED DIMENSIONS ───────────────────────────────────────
+// Total rear cavity depth = standoffs + Pi + cable headroom
+rear_d      = pi_standoff + pi_d + 10;  // 10 mm cable headroom
+// Outer enclosure size
+enc_w       = scr_w + 2*wall;
+enc_h       = scr_h + 2*wall;
+enc_d       = rear_d + wall;            // rear cover depth
+
+// Pi center position relative to screen center
+pi_cx = scr_w/2 + pi_offset_x;
+pi_cy = scr_h/2 + pi_offset_y;
+
+$fn = 48;
+
+// ============================================================
+// MODULES
+// ============================================================
+
+// Chamfered box (external chamfer via intersection with offset cube)
+module cbox(w, h, d, c=chamfer) {
+    hull() {
+        translate([c,c,0])       cube([w-2*c, h-2*c, d]);
+        translate([0,c,c])       cube([w,     h-2*c, d-2*c]);
+        translate([c,0,c])       cube([w-2*c, h,     d-2*c]);
+    }
+}
+
+// Rounded slot (for vents)
+module slot(len, w, d) {
+    r = w/2;
+    hull() {
+        translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
+        translate([0,  len/2-r, 0]) cylinder(r=r, h=d);
+    }
+}
+
+// M2.5 mounting hole
+module m25_hole(d=10) {
+    cylinder(d=2.7, h=d);
+}
+
+// Heat-set insert boss + M3 hole
+module insert_boss(h=insert_h+4) {
+    difference() {
+        cylinder(d=insert_dia+3, h=h);
+        cylinder(d=insert_dia,   h=insert_h);
+        translate([0,0,insert_h]) cylinder(d=m3_dia, h=h);
+    }
+}
+
+// Single vent slot row (horizontal slots)
+module vent_row(count, slot_len, slot_w, pitch, depth) {
+    for(i=[0:count-1]) {
+        translate([i*(slot_w+pitch), 0, 0])
+            slot(slot_len, slot_w, depth+0.1);
+    }
+}
+
+// ============================================================
+// FRONT BEZEL
+// ============================================================
+module front_bezel() {
+    difference() {
+        // Outer chamfered shell
+        cbox(enc_w, enc_h, wall + recess);
+
+        // Active display window (recessed by 1 mm, then open)
+        translate([(enc_w - scr_active_w)/2,
+                   (enc_h - scr_active_h)/2,
+                   -0.1])
+            cube([scr_active_w, scr_active_h, wall + recess + 0.2]);
+
+        // Bezel lip sits 1 mm over screen edge — recess pocket
+        translate([(enc_w - scr_w)/2,
+                   (enc_h - scr_h)/2,
+                   wall])
+            cube([scr_w, scr_h, recess + 0.1]);
+
+        // Corner M3 screw holes (through bezel flange, 4 corners)
+        for(x=[wall+6, enc_w-wall-6])
+            for(y=[wall+6, enc_h-wall-6])
+                translate([x, y, -0.1])
+                    cylinder(d=m3_dia, h=wall+recess+0.2);
+    }
+}
+
+// ============================================================
+// REAR COVER
+// ============================================================
+module rear_cover() {
+    difference() {
+        union() {
+            // Main body
+            cbox(enc_w, enc_h, enc_d);
+
+            // Pedestal foot (integral)
+            pedestal_foot();
+
+            // Heat-set insert bosses at 4 corners (inside)
+            for(x=[wall+6, enc_w-wall-6])
+                for(y=[wall+6, enc_h-wall-6])
+                    translate([x, y, enc_d])
+                        rotate([180,0,0])
+                            insert_boss();
+        }
+
+        // Hollow interior
+        translate([wall, wall, wall])
+            cube([scr_w, scr_h, enc_d]);
+
+        // ── PORT CUTOUTS ──────────────────────────────────────
+
+        // USB-C power + 2× HDMI on LEFT edge (Pi left side)
+        // Pi left edge X position in enclosure coords
+        pi_left_x = pi_cx - pi_w/2 + wall;
+        // USB-C power (Pi left edge, near bottom of Pi)
+        translate([-0.1,
+                   pi_cy - 8 + wall,
+                   wall + pi_standoff + 2])
+            cube([wall+0.2, 10, 10]);
+        // HDMI #1
+        translate([-0.1,
+                   pi_cx - pi_w/2 + wall + 15,
+                   wall + pi_standoff + 2])
+            cube([wall+0.2, 16, 8]);
+        // HDMI #2
+        translate([-0.1,
+                   pi_cx - pi_w/2 + wall + 34,
+                   wall + pi_standoff + 2])
+            cube([wall+0.2, 16, 8]);
+
+        // Ethernet RJ45 on RIGHT edge
+        translate([enc_w - wall - 0.1,
+                   pi_cy + pi_h/2 - 22 + wall,
+                   wall + pi_standoff + 1])
+            cube([wall+0.2, 22, 16]);
+
+        // USB-A ×4 on RIGHT edge
+        translate([enc_w - wall - 0.1,
+                   pi_cy - pi_h/2 + wall + 2,
+                   wall + pi_standoff + 1])
+            cube([wall+0.2, 50, 14]);
+
+        // GPIO header on TOP edge
+        translate([pi_cx - 30 + wall,
+                   enc_h - wall - 0.1,
+                   wall + pi_standoff])
+            cube([52, wall+0.2, 12]);
+
+        // USB-C touch on left side edge of SCREEN (not Pi)
+        translate([-0.1, enc_h/2 - 6, wall + scr_d - 5])
+            cube([wall+0.2, 12, 8]);
+
+        // ── COOLING VENTS ──────────────────────────────────────
+
+        // Bottom intake slots
+        translate([enc_w/2 - (5*(vent_w+vent_sp))/2, -0.1, wall+8])
+            rotate([-90, 0, 0])
+                vent_row(5, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // Top exhaust slots
+        translate([enc_w/2 - (5*(vent_w+vent_sp))/2,
+                   enc_h - wall + 0.1,
+                   wall+8])
+            rotate([90, 0, 0])
+                vent_row(5, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // SoC direct vent (rear panel, over Pi SoC area)
+        // SoC assumed ~center of Pi board
+        translate([pi_cx - soc_vent_sz/2 + wall,
+                   pi_cy - soc_vent_sz/2 + wall,
+                   enc_d - wall - 0.1]) {
+            count_soc = floor(soc_vent_sz / (vent_w + vent_sp));
+            for(i=[0:count_soc-1])
+                translate([i*(vent_w+vent_sp), soc_vent_sz/2-vent_l/2, 0])
+                    slot(vent_l, vent_w, wall+0.2);
+        }
+
+        // ── CABLE GLANDS ──────────────────────────────────────
+        for(i=[0:gland_count-1]) {
+            cx = enc_w/2 + (i - (gland_count-1)/2) * gland_spacing;
+            translate([cx, -0.1, wall + gland_dia/2 + 4])
+                rotate([-90,0,0])
+                    cylinder(d=gland_dia, h=wall+0.2);
+        }
+    }
+}
+
+// ============================================================
+// PEDESTAL FOOT (integral with rear cover)
+// ============================================================
+module pedestal_foot() {
+    // The foot projects from the bottom of the rear cover.
+    // It's a wedge that creates the tilt angle.
+    // When the assembly stands on the foot, the screen tilts back ped_tilt°.
+    //
+    // tilt_angle from vertical → wedge front height > back height.
+    // foot_front_h = ped_depth * tan(90-ped_tilt)
+    foot_front_h = ped_depth * tan(90 - ped_tilt);
+
+    foot_x0 = (enc_w - ped_width) / 2;
+
+    translate([foot_x0, 0, 0]) {
+        // Wedge base plate
+        hull() {
+            // Front edge (taller)
+            translate([0, -ped_depth, 0])
+                cube([ped_width, 0.1, foot_front_h + ped_thick]);
+            // Back edge (at enc base, flush)
+            translate([0, 0, 0])
+                cube([ped_width, 0.1, ped_thick]);
+        }
+
+        // Triangular side braces for rigidity
+        for(bx=[0, ped_width-ped_thick]) {
+            translate([bx, -ped_depth, 0])
+                linear_extrude(ped_thick)
+                    polygon([[0,0],
+                             [ped_depth, 0],
+                             [ped_depth, foot_front_h]]);
+        }
+    }
+}
+
+// ============================================================
+// RENDER — exploded assembly view
+// ============================================================
+// Front bezel at Z=0 (face down for printing, shown face up)
+color("DarkSlateGray", 0.9)
+    translate([0, 0, enc_d + 5])
+        front_bezel();
+
+// Rear cover
+color("SlateGray", 0.9)
+    rear_cover();

rpi-case/rpi5_industrial_case_002.scad

@@ -0,0 +1,300 @@
+// ============================================================
+// RPi5 Industrial Enclosure — Luckfox DHX-10.1" Touchscreen
+// Version: 002
+//   Fixes vs 001:
+//     1. Pedestal foot now projects from REAR FACE in -Z direction
+//     2. Tilt wedge orientation corrected (leans screen back, not forward)
+//     3. Cable glands moved to rear panel face (foot owns the bottom edge)
+//     4. GPIO cutout repositioned to match Pi board top-edge location
+//     5. Port cutout Z-depths corrected using pi_enc_cx/cy consistently
+// ============================================================
+
+// ── SCREEN PARAMETERS ───────────────────────────────────────
+scr_w        = 236;    // screen outer width  (mm)
+scr_h        = 144;    // screen outer height (mm)
+scr_d        = 19;     // screen outer depth  (mm)
+scr_active_w = 222;    // active area width   (mm)  ← confirm
+scr_active_h = 130;    // active area height  (mm)  ← confirm
+scr_mount_x  = 75;     // screen rear M2.5 mount pattern X (mm) ← verify
+scr_mount_y  = 75;     // screen rear M2.5 mount pattern Y (mm) ← verify
+
+// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
+pi_w         = 85;     // Pi board width  (mm)
+pi_h         = 56;     // Pi board height (mm)
+pi_d         = 17;     // Pi board depth incl. tallest component (mm)
+pi_mnt_x     = 58;     // Pi mount hole pattern X (mm)
+pi_mnt_y     = 49;     // Pi mount hole pattern Y (mm)
+pi_standoff  = 5;      // standoff height: screen rear → Pi board (mm)
+pi_offset_x  = 0;      // Pi centre horizontal offset from screen centre (mm)
+pi_offset_y  = 5;      // Pi centre vertical offset upward from screen centre (mm)
+
+// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
+wall         = 2.5;    // wall thickness (mm)
+chamfer      = 1.5;    // external edge chamfer (mm)
+recess       = 1.0;    // screen recess depth in front bezel (mm)
+gap          = 0.3;    // bezel ↔ rear cover fit clearance (mm)
+
+// ── VENT PARAMETERS ──────────────────────────────────────────
+vent_w       = 3;      // vent slot width  (mm)
+vent_l       = 20;     // vent slot length (mm)
+vent_sp      = 4;      // slot spacing edge-to-edge (mm)
+soc_vent_sz  = 30;     // SoC direct-vent zone size (mm, square)
+
+// ── CABLE GLAND PARAMETERS ───────────────────────────────────
+gland_count  = 2;      // number of M16 cable glands
+gland_dia    = 16.5;   // M16 clearance hole diameter (mm)
+gland_spacing= 40;     // centre-to-centre spacing (mm)
+
+// ── PEDESTAL PARAMETERS ──────────────────────────────────────
+// ped_tilt = angle of screen from horizontal (deg).
+//   75° from horizontal = 15° lean-back from vertical (near-upright monitor stance).
+//   The foot is a wedge that, when flat on a desk, holds the rear cover at
+//   (90 - ped_tilt)° from vertical.
+ped_tilt     = 75;     // screen angle from horizontal (deg)
+ped_depth    = 80;     // foot plate depth front-to-back (mm)
+ped_width    = 200;    // foot plate width (mm)
+ped_thick    = 6;      // foot plate thickness (mm)
+
+// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
+m3_dia       = 3.4;    // M3 clearance hole diameter (mm)
+insert_dia   = 4.2;    // M3 heat-set insert OD (mm)
+insert_h     = 6;      // heat-set insert depth (mm)
+
+// ── DERIVED DIMENSIONS (do not edit) ─────────────────────────
+rear_d    = pi_standoff + pi_d + 10;   // rear cavity depth (10 mm cable headroom)
+enc_w     = scr_w + 2*wall;            // enclosure outer width
+enc_h     = scr_h + 2*wall;            // enclosure outer height
+enc_d     = rear_d + wall;             // rear cover total depth
+
+// Pi centre in enclosure coordinates (enclosure origin = rear-cover corner)
+pi_enc_cx = wall + scr_w/2 + pi_offset_x;   // = 120.5 with defaults
+pi_enc_cy = wall + scr_h/2 + pi_offset_y;   // =  79.5 with defaults
+
+// Z position of Pi board surface (measured from rear of rear cover)
+pi_z      = wall + pi_standoff;              // = 7.5 with defaults
+
+// Foot wedge geometry
+// foot_drop: how far the far tip drops below Y=0 so the bottom surface
+//   becomes horizontal when the unit stands at ped_tilt from horizontal.
+foot_drop = ped_depth * tan(90 - ped_tilt);  // ≈ 21.4 mm for ped_tilt=75
+
+$fn = 48;
+
+// ============================================================
+// PRIMITIVES
+// ============================================================
+
+// Chamfered box — chamfer on all 12 edges via hull of 3 axis-aligned cubes
+module cbox(w, h, d, c=chamfer) {
+    hull() {
+        translate([c,c,0])   cube([w-2*c, h-2*c, d      ]);
+        translate([0,c,c])   cube([w,     h-2*c, d-2*c  ]);
+        translate([c,0,c])   cube([w-2*c, h,     d-2*c  ]);
+    }
+}
+
+// Rounded-end vent slot, length along Y, centred at origin
+module slot(len, w, d) {
+    r = w/2;
+    hull() {
+        translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
+        translate([0,  len/2-r, 0]) cylinder(r=r, h=d);
+    }
+}
+
+// Row of n vent slots along X
+module vent_row(n, len, w, spacing, depth) {
+    for(i=[0:n-1])
+        translate([i*(w+spacing), 0, 0])
+            slot(len, w, depth);
+}
+
+// Heat-set insert boss (M3)
+module insert_boss(h=insert_h+4) {
+    difference() {
+        cylinder(d=insert_dia+3, h=h);
+        cylinder(d=insert_dia,   h=insert_h);
+        translate([0,0,insert_h]) cylinder(d=m3_dia, h=h);
+    }
+}
+
+// ============================================================
+// PEDESTAL FOOT  (integral with rear cover, no supports needed)
+// ============================================================
+// Geometry in model space (rear cover lying on its back, rear face = Z=0):
+//   • Foot extends in the -Z direction from Z=0 (behind the rear face)
+//   • Top surface is flush with the enclosure bottom at Y=0
+//   • Bottom surface is angled: at Z=0 it is ped_thick below Y=0;
+//     at Z=-ped_depth it is (ped_thick + foot_drop) below Y=0.
+//   • When the unit stands on the desk the angled surface lies flat and the
+//     screen tilts back (90-ped_tilt)° from vertical.
+//   • Print orientation: rear cover face-down (foot on bed), zero supports.
+module pedestal_foot() {
+    foot_x0 = (enc_w - ped_width) / 2;
+
+    translate([foot_x0, 0, 0]) {
+        // Main wedge plate
+        hull() {
+            translate([0, -ped_thick,             0        ])
+                cube([ped_width, ped_thick,       wall     ]);
+            translate([0, -(ped_thick+foot_drop), -ped_depth])
+                cube([ped_width, ped_thick+foot_drop, wall ]);
+        }
+        // Left and right stiffening ribs
+        for(bx = [0, ped_width - ped_thick]) {
+            hull() {
+                translate([bx, -ped_thick,              0        ])
+                    cube([ped_thick, ped_thick,          wall     ]);
+                translate([bx, -(ped_thick+foot_drop),  -ped_depth])
+                    cube([ped_thick, ped_thick+foot_drop, wall   ]);
+                // Toe point keeps underside triangular (no saggy bridge)
+                translate([bx, -ped_thick,              -ped_depth])
+                    cube([ped_thick, ped_thick,           wall   ]);
+            }
+        }
+    }
+}
+
+// ============================================================
+// FRONT BEZEL
+// ============================================================
+module front_bezel() {
+    difference() {
+        cbox(enc_w, enc_h, wall + recess);
+
+        // Active display window (full cut-through)
+        translate([(enc_w-scr_active_w)/2, (enc_h-scr_active_h)/2, -0.1])
+            cube([scr_active_w, scr_active_h, wall+recess+0.2]);
+
+        // Recess pocket so bezel lip sits 1 mm over screen edge
+        translate([(enc_w-scr_w)/2, (enc_h-scr_h)/2, wall])
+            cube([scr_w, scr_h, recess+0.1]);
+
+        // M3 corner screw holes (4×)
+        for(x = [wall+6, enc_w-wall-6])
+            for(y = [wall+6, enc_h-wall-6])
+                translate([x, y, -0.1]) cylinder(d=m3_dia, h=wall+recess+0.2);
+    }
+}
+
+// ============================================================
+// REAR COVER
+// ============================================================
+module rear_cover() {
+    n_vent = 6;
+    vent_block_w = n_vent*(vent_w+vent_sp) - vent_sp;  // total width of vent array
+
+    difference() {
+        union() {
+            cbox(enc_w, enc_h, enc_d);
+            pedestal_foot();
+
+            // M3 insert bosses at 4 corners (inner face)
+            for(x = [wall+6, enc_w-wall-6])
+                for(y = [wall+6, enc_h-wall-6])
+                    translate([x, y, enc_d])
+                        rotate([180,0,0]) insert_boss();
+        }
+
+        // ── HOLLOW INTERIOR ───────────────────────────────────
+        translate([wall, wall, wall]) cube([scr_w, scr_h, enc_d]);
+
+        // ── LEFT WALL: USB-C power + HDMI ×2 ─────────────────
+        // These are on the Pi's left short-edge (56 mm face), facing X=0.
+        // Cutout Y-centre is set near the Pi's lower half.
+        // Z positions follow port heights above PCB surface.
+        // (Short ribbon extensions needed to reach the wall at X=0.)
+        //
+        // USB-C power
+        translate([-0.1,
+                   pi_enc_cy - pi_h/2 + 3,
+                   pi_z + 2])
+            cube([wall+0.2, 11, 11]);
+        // HDMI 0
+        translate([-0.1,
+                   pi_enc_cy - pi_h/2 + 16,
+                   pi_z + 2])
+            cube([wall+0.2, 17, 9]);
+        // HDMI 1
+        translate([-0.1,
+                   pi_enc_cy - pi_h/2 + 35,
+                   pi_z + 2])
+            cube([wall+0.2, 17, 9]);
+
+        // ── RIGHT WALL: RJ45 + USB-A ×4 ──────────────────────
+        // RJ45 (top of Pi right edge in board orientation)
+        translate([enc_w-wall-0.1,
+                   pi_enc_cy + pi_h/2 - 24,
+                   pi_z + 1])
+            cube([wall+0.2, 22, 16]);
+        // USB-A ×4 (two stacked pairs, below RJ45 on right edge)
+        translate([enc_w-wall-0.1,
+                   pi_enc_cy - pi_h/2 + 2,
+                   pi_z + 1])
+            cube([wall+0.2, 50, 15]);
+
+        // ── TOP WALL: GPIO header (40-pin) ────────────────────
+        // GPIO is on the Pi's top long edge (85 mm edge at Y = pi_enc_cy + pi_h/2).
+        // Cutout aligns with the header strip X-extent (51 mm) centred on Pi.
+        // Z-extent: board surface + header height (~11 mm).
+        translate([pi_enc_cx - 26,
+                   pi_enc_cy + pi_h/2 - 0.1,
+                   pi_z])
+            cube([52, wall+0.2, 11]);
+
+        // ── USB-C TOUCH: screen side edge (left, near screen depth) ───
+        translate([-0.1,
+                   enc_h/2 - 6,
+                   wall + scr_d - 5])
+            cube([wall+0.2, 12, 8]);
+
+        // ── COOLING VENTS ─────────────────────────────────────
+
+        // Bottom intake slots (6 × 3×20 mm, 4 mm spacing)
+        translate([enc_w/2 - vent_block_w/2,
+                   -0.1,
+                   wall + 8])
+            rotate([-90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // Top exhaust slots
+        translate([enc_w/2 - vent_block_w/2,
+                   enc_h - wall + 0.1,
+                   wall + 8])
+            rotate([90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // SoC direct-vent array on rear panel, centred over Pi SoC
+        translate([pi_enc_cx - soc_vent_sz/2,
+                   pi_enc_cy - soc_vent_sz/2,
+                   enc_d - wall - 0.1]) {
+            n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
+            for(i = [0:n_soc-1])
+                translate([i*(vent_w+vent_sp),
+                           soc_vent_sz/2 - vent_l/2,
+                           0])
+                    slot(vent_l, vent_w, wall+0.2);
+        }
+
+        // ── CABLE GLANDS: rear panel face, bottom area ────────
+        // Two M16 glands through the rear face (Z=0 plane).
+        // Positioned below the Pi, above the foot junction.
+        for(i = [0:gland_count-1]) {
+            cx = enc_w/2 + (i - (gland_count-1)/2) * gland_spacing;
+            translate([cx,
+                       wall + gland_dia/2 + 4,
+                       -0.1])
+                cylinder(d=gland_dia, h=wall+0.2);
+        }
+    }
+}
+
+// ============================================================
+// RENDER — exploded assembly (front bezel floats above rear cover)
+// ============================================================
+color("DarkSlateGray", 0.9)
+    translate([0, 0, enc_d + 10])
+        front_bezel();
+
+color("SlateGray", 0.85)
+    rear_cover();

rpi-case/rpi5_industrial_case_003.scad

@@ -0,0 +1,328 @@
+// ============================================================
+// RPi5 Industrial Enclosure — Luckfox DHX-10.1" Touchscreen
+// Version: 003
+//   Fixes vs 002:
+//     1. Kickstand completely redesigned — shorter, thinner, clearly
+//        attached to rear cover bottom, triangular gussets on each side
+//     2. GPIO top-wall cutout removed (GPIO is fully internal; access
+//        requires removing the rear cover, correct for industrial use)
+//     3. Pi cavity depth verified and annotated
+//     4. Bezel two-piece connection: corner bosses on rear cover +
+//        matching through-holes on bezel — intentional removable joint
+// ============================================================
+
+// ── SCREEN PARAMETERS ───────────────────────────────────────
+scr_w        = 236;    // screen outer width  (mm)
+scr_h        = 144;    // screen outer height (mm)
+scr_d        = 19;     // screen outer depth  (mm)
+scr_active_w = 222;    // active area width   (mm)  ← confirm with screen datasheet
+scr_active_h = 130;    // active area height  (mm)  ← confirm with screen datasheet
+scr_mount_x  = 75;     // screen rear M2.5 hole pattern X (mm) ← verify
+scr_mount_y  = 75;     // screen rear M2.5 hole pattern Y (mm) ← verify
+
+// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
+pi_w         = 85;     // Pi board width  (mm)
+pi_h         = 56;     // Pi board height (mm)
+pi_d         = 17;     // Pi board + tallest component height (mm)
+pi_mnt_x     = 58;     // Pi mount hole pattern X (mm)
+pi_mnt_y     = 49;     // Pi mount hole pattern Y (mm)
+pi_standoff  = 5;      // standoff height: screen rear face → Pi PCB (mm)
+pi_offset_x  = 0;      // Pi centre X offset from screen centre (mm)
+pi_offset_y  = 5;      // Pi centre Y offset upward from screen centre (mm)
+
+// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
+wall         = 2.5;    // wall thickness throughout (mm)
+chamfer      = 1.5;    // external edge chamfer size (mm)
+recess       = 1.0;    // screen recess depth in front bezel (mm)
+gap          = 0.3;    // bezel ↔ rear cover fit clearance (mm)
+
+// ── VENT PARAMETERS ──────────────────────────────────────────
+vent_w       = 3;      // vent slot width  (mm)
+vent_l       = 20;     // vent slot length (mm)
+vent_sp      = 4;      // slot gap edge-to-edge (mm)
+soc_vent_sz  = 30;     // SoC direct-vent zone size (mm, square)
+
+// ── CABLE GLAND PARAMETERS ───────────────────────────────────
+gland_count  = 2;      // number of M16 cable glands
+gland_dia    = 16.5;   // M16 clearance hole diameter (mm)
+gland_spacing= 40;     // centre-to-centre spacing (mm)
+
+// ── KICKSTAND PARAMETERS ─────────────────────────────────────
+// The kickstand is a flat plate + two triangular gussets, integral
+// with the rear cover bottom.  When the unit stands on the kickstand
+// the plate lies flat on the desk and the screen tilts back
+// (90 - ks_tilt) degrees from vertical.
+ks_tilt      = 75;     // screen angle from horizontal when standing (deg)
+                       //   75° from horiz = 15° lean-back from vertical
+ks_depth     = 55;     // plate reach behind rear face (mm) — shorter than 002
+ks_width     = 180;    // plate span across enclosure width (mm)
+ks_thick     = 5;      // plate thickness (mm)
+ks_gusset_h  = 30;     // gusset height up the rear cover face (mm)
+
+// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
+m3_dia       = 3.4;    // M3 clearance hole (mm)
+insert_dia   = 4.2;    // M3 heat-set insert OD (mm)
+insert_h     = 6;      // heat-set insert depth (mm)
+boss_od      = insert_dia + 3.5; // insert boss outer diameter (mm)
+corner_inset = wall + boss_od/2 + 1; // corner boss/hole X and Y inset (mm)
+
+// ── DERIVED DIMENSIONS ───────────────────────────────────────
+//
+// Rear cavity depth check:
+//   pi_standoff (5) + pi_d (17) + cable headroom (10) = 32 mm  → rear_d
+//   rear_d is the full depth of the rear cover cavity.
+//   The screen body (scr_d=19 mm) is NOT included in rear_d;
+//   the rear cover encloses only the space BEHIND the screen rear face.
+//
+rear_d       = pi_standoff + pi_d + 10;  // = 32 mm, Pi fits with 10 mm to spare
+enc_w        = scr_w + 2*wall;           // enclosure outer width  (241 mm)
+enc_h        = scr_h + 2*wall;           // enclosure outer height (149 mm)
+enc_d        = rear_d + wall;            // rear cover total depth  ( 34.5 mm)
+
+// Pi centre in enclosure XY coordinates (wall-offset from screen centre)
+pi_enc_cx    = wall + scr_w/2 + pi_offset_x;   // 120.5 mm with defaults
+pi_enc_cy    = wall + scr_h/2 + pi_offset_y;   //  79.5 mm with defaults
+
+// Z of Pi PCB surface, measured from rear cover rear face
+pi_z         = wall + pi_standoff;              //   7.5 mm with defaults
+
+// Kickstand tip drop: how far below Y=0 the far edge must sit so the
+// bottom surface is horizontal when the unit tilts to ks_tilt from horizontal
+ks_drop      = ks_depth * tan(90 - ks_tilt);   // ≈ 14.7 mm for ks_tilt=75
+
+$fn = 48;
+
+// ============================================================
+// PRIMITIVES
+// ============================================================
+
+// Chamfered rectangular box (all 12 edges, chamfer = c)
+module cbox(w, h, d, c=chamfer) {
+    hull() {
+        translate([c, c, 0]) cube([w-2*c, h-2*c, d      ]);
+        translate([0, c, c]) cube([w,     h-2*c, d-2*c  ]);
+        translate([c, 0, c]) cube([w-2*c, h,     d-2*c  ]);
+    }
+}
+
+// Rounded-end vent slot: length along Y, width w, extrudes in +Z by d
+module slot(len, w, d) {
+    r = w/2;
+    hull() {
+        translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
+        translate([0,  len/2-r, 0]) cylinder(r=r, h=d);
+    }
+}
+
+// Row of n vent slots stepping in X
+module vent_row(n, len, w, spacing, depth) {
+    for(i = [0:n-1])
+        translate([i*(w+spacing), 0, 0])
+            slot(len, w, depth);
+}
+
+// M3 heat-set insert boss (sits proud from an inner face)
+module insert_boss(total_h = insert_h + 4) {
+    difference() {
+        cylinder(d=boss_od, h=total_h);
+        cylinder(d=insert_dia, h=insert_h);
+        translate([0,0,insert_h]) cylinder(d=m3_dia, h=total_h);
+    }
+}
+
+// ============================================================
+// KICKSTAND
+// ============================================================
+// Geometry (all in rear-cover model space, rear face = Z=0 plane):
+//
+//   Side view (Y-Z plane):
+//
+//   Y=ks_gusset_h ─┐
+//                   │  ← gusset strip on rear face
+//   Y=0  ───────────┼──────────────────────────────────── rear cover bottom
+//                   │╲   ← gusset triangle
+//           plate ──┼─╲──────────────────────────────────────────
+//           (ks_thick)│  ╲  (sloping, thicker at tip)
+//                      ╲  ╲___________________________________
+//   Y=-(ks_thick+ks_drop)                                Z=-ks_depth
+//
+// The plate and gussets are extruded across ks_width in X.
+// The gussets (hull triangles) brace the plate against the rear face,
+// preventing the kickstand from snapping off at the root.
+//
+module kickstand() {
+    ks_x0 = (enc_w - ks_width) / 2;
+
+    translate([ks_x0, 0, 0]) {
+
+        // ── Main plate ────────────────────────────────────────
+        // Wedge: root at Z=0 is ks_thick tall;
+        //        tip  at Z=-ks_depth is (ks_thick+ks_drop) tall.
+        // Top surface flush with enclosure bottom (Y=0).
+        hull() {
+            // Root strip — along rear face
+            translate([0, -ks_thick, 0])
+                cube([ks_width, ks_thick, wall]);
+            // Tip strip — at full reach, thicker to keep plate horizontal
+            translate([0, -(ks_thick + ks_drop), -ks_depth])
+                cube([ks_width, ks_thick + ks_drop, wall]);
+        }
+
+        // ── Triangular gussets (left + right ends) ────────────
+        // Each gusset is a hull of three patches:
+        //   A  – vertical strip up the rear face (height = ks_gusset_h)
+        //   B  – small square at plate root (Y=-ks_thick, Z=0)
+        //   C  – small square at plate tip  (Y=-(ks_thick+ks_drop), Z=-ks_depth)
+        for(bx = [0, ks_width - ks_thick]) {
+            hull() {
+                // A: attachment strip going up the rear face
+                translate([bx, 0, -wall])
+                    cube([ks_thick, ks_gusset_h, wall]);
+                // B: plate root corner
+                translate([bx, -ks_thick, -wall])
+                    cube([ks_thick, ks_thick, wall]);
+                // C: plate tip corner
+                translate([bx, -(ks_thick + ks_drop), -ks_depth])
+                    cube([ks_thick, ks_thick, wall]);
+            }
+        }
+    }
+}
+
+// ============================================================
+// FRONT BEZEL
+// ============================================================
+// Two-piece design: bezel + rear cover join with M3 screws through
+// the bezel corners into heat-set inserts in the rear cover bosses.
+// The bezel is intentionally removable for Pi access.
+module front_bezel() {
+    difference() {
+        cbox(enc_w, enc_h, wall + recess);
+
+        // Active display window (full depth cut)
+        translate([(enc_w - scr_active_w)/2,
+                   (enc_h - scr_active_h)/2,
+                   -0.1])
+            cube([scr_active_w, scr_active_h, wall+recess+0.2]);
+
+        // 1 mm recess pocket — bezel lip grips screen edge
+        translate([(enc_w - scr_w)/2,
+                   (enc_h - scr_h)/2,
+                   wall])
+            cube([scr_w, scr_h, recess+0.1]);
+
+        // M3 screw clearance holes at 4 corners
+        for(x = [corner_inset, enc_w - corner_inset])
+            for(y = [corner_inset, enc_h - corner_inset])
+                translate([x, y, -0.1])
+                    cylinder(d=m3_dia, h=wall+recess+0.2);
+    }
+}
+
+// ============================================================
+// REAR COVER
+// ============================================================
+module rear_cover() {
+    n_vent       = 6;
+    vent_block_w = n_vent*(vent_w+vent_sp) - vent_sp;
+
+    difference() {
+        union() {
+            // Main body
+            cbox(enc_w, enc_h, enc_d);
+
+            // Kickstand (integral, no supports needed — prints face-down)
+            kickstand();
+
+            // Insert bosses at 4 corners (inner rear face, flush with enc_d)
+            for(x = [corner_inset, enc_w - corner_inset])
+                for(y = [corner_inset, enc_h - corner_inset])
+                    translate([x, y, enc_d])
+                        rotate([180, 0, 0])
+                            insert_boss();
+        }
+
+        // ── HOLLOW INTERIOR ───────────────────────────────────
+        // Cavity = full screen footprint, from wall to enc_d (open toward bezel)
+        translate([wall, wall, wall])
+            cube([scr_w, scr_h, enc_d]);
+
+        // ── PORT CUTOUTS ──────────────────────────────────────
+        // NOTE: The Pi's port edges are internal (Pi centred on screen).
+        // Cutouts in the enclosure walls are reference openings for
+        // short cable extensions routed to the wall. Adjust Y/Z offsets
+        // to match your exact cable routing once screen mount is verified.
+
+        // LEFT WALL — USB-C power + HDMI ×2
+        // Approximate Y positions relative to Pi bottom edge
+        pi_bot  = pi_enc_cy - pi_h/2;
+        // USB-C power
+        translate([-0.1, pi_bot + 3,  pi_z + 2]) cube([wall+0.2, 11, 11]);
+        // HDMI 0
+        translate([-0.1, pi_bot + 16, pi_z + 2]) cube([wall+0.2, 17,  9]);
+        // HDMI 1
+        translate([-0.1, pi_bot + 35, pi_z + 2]) cube([wall+0.2, 17,  9]);
+
+        // RIGHT WALL — RJ45 + USB-A ×4
+        pi_top  = pi_enc_cy + pi_h/2;
+        // RJ45
+        translate([enc_w-wall-0.1, pi_top - 24, pi_z + 1])
+            cube([wall+0.2, 22, 16]);
+        // USB-A ×4 (two stacked pairs)
+        translate([enc_w-wall-0.1, pi_bot + 2,  pi_z + 1])
+            cube([wall+0.2, 50, 15]);
+
+        // BOTTOM WALL — USB-C touch connector on screen side edge
+        // (screen's own USB-C touch port, not Pi — sits at screen depth)
+        translate([-0.1,
+                   enc_h/2 - 6,
+                   wall + scr_d - 5])
+            cube([wall+0.2, 12, 8]);
+
+        // ── COOLING VENTS ─────────────────────────────────────
+
+        // Bottom intake — 6 slots through bottom wall
+        translate([enc_w/2 - vent_block_w/2, -0.1, wall + 8])
+            rotate([-90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // Top exhaust — 6 slots through top wall
+        translate([enc_w/2 - vent_block_w/2,
+                   enc_h - wall + 0.1,
+                   wall + 8])
+            rotate([90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // SoC direct-vent — slot array in rear panel centred over Pi SoC
+        translate([pi_enc_cx - soc_vent_sz/2,
+                   pi_enc_cy - soc_vent_sz/2,
+                   enc_d - wall - 0.1]) {
+            n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
+            for(i = [0:n_soc-1])
+                translate([i*(vent_w+vent_sp),
+                           soc_vent_sz/2 - vent_l/2,
+                           0])
+                    slot(vent_l, vent_w, wall+0.2);
+        }
+
+        // ── CABLE GLANDS — rear panel, bottom area ────────────
+        // Two M16 glands through the rear face (Z=0 plane).
+        // Positioned below Pi, above kickstand root.
+        for(i = [0:gland_count-1]) {
+            cx = enc_w/2 + (i - (gland_count-1)/2) * gland_spacing;
+            translate([cx, wall + gland_dia/2 + 4, -0.1])
+                cylinder(d=gland_dia, h=wall+0.2);
+        }
+    }
+}
+
+// ============================================================
+// SCENE — exploded assembly view
+//   Front bezel floats above rear cover to show the joint
+// ============================================================
+color("DarkSlateGray", 0.9)
+    translate([0, 0, enc_d + 12])
+        front_bezel();
+
+color("SlateGray", 0.85)
+    rear_cover();

rpi-case/rpi5_industrial_case_004.scad

@@ -0,0 +1,338 @@
+// ============================================================
+// RPi5 Industrial Enclosure — Luckfox DHX-10.1" Touchscreen
+// Version: 004
+//   Changes vs 003:
+//     1. KICKSTAND is now a separate, removable piece (own module + color)
+//        - Full enc_w width (no shorter ks_width param)
+//        - 3 prongs on rear edge that slide into slots in case bottom wall
+//        - Tapered prong tips for easy insertion
+//     2. Prong slots added to rear cover bottom wall
+//     3. USB-C touch cutout on left wall REMOVED (per user request)
+//     4. Wall thickness increased 2.5 → 4 mm for rigidity
+//     5. Bezel screw holes now countersunk + clearly sized
+//     6. Insert bosses on rear cover made taller and more prominent
+//        so the two-piece (bezel + rear cover) joint is obvious in renders
+//     7. Render shows THREE separate bodies: bezel / rear cover / kickstand
+// ============================================================
+
+// ── SCREEN PARAMETERS ───────────────────────────────────────
+scr_w        = 236;    // screen outer width  (mm)
+scr_h        = 144;    // screen outer height (mm)
+scr_d        = 19;     // screen outer depth  (mm)
+scr_active_w = 222;    // active display area width  (mm) ← confirm
+scr_active_h = 130;    // active display area height (mm) ← confirm
+scr_mount_x  = 75;     // screen rear M2.5 hole pattern X (mm) ← verify
+scr_mount_y  = 75;     // screen rear M2.5 hole pattern Y (mm) ← verify
+
+// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
+pi_w         = 85;     // Pi board width  (mm)
+pi_h         = 56;     // Pi board height (mm)
+pi_d         = 17;     // Pi board + tallest component (mm)
+pi_mnt_x     = 58;     // Pi mount hole pattern X (mm)
+pi_mnt_y     = 49;     // Pi mount hole pattern Y (mm)
+pi_standoff  = 5;      // standoff height screen-rear → Pi PCB (mm)
+pi_offset_x  = 0;      // Pi centre X offset from screen centre (mm)
+pi_offset_y  = 5;      // Pi centre Y offset upward from screen centre (mm)
+
+// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
+wall         = 4.0;    // wall thickness — increased for rigidity (mm)
+chamfer      = 1.5;    // external edge chamfer (mm)
+recess       = 1.0;    // screen recess in front bezel (mm)
+gap          = 0.3;    // bezel ↔ rear cover fit clearance (mm)
+
+// ── VENT PARAMETERS ──────────────────────────────────────────
+vent_w       = 3;      // vent slot width  (mm)
+vent_l       = 20;     // vent slot length (mm)
+vent_sp      = 4;      // slot gap edge-to-edge (mm)
+soc_vent_sz  = 30;     // SoC direct-vent area size (mm)
+
+// ── CABLE GLAND PARAMETERS ───────────────────────────────────
+gland_count  = 2;      // number of M16 cable glands
+gland_dia    = 16.5;   // M16 clearance hole diameter (mm)
+gland_spacing= 40;     // gland centre-to-centre (mm)
+
+// ── KICKSTAND PARAMETERS ─────────────────────────────────────
+// Separate removable piece — slides onto case bottom via 3 prongs.
+// Wedge shape: thin at rear (prong end), thick at front desk-contact end.
+// When flat on desk the screen sits at ks_tilt degrees from horizontal.
+ks_tilt      = 75;     // screen angle from horizontal when standing (deg)
+                       //   75° from horiz ≈ 15° lean-back from vertical
+ks_depth     = 60;     // plate reach in -Z from case rear face (mm)
+ks_thick     = 5;      // plate thickness at thin (rear) end (mm)
+
+// Prong dimensions — 3 prongs slide into 3 slots in case bottom wall
+ks_prong_n   = 3;      // number of prongs
+ks_prong_w   = 12;     // prong width  (X, mm)
+ks_prong_h   = 14;     // prong insertion height into cavity (mm)
+ks_prong_t   = 5;      // prong depth  (Z, mm) — same as slot depth
+ks_prong_clr = 0.25;   // diametral clearance for fit (mm)
+
+// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
+m3_dia       = 3.4;    // M3 clearance hole (mm)
+m3_cs_dia    = 6.5;    // M3 countersink diameter (mm)
+m3_cs_depth  = 3.0;    // countersink depth (mm)
+insert_dia   = 4.2;    // M3 heat-set insert OD (mm)
+insert_h     = 6;      // heat-set insert depth (mm)
+boss_od      = 10;     // insert boss outer diameter — prominent (mm)
+boss_h       = insert_h + 5;  // boss total height from inner face (mm)
+
+// ── DERIVED DIMENSIONS ───────────────────────────────────────
+rear_d       = pi_standoff + pi_d + 10;   // cavity depth = 32 mm
+enc_w        = scr_w + 2*wall;            // outer width  = 244 mm
+enc_h        = scr_h + 2*wall;            // outer height = 152 mm
+enc_d        = rear_d + wall;             // rear cover depth = 36 mm
+
+// Corner inset for boss/screw centres (keeps them inside the wall)
+corner_inset = wall + boss_od/2 + 0.5;   // ≈ 9.5 mm
+
+// Pi centre in enclosure coordinates
+pi_enc_cx    = wall + scr_w/2 + pi_offset_x;  // 122 mm
+pi_enc_cy    = wall + scr_h/2 + pi_offset_y;  //  81 mm
+pi_z         = wall + pi_standoff;             //   9 mm (Pi PCB Z from rear face)
+
+// Kickstand geometry
+ks_drop      = ks_depth * tan(90 - ks_tilt);  // ≈ 16 mm tip drop
+
+// Prong slot Z position — prongs sit right at the case rear face
+ks_prong_z   = 0;      // prong rear face flush with case Z=0
+
+$fn = 48;
+
+// ============================================================
+// PRIMITIVES
+// ============================================================
+
+module cbox(w, h, d, c=chamfer) {
+    hull() {
+        translate([c, c, 0]) cube([w-2*c, h-2*c, d    ]);
+        translate([0, c, c]) cube([w,     h-2*c, d-2*c]);
+        translate([c, 0, c]) cube([w-2*c, h,     d-2*c]);
+    }
+}
+
+module slot(len, w, d) {
+    r = w/2;
+    hull() {
+        translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
+        translate([0,  len/2-r, 0]) cylinder(r=r, h=d);
+    }
+}
+
+module vent_row(n, len, w, spacing, depth) {
+    for(i = [0:n-1])
+        translate([i*(w+spacing), 0, 0])
+            slot(len, w, depth);
+}
+
+// Heat-set insert boss
+module insert_boss() {
+    difference() {
+        cylinder(d=boss_od, h=boss_h);
+        cylinder(d=insert_dia, h=insert_h);
+        translate([0,0,insert_h]) cylinder(d=m3_dia, h=boss_h);
+    }
+}
+
+// Countersunk M3 hole (for bezel face)
+module m3_countersunk(depth) {
+    cylinder(d=m3_dia, h=depth+0.1);
+    translate([0, 0, depth - m3_cs_depth])
+        cylinder(d1=m3_dia, d2=m3_cs_dia, h=m3_cs_depth+0.1);
+}
+
+// Prong slot — cut from bottom wall, prong inserts up into cavity
+module prong_slot() {
+    translate([-ks_prong_w/2 - ks_prong_clr,
+               -0.1,
+               ks_prong_z - ks_prong_clr])
+        cube([ks_prong_w + 2*ks_prong_clr,
+              ks_prong_h + wall + 0.2,
+              ks_prong_t + 2*ks_prong_clr]);
+}
+
+// ============================================================
+// KICKSTAND  (separate removable piece)
+// ============================================================
+//
+//  Side view (Y-Z plane, unit standing on kickstand):
+//
+//  Y=0 (case bottom) ─────────────────────────────
+//                    │↑↑↑ prongs (insert into case)
+//  Y=-ks_thick  ─────┼─────────────────────────────────┐
+//                     \   wedge plate (bottom surface   │
+//                      \   angled so it lies flat when  │
+//  Y=-(ks_thick+ks_drop)\ screen tilts to ks_tilt)     │
+//                        └──────────────────────────────┘
+//                    Z=0                          Z=-ks_depth
+//
+module kickstand() {
+    ks_front_h = ks_thick + ks_drop;   // total height at the front (desk-contact) edge
+
+    // Main wedge plate
+    hull() {
+        // Rear (thin) edge, at Z=0 — where prongs attach
+        translate([0, -ks_thick, 0])
+            cube([enc_w, ks_thick, wall]);
+        // Front (thick) edge, at Z=-ks_depth — rests on desk
+        translate([0, -ks_front_h, -ks_depth])
+            cube([enc_w, ks_front_h, wall]);
+    }
+
+    // Three prongs — evenly spaced, rise from Y=0 into case cavity
+    for(i = [0:ks_prong_n-1]) {
+        px = enc_w * (i+1) / (ks_prong_n+1);
+        translate([px - ks_prong_w/2, 0, ks_prong_z]) {
+            // Tapered tip so prong slides in easily
+            hull() {
+                // Base: full-width prong up to the tapered section
+                cube([ks_prong_w,
+                      ks_prong_h - 2,
+                      ks_prong_t]);
+                // Tip: narrowed 1 mm per side for 45° insertion chamfer
+                translate([1, ks_prong_h - 2, 0])
+                    cube([ks_prong_w - 2, 2, ks_prong_t]);
+            }
+        }
+    }
+}
+
+// ============================================================
+// FRONT BEZEL
+// ============================================================
+// Removable front frame — held to rear cover by 4× M3 screws
+// through countersunk holes at each corner, threading into
+// heat-set inserts pressed into the rear cover's corner bosses.
+module front_bezel() {
+    difference() {
+        cbox(enc_w, enc_h, wall + recess);
+
+        // Active display window
+        translate([(enc_w - scr_active_w)/2,
+                   (enc_h - scr_active_h)/2,
+                   -0.1])
+            cube([scr_active_w, scr_active_h, wall+recess+0.2]);
+
+        // 1 mm recess pocket — bezel lip grips screen edge
+        translate([(enc_w - scr_w)/2,
+                   (enc_h - scr_h)/2,
+                   wall])
+            cube([scr_w, scr_h, recess+0.1]);
+
+        // 4× M3 countersunk screw holes at corners
+        for(x = [corner_inset, enc_w - corner_inset])
+            for(y = [corner_inset, enc_h - corner_inset])
+                translate([x, y, 0])
+                    m3_countersunk(wall + recess);
+    }
+}
+
+// ============================================================
+// REAR COVER
+// ============================================================
+module rear_cover() {
+    n_vent       = 6;
+    vent_block_w = n_vent*(vent_w+vent_sp) - vent_sp;
+
+    difference() {
+        union() {
+            cbox(enc_w, enc_h, enc_d);
+
+            // ── Insert bosses: 4 corners, proud on inner rear face ──
+            // These are clearly visible tall cylinders that receive the
+            // heat-set inserts; M3 screws from the bezel thread into them.
+            for(x = [corner_inset, enc_w - corner_inset])
+                for(y = [corner_inset, enc_h - corner_inset])
+                    translate([x, y, enc_d])
+                        rotate([180, 0, 0])
+                            insert_boss();
+        }
+
+        // ── HOLLOW INTERIOR ───────────────────────────────────
+        translate([wall, wall, wall])
+            cube([scr_w, scr_h, enc_d]);
+
+        // ── PORT CUTOUTS ──────────────────────────────────────
+
+        // LEFT WALL — USB-C power + HDMI ×2 (Pi left short-edge ports)
+        pi_bot = pi_enc_cy - pi_h/2;
+        // USB-C power
+        translate([-0.1, pi_bot + 3,  pi_z + 2]) cube([wall+0.2, 11, 11]);
+        // HDMI 0
+        translate([-0.1, pi_bot + 16, pi_z + 2]) cube([wall+0.2, 17,  9]);
+        // HDMI 1
+        translate([-0.1, pi_bot + 35, pi_z + 2]) cube([wall+0.2, 17,  9]);
+
+        // RIGHT WALL — RJ45 + USB-A ×4 (Pi right short-edge ports)
+        pi_top = pi_enc_cy + pi_h/2;
+        // RJ45
+        translate([enc_w-wall-0.1, pi_top - 24, pi_z + 1])
+            cube([wall+0.2, 22, 16]);
+        // USB-A ×4
+        translate([enc_w-wall-0.1, pi_bot + 2,  pi_z + 1])
+            cube([wall+0.2, 50, 15]);
+
+        // NOTE: USB-C touch cutout (screen side) REMOVED per v004 request.
+        // GPIO header is internal — access by removing bezel + rear cover.
+
+        // ── COOLING VENTS ─────────────────────────────────────
+
+        // Bottom intake slots (through bottom wall)
+        translate([enc_w/2 - vent_block_w/2, -0.1, wall + 8])
+            rotate([-90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // Top exhaust slots (through top wall)
+        translate([enc_w/2 - vent_block_w/2,
+                   enc_h - wall + 0.1,
+                   wall + 8])
+            rotate([90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // SoC direct-vent on rear panel
+        translate([pi_enc_cx - soc_vent_sz/2,
+                   pi_enc_cy - soc_vent_sz/2,
+                   enc_d - wall - 0.1]) {
+            n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
+            for(i = [0:n_soc-1])
+                translate([i*(vent_w+vent_sp),
+                           soc_vent_sz/2 - vent_l/2,
+                           0])
+                    slot(vent_l, vent_w, wall+0.2);
+        }
+
+        // ── CABLE GLANDS — rear panel, bottom area ────────────
+        for(i = [0:gland_count-1]) {
+            cx = enc_w/2 + (i - (gland_count-1)/2) * gland_spacing;
+            translate([cx, wall + gland_dia/2 + 4, -0.1])
+                cylinder(d=gland_dia, h=wall+0.2);
+        }
+
+        // ── KICKSTAND PRONG SLOTS — bottom wall ───────────────
+        // 3 slots matching kickstand prong positions and sizes.
+        // Slots pass through the bottom wall into the cavity so prongs
+        // engage wall + (ks_prong_h - wall) mm inside the cavity.
+        for(i = [0:ks_prong_n-1]) {
+            px = enc_w * (i+1) / (ks_prong_n+1);
+            translate([px, 0, ks_prong_z])
+                prong_slot();
+        }
+    }
+}
+
+// ============================================================
+// SCENE — three separate bodies, exploded for clarity
+// ============================================================
+
+// Front bezel — exploded up, face toward viewer
+color("DarkSlateGray", 0.92)
+    translate([0, 0, enc_d + 14])
+        front_bezel();
+
+// Rear cover — at origin
+color("SlateGray", 0.88)
+    rear_cover();
+
+// Kickstand — exploded below, separate piece
+color("DimGray", 0.85)
+    translate([0, -(ks_thick + ks_drop + 20), 0])
+        kickstand();

rpi-case/rpi5_industrial_case_005.scad

@@ -0,0 +1,354 @@
+// ============================================================
+// RPi5 Industrial Enclosure — 7" Capacitive Touchscreen
+// Version: 005
+//
+// ASSEMBLY LOGIC (read before printing):
+//
+//   THREE separate printed parts:
+//
+//   1. REAR COVER — the main box. Open face points toward screen.
+//      Four corner TOWERS rise from the open front face; each tower
+//      has a self-tapping M3 pilot hole that opens toward the screen.
+//      The kickstand prong columns rise from the inner bottom face.
+//
+//   2. FRONT BEZEL — the display frame. Four countersunk M3 holes at
+//      the corners align with the rear cover's tower holes.
+//      Assembly: lay screen face-down, place rear cover over it,
+//      lay bezel over the front, drive 4× M3×30 self-tapping screws
+//      from the bezel face through into the corner towers.
+//
+//   3. KICKSTAND — separate wedge plate. Slide its 3 prongs upward
+//      into the 3 slots in the case bottom wall. The prong guide
+//      columns inside the case prevent the prongs from falling into
+//      the main cavity and give a solid 14 mm engagement.
+//
+// Changes vs 004:
+//   - Screen resized to 164.9 × 124.27 mm (7" 1024×600 capacitive)
+//   - Corner towers replace insert bosses: visible M3 holes on the
+//     OPEN front face of the rear cover — no hidden geometry
+//   - Prong guide columns (nested-difference CSG) give the slots a
+//     closed ceiling so the kickstand prongs cannot fall through
+//   - Left-wall USB-C touch cutout permanently removed
+//   - Wall 4 mm retained
+// ============================================================
+
+// ── SCREEN PARAMETERS ───────────────────────────────────────
+scr_w        = 164.9;  // screen outer width  (mm)
+scr_h        = 124.27; // screen outer height (mm)
+scr_d        = 12;     // screen body depth   (mm) ← confirm with calipers
+scr_active_w = 154;    // active display width  (mm) ← confirm
+scr_active_h = 90;     // active display height (mm) ← confirm
+scr_mount_x  = 75;     // rear M2.5 hole pattern X (mm) ← verify
+scr_mount_y  = 75;     // rear M2.5 hole pattern Y (mm) ← verify
+
+// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
+pi_w         = 85;     // Pi board width  (mm)
+pi_h         = 56;     // Pi board height (mm)
+pi_d         = 17;     // Pi board + tallest component (mm)
+pi_mnt_x     = 58;     // Pi mount hole pattern X (mm)
+pi_mnt_y     = 49;     // Pi mount hole pattern Y (mm)
+pi_standoff  = 5;      // standoff: screen rear → Pi PCB (mm)
+pi_offset_x  = 0;      // Pi centre X offset from screen centre (mm)
+pi_offset_y  = 0;      // Pi centre Y offset from screen centre (mm)
+
+// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
+wall         = 4.0;    // wall thickness (mm)
+chamfer      = 1.5;    // external edge chamfer (mm)
+recess       = 1.0;    // screen recess depth in front bezel (mm)
+
+// ── VENT PARAMETERS ──────────────────────────────────────────
+vent_w       = 3;      // slot width  (mm)
+vent_l       = 18;     // slot length (mm)
+vent_sp      = 4;      // gap edge-to-edge (mm)
+soc_vent_sz  = 28;     // SoC vent zone (mm, square)
+
+// ── CABLE GLAND PARAMETERS ───────────────────────────────────
+gland_count  = 2;      // number of M16 cable glands
+gland_dia    = 16.5;   // M16 clearance hole diameter (mm)
+gland_spacing= 36;     // gland centre-to-centre (mm)
+
+// ── KICKSTAND PARAMETERS ─────────────────────────────────────
+ks_tilt      = 75;     // screen angle from horizontal when standing (deg)
+ks_depth     = 60;     // plate reach behind rear face (mm)
+ks_thick     = 5;      // plate thickness at thin (prong) end (mm)
+ks_prong_n   = 3;      // number of prongs
+ks_prong_w   = 12;     // prong width in X (mm)
+ks_prong_h   = 14;     // prong engagement height (mm) — guided inside column
+ks_prong_t   = 5;      // prong thickness in Z (mm)
+ks_prong_clr = 0.25;   // clearance per side for slide fit (mm)
+
+// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
+m3_dia       = 3.4;    // M3 clearance hole (mm)
+m3_pilot     = 2.5;    // M3 self-tapping pilot hole (mm)
+m3_cs_dia    = 6.5;    // M3 countersink OD (mm)
+m3_cs_depth  = 3.5;    // countersink depth (mm)
+// Corner tower — a full-depth solid pillar at each inner corner.
+// The M3 pilot hole is drilled from the open front face of the rear cover.
+tower_w      = 10;     // tower footprint width and depth (mm)
+tower_hole_d = 12;     // M3 pilot hole depth from front face (mm)
+
+// ── DERIVED DIMENSIONS ───────────────────────────────────────
+rear_d       = pi_standoff + pi_d + 10;  // rear cavity depth = 32 mm
+enc_w        = scr_w + 2*wall;           // outer width  = 172.9 mm
+enc_h        = scr_h + 2*wall;           // outer height = 132.27 mm
+enc_d        = rear_d + wall;            // rear cover depth = 36 mm
+
+// Pi centre in enclosure coordinates
+pi_enc_cx    = wall + scr_w/2 + pi_offset_x;
+pi_enc_cy    = wall + scr_h/2 + pi_offset_y;
+pi_z         = wall + pi_standoff;        // Pi PCB Z from rear face
+
+// Corner tower position — inset so tower is entirely within the wall zone
+// (tower must NOT overlap the screen footprint X=wall..wall+scr_w)
+tower_cx     = wall/2;   // tower centre offset from outer edge
+// Four tower centre positions
+tower_xs     = [tower_cx, enc_w - tower_cx];
+tower_ys     = [tower_cx, enc_h - tower_cx];
+
+// Kickstand wedge geometry
+ks_drop      = ks_depth * tan(90 - ks_tilt);  // tip drop ≈ 16 mm
+
+// Prong column Z extent (guide column behind and into cavity)
+col_z_size   = ks_prong_t + 2*wall;   // = 13 mm
+col_y_size   = ks_prong_h;            // = 14 mm (above inner bottom face)
+col_x_size   = ks_prong_w + wall;     // = 16 mm (centred on prong)
+
+$fn = 48;
+
+// ============================================================
+// PRIMITIVES
+// ============================================================
+
+module cbox(w, h, d, c=chamfer) {
+    hull() {
+        translate([c, c, 0]) cube([w-2*c, h-2*c, d      ]);
+        translate([0, c, c]) cube([w,     h-2*c, d-2*c  ]);
+        translate([c, 0, c]) cube([w-2*c, h,     d-2*c  ]);
+    }
+}
+
+module slot(len, w, d) {
+    r = w/2;
+    hull() {
+        translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
+        translate([0,  len/2-r, 0]) cylinder(r=r, h=d);
+    }
+}
+
+module vent_row(n, len, w, spacing, depth) {
+    for(i = [0:n-1])
+        translate([i*(w+spacing), 0, 0])
+            slot(len, w, depth);
+}
+
+// Countersunk M3 through-hole for bezel face
+module m3_countersunk(total_depth) {
+    cylinder(d=m3_dia, h=total_depth+0.1);
+    cylinder(d1=m3_cs_dia, d2=m3_dia, h=m3_cs_depth+0.1);
+}
+
+// Prong slot cutter — used in both the rear cover and the guide column
+// Origin at the prong centre-X, outer bottom face (Y=0), prong-Z start
+module prong_slot_cut() {
+    translate([-ks_prong_w/2 - ks_prong_clr,
+               -0.1,
+               -ks_prong_clr])
+        cube([ks_prong_w + 2*ks_prong_clr,
+              wall + ks_prong_h + 0.2,
+              ks_prong_t + 2*ks_prong_clr]);
+}
+
+// ============================================================
+// KICKSTAND  (separate removable piece, print separately)
+// ============================================================
+module kickstand() {
+    ks_front_h = ks_thick + ks_drop;   // height at the thick/front end
+
+    // Wedge plate — thin at prong end (Z=0), thick at desk end (Z=-ks_depth)
+    hull() {
+        translate([0, -ks_thick, 0])
+            cube([enc_w, ks_thick, wall]);
+        translate([0, -ks_front_h, -ks_depth])
+            cube([enc_w, ks_front_h, wall]);
+    }
+
+    // Three tapered prongs on the top edge (rear/thin end)
+    for(i = [0:ks_prong_n-1]) {
+        px = enc_w * (i+1) / (ks_prong_n+1);
+        translate([px - ks_prong_w/2, 0, 0]) {
+            // Body of prong
+            cube([ks_prong_w, ks_prong_h - 2, ks_prong_t]);
+            // Tapered tip (last 2 mm, narrowed 1 mm per side)
+            translate([0, ks_prong_h - 2, 0])
+                hull() {
+                    cube([ks_prong_w, 0.01, ks_prong_t]);
+                    translate([1, 2, 0])
+                        cube([ks_prong_w - 2, 0.01, ks_prong_t]);
+                }
+        }
+    }
+}
+
+// ============================================================
+// FRONT BEZEL  (removable — 4× M3 countersunk screws)
+// ============================================================
+module front_bezel() {
+    difference() {
+        cbox(enc_w, enc_h, wall + recess);
+
+        // Display window
+        translate([(enc_w - scr_active_w)/2,
+                   (enc_h - scr_active_h)/2,
+                   -0.1])
+            cube([scr_active_w, scr_active_h, wall+recess+0.2]);
+
+        // 1 mm recess pocket — bezel lip grips screen edge
+        translate([(enc_w - scr_w)/2,
+                   (enc_h - scr_h)/2,
+                   wall])
+            cube([scr_w, scr_h, recess+0.1]);
+
+        // 4× M3 countersunk screw holes, aligned to corner towers
+        for(x = tower_xs) for(y = tower_ys)
+            translate([x, y, 0])
+                m3_countersunk(wall + recess);
+    }
+}
+
+// ============================================================
+// REAR COVER
+// ============================================================
+//
+// CORNER TOWER DESIGN — replaces hidden insert bosses:
+//   Each corner has a solid square tower (tower_w × tower_w) that
+//   runs the FULL DEPTH of the cavity (from inner rear face to the
+//   open front at Z=enc_d).  An M3 pilot hole enters from the front
+//   face (Z=enc_d) and goes tower_hole_d into the tower body.
+//   Because the tower reaches the front opening, the holes are
+//   plainly visible from the front of the assembled unit — no
+//   hidden geometry.
+//
+// PRONG COLUMN DESIGN — prevents prongs falling into cavity:
+//   A solid rectangular column rises from the inner bottom face at
+//   each prong position.  The prong slot cuts through the bottom wall
+//   AND the column.  The column ceiling is at Y=wall+ks_prong_h,
+//   which acts as the hard stop for the prong — it cannot travel
+//   beyond that height.  The column is added AFTER the main interior
+//   hollow is subtracted (nested-difference CSG), so the hollow
+//   does not remove it.
+//
+module rear_cover() {
+    n_vent       = 5;
+    vent_block_w = n_vent*(vent_w+vent_sp) - vent_sp;
+
+    difference() {
+
+        // ── SOLID GEOMETRY ────────────────────────────────────
+        union() {
+
+            // 1. Main shell with interior already removed
+            //    (nested so subsequent additions are NOT removed by hollow)
+            difference() {
+                cbox(enc_w, enc_h, enc_d);
+                // Interior hollow — from rear inner face to front opening
+                translate([wall, wall, wall])
+                    cube([scr_w, scr_h, enc_d]);
+            }
+
+            // 2. Corner towers — full cavity height, clearly visible from front
+            for(x = tower_xs) for(y = tower_ys)
+                translate([x - tower_w/2, y - tower_w/2, wall])
+                    cube([tower_w, tower_w, enc_d - wall]);
+
+            // 3. Prong guide columns — solid pillars on inner bottom face
+            //    One per prong, gives 14 mm of guided engagement
+            for(i = [0:ks_prong_n-1]) {
+                px = enc_w * (i+1) / (ks_prong_n+1);
+                translate([px - col_x_size/2,
+                           wall,
+                           0])
+                    cube([col_x_size, col_y_size, col_z_size]);
+            }
+        }
+
+        // ── ALL CUTOUTS ───────────────────────────────────────
+
+        // Corner tower M3 pilot holes (from front/open face, going inward)
+        for(x = tower_xs) for(y = tower_ys)
+            translate([x, y, enc_d + 0.1])
+                rotate([180, 0, 0])
+                    cylinder(d=m3_pilot, h=tower_hole_d);
+
+        // ── PORT CUTOUTS ──────────────────────────────────────
+        pi_bot = pi_enc_cy - pi_h/2;
+        pi_top = pi_enc_cy + pi_h/2;
+
+        // LEFT WALL — USB-C power + HDMI ×2
+        translate([-0.1, pi_bot + 3,  pi_z + 2]) cube([wall+0.2, 11, 11]);
+        translate([-0.1, pi_bot + 16, pi_z + 2]) cube([wall+0.2, 17,  9]);
+        translate([-0.1, pi_bot + 35, pi_z + 2]) cube([wall+0.2, 17,  9]);
+
+        // RIGHT WALL — RJ45 + USB-A ×4
+        translate([enc_w-wall-0.1, pi_top - 24, pi_z + 1])
+            cube([wall+0.2, 22, 16]);
+        translate([enc_w-wall-0.1, pi_bot +  2, pi_z + 1])
+            cube([wall+0.2, 50, 15]);
+
+        // ── COOLING VENTS ─────────────────────────────────────
+
+        // Bottom intake
+        translate([enc_w/2 - vent_block_w/2, -0.1, wall + 6])
+            rotate([-90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // Top exhaust
+        translate([enc_w/2 - vent_block_w/2, enc_h - wall + 0.1, wall + 6])
+            rotate([90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // SoC direct-vent on rear panel
+        translate([pi_enc_cx - soc_vent_sz/2,
+                   pi_enc_cy - soc_vent_sz/2,
+                   enc_d - wall - 0.1]) {
+            n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
+            for(i = [0:n_soc-1])
+                translate([i*(vent_w+vent_sp), soc_vent_sz/2 - vent_l/2, 0])
+                    slot(vent_l, vent_w, wall+0.2);
+        }
+
+        // ── CABLE GLANDS — rear panel face ────────────────────
+        for(i = [0:gland_count-1]) {
+            cx = enc_w/2 + (i - (gland_count-1)/2) * gland_spacing;
+            translate([cx, wall + gland_dia/2 + 4, -0.1])
+                cylinder(d=gland_dia, h=wall+0.2);
+        }
+
+        // ── KICKSTAND PRONG SLOTS ─────────────────────────────
+        // Each slot cuts through the outer bottom wall AND the guide
+        // column above it.  The column ceiling at Y=wall+ks_prong_h
+        // is the hard stop — the prong cannot fall through.
+        for(i = [0:ks_prong_n-1]) {
+            px = enc_w * (i+1) / (ks_prong_n+1);
+            translate([px, 0, 0])
+                prong_slot_cut();
+        }
+    }
+}
+
+// ============================================================
+// SCENE — three parts exploded for visual clarity
+// ============================================================
+
+// FRONT BEZEL — floated forward (toward viewer)
+color("DarkSlateGray", 0.92)
+    translate([0, 0, enc_d + 14])
+        front_bezel();
+
+// REAR COVER — at origin
+color("SlateGray", 0.88)
+    rear_cover();
+
+// KICKSTAND — floated below the case to show it is a separate piece
+color("DimGray", 0.85)
+    translate([0, -(ks_thick + ks_drop + 20), 0])
+        kickstand();

rpi-case/rpi5_industrial_case_006.scad

@@ -0,0 +1,338 @@
+// ============================================================
+// RPi5 Industrial Enclosure — 7" Capacitive Touchscreen
+// Version: 006
+//
+// ASSEMBLY (three printed parts):
+//
+//   REAR COVER — box, open face toward screen.
+//     • 4 corner towers, full cavity height, M3 pilot hole from front.
+//     • 3 prong guide columns on inner bottom face — the columns give
+//       the prong slots a solid ceiling so nothing falls through.
+//     • ALL SIDE WALLS ARE SOLID. No port holes.
+//
+//   FRONT BEZEL — display frame.
+//     • 4× M3 countersunk holes, corners, aligned to tower holes.
+//     • Screw route: bezel face → screen gap → tower pilot hole.
+//     • Use M3 × 30 mm self-tapping screws.
+//
+//   KICKSTAND — separate removable wedge plate.
+//     • Main wedge behind case creates the tilt.
+//     • Thin ledge extends UNDER the rear of the case 14 mm.
+//       The ledge carries the 3 prongs which enter the case
+//       through the BOTTOM face only — rear wall stays solid.
+//     • Slide ledge+prongs under the case from behind; prongs
+//       click up into their columns and lock the stand.
+//
+// Changes vs 005:
+//   • Right-wall USB-A rectangle REMOVED (and all side-wall cuts).
+//     Both left and right walls are now fully solid.
+//   • Prong slots moved to Z = 5.5–10.5 mm (inside cavity).
+//     Rear face (Z = 0) is completely uncut — no holes on back.
+//   • Kickstand gains a 14 mm ledge so prongs reach the new slot Z.
+//   • Cable glands removed (no rear-face holes).
+// ============================================================
+
+// ── SCREEN PARAMETERS ───────────────────────────────────────
+scr_w        = 164.9;  // screen outer width  (mm)
+scr_h        = 124.27; // screen outer height (mm)
+scr_d        = 12;     // screen body depth   (mm) ← confirm with calipers
+scr_active_w = 154;    // active area width   (mm) ← confirm from datasheet
+scr_active_h = 90;     // active area height  (mm) ← confirm from datasheet
+scr_mount_x  = 75;     // rear M2.5 mount pattern X (mm) ← verify
+scr_mount_y  = 75;     // rear M2.5 mount pattern Y (mm) ← verify
+
+// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
+pi_w         = 85;     // Pi board width  (mm)
+pi_h         = 56;     // Pi board height (mm)
+pi_d         = 17;     // Pi board + tallest component (mm)
+pi_mnt_x     = 58;     // Pi mount pattern X (mm)
+pi_mnt_y     = 49;     // Pi mount pattern Y (mm)
+pi_standoff  = 5;      // standoff: screen rear → Pi PCB (mm)
+pi_offset_x  = 0;      // Pi centre X offset from screen centre (mm)
+pi_offset_y  = 0;      // Pi centre Y offset from screen centre (mm)
+
+// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
+wall         = 4.0;    // wall thickness (mm)
+chamfer      = 1.5;    // external edge chamfer (mm)
+recess       = 1.0;    // screen recess depth in front bezel (mm)
+
+// ── VENT PARAMETERS ──────────────────────────────────────────
+vent_w       = 3;
+vent_l       = 18;
+vent_sp      = 4;
+soc_vent_sz  = 28;
+
+// ── KICKSTAND PARAMETERS ─────────────────────────────────────
+ks_tilt      = 75;     // screen angle from horizontal when standing (deg)
+ks_depth     = 60;     // wedge reach behind rear face (mm)
+ks_thick     = 5;      // plate/ledge thickness (mm)
+
+// Prong dimensions
+ks_prong_n   = 3;      // number of prongs
+ks_prong_w   = 12;     // prong width in X (mm)
+ks_prong_h   = 14;     // prong engagement height (mm)
+ks_prong_t   = 5;      // prong thickness in Z (mm)
+ks_prong_clr = 0.25;   // clearance per side (mm)
+
+// Ledge: extends under the case so prongs reach inside the cavity
+// without cutting through the rear wall.
+ks_ledge     = 14;     // ledge depth in +Z under case (mm)
+                       //   must be > wall + ks_prong_t + margin
+
+// Z start of prong slot measured from rear face.
+// Must be > wall so the slot never touches the rear face.
+ks_prong_z0  = wall + 1.5;   // = 5.5 mm — slot from 5.25 to 10.75 mm
+
+// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
+m3_dia       = 3.4;    // M3 clearance hole (mm)
+m3_pilot     = 2.5;    // M3 self-tapping pilot (mm)
+m3_cs_dia    = 6.5;    // M3 countersink OD (mm)
+m3_cs_depth  = 3.5;    // countersink depth (mm)
+tower_w      = 9;      // corner tower footprint (mm square)
+tower_hole_d = 14;     // pilot hole depth into tower from front face (mm)
+corner_inset = 7;      // tower/hole centre from outer edge (mm)
+
+// ── DERIVED ──────────────────────────────────────────────────
+rear_d       = pi_standoff + pi_d + 10;  // cavity depth = 32 mm
+enc_w        = scr_w + 2*wall;           // 172.9 mm
+enc_h        = scr_h + 2*wall;           // 132.27 mm
+enc_d        = rear_d + wall;            // 36 mm
+
+pi_enc_cx    = wall + scr_w/2 + pi_offset_x;
+pi_enc_cy    = wall + scr_h/2 + pi_offset_y;
+pi_z         = wall + pi_standoff;
+
+ks_drop      = ks_depth * tan(90 - ks_tilt);  // wedge tip drop ≈ 16 mm
+
+// Guide column dimensions (added back inside cavity after hollow)
+col_w        = ks_prong_w + wall;   // 16 mm — solid wall each side of slot
+col_h        = ks_prong_h;          // 14 mm — prong engagement
+col_d        = ks_ledge;            // 14 mm — same as ledge depth
+
+$fn = 48;
+
+// ============================================================
+// PRIMITIVES
+// ============================================================
+
+module cbox(w, h, d, c=chamfer) {
+    hull() {
+        translate([c, c, 0]) cube([w-2*c, h-2*c, d      ]);
+        translate([0, c, c]) cube([w,     h-2*c, d-2*c  ]);
+        translate([c, 0, c]) cube([w-2*c, h,     d-2*c  ]);
+    }
+}
+
+module slot(len, w, d) {
+    r = w/2;
+    hull() {
+        translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
+        translate([0,  len/2-r, 0]) cylinder(r=r, h=d);
+    }
+}
+
+module vent_row(n, len, w, spacing, depth) {
+    for(i = [0:n-1])
+        translate([i*(w+spacing), 0, 0])
+            slot(len, w, depth);
+}
+
+module m3_countersunk(total_d) {
+    cylinder(d=m3_dia,    h=total_d+0.1);
+    cylinder(d1=m3_cs_dia, d2=m3_dia, h=m3_cs_depth+0.1);
+}
+
+// Prong slot cutter — called with origin at (prong_cx, 0, ks_prong_z0).
+// Cuts bottom wall (Y: -0.1 → wall) + guide column (Y: wall → wall+col_h).
+// Z extent stays within [ks_prong_z0-clr, ks_prong_z0+ks_prong_t+clr]
+// which is entirely inside the cavity — rear face untouched.
+module prong_slot_cut() {
+    translate([-ks_prong_w/2 - ks_prong_clr,
+               -0.1,
+               -ks_prong_clr])
+        cube([ks_prong_w + 2*ks_prong_clr,
+              wall + col_h + 0.2,
+              ks_prong_t + 2*ks_prong_clr]);
+}
+
+// ============================================================
+// KICKSTAND  (separate removable piece — print separately)
+// ============================================================
+//
+//  Side cross-section (Y-Z plane):
+//
+//  Y=0 (case bottom) ─────┬─────────────────┐ ← ledge top (fits under case)
+//  Y=-ks_thick       ─────┴─────────────────┘ ← ledge bottom
+//                    Z=ks_ledge            Z=0 │
+//                                             │ ← wedge (behind case)
+//                                    thick ╲  │ thin
+//                    desk contact → ────────╲─┘
+//                                   Z=-ks_depth   Z=0
+//
+//  The ledge (Z=0→ks_ledge) slides under the case rear.
+//  Prongs rise from Y=0 at Z=ks_prong_z0, entering the case bottom slots.
+//  The wedge (Z=-ks_depth→0) rests on the desk and creates the tilt.
+//
+module kickstand() {
+    ks_front_h = ks_thick + ks_drop;   // thick end of wedge
+
+    // 1. Wedge behind case (Z = -ks_depth → 0)
+    hull() {
+        translate([0, -ks_thick,    0       ]) cube([enc_w, ks_thick,    wall]);
+        translate([0, -ks_front_h, -ks_depth]) cube([enc_w, ks_front_h, wall]);
+    }
+
+    // 2. Ledge under rear of case (Z = 0 → ks_ledge)
+    translate([0, -ks_thick, 0])
+        cube([enc_w, ks_thick, ks_ledge]);
+
+    // 3. Three prongs rising from ledge top (Y=0) into case bottom slots
+    for(i = [0:ks_prong_n-1]) {
+        px = enc_w * (i+1) / (ks_prong_n+1);
+        translate([px - ks_prong_w/2, 0, ks_prong_z0]) {
+            // Main shaft
+            cube([ks_prong_w, ks_prong_h - 2, ks_prong_t]);
+            // Tapered tip (45° chamfer for easy insertion)
+            translate([0, ks_prong_h - 2, 0])
+                hull() {
+                    cube([ks_prong_w,     0.01, ks_prong_t    ]);
+                    translate([1, 2, 0])
+                        cube([ks_prong_w-2, 0.01, ks_prong_t  ]);
+                }
+        }
+    }
+}
+
+// ============================================================
+// FRONT BEZEL
+// ============================================================
+module front_bezel() {
+    ci = corner_inset;
+    difference() {
+        cbox(enc_w, enc_h, wall + recess);
+
+        // Display window
+        translate([(enc_w - scr_active_w)/2,
+                   (enc_h - scr_active_h)/2, -0.1])
+            cube([scr_active_w, scr_active_h, wall+recess+0.2]);
+
+        // 1 mm recess pocket grips screen edge
+        translate([(enc_w - scr_w)/2,
+                   (enc_h - scr_h)/2, wall])
+            cube([scr_w, scr_h, recess+0.1]);
+
+        // 4× M3 countersunk screw holes at corners
+        for(x = [ci, enc_w-ci])
+            for(y = [ci, enc_h-ci])
+                translate([x, y, 0])
+                    m3_countersunk(wall + recess);
+    }
+}
+
+// ============================================================
+// REAR COVER
+// ============================================================
+module rear_cover() {
+    ci       = corner_inset;
+    n_vent   = 5;
+    vbw      = n_vent*(vent_w+vent_sp) - vent_sp;  // vent block width
+
+    difference() {
+
+        // ── SOLID GEOMETRY (nested CSG) ───────────────────────
+        union() {
+
+            // A) Shell with interior already removed.
+            //    Nested so the additions below are NOT eaten by the hollow.
+            difference() {
+                cbox(enc_w, enc_h, enc_d);
+                translate([wall, wall, wall])
+                    cube([scr_w, scr_h, enc_d]);
+            }
+
+            // B) Corner towers — full cavity height.
+            //    M3 pilot hole is drilled from the open front face,
+            //    clearly visible when looking into the case before assembly.
+            for(x = [ci, enc_w-ci])
+                for(y = [ci, enc_h-ci])
+                    translate([x - tower_w/2, y - tower_w/2, wall])
+                        cube([tower_w, tower_w, enc_d - wall]);
+
+            // C) Prong guide columns.
+            //    One solid column per prong, rising from the inner bottom
+            //    face (Y=wall) by col_h=14 mm, spanning Z=0→col_d=14 mm.
+            //    The prong slot cuts through this column, giving a closed
+            //    ceiling at Y=wall+col_h — prongs cannot fall through.
+            //    The column Z=0→5.25 mm is NOT cut by the slot, so the
+            //    rear face (Z=0) remains completely solid at these spots.
+            for(i = [0:ks_prong_n-1]) {
+                px = enc_w * (i+1) / (ks_prong_n+1);
+                translate([px - col_w/2, wall, 0])
+                    cube([col_w, col_h, col_d]);
+            }
+        }
+
+        // ── CUTOUTS (applied to everything above) ─────────────
+
+        // Corner tower pilot holes from open front face
+        for(x = [ci, enc_w-ci])
+            for(y = [ci, enc_h-ci])
+                translate([x, y, enc_d + 0.1])
+                    rotate([180, 0, 0])
+                        cylinder(d=m3_pilot, h=tower_hole_d);
+
+        // Cooling — bottom intake slots (through bottom wall, Y direction)
+        translate([enc_w/2 - vbw/2, -0.1, wall + 6])
+            rotate([-90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // Cooling — top exhaust slots (through top wall, Y direction)
+        translate([enc_w/2 - vbw/2, enc_h - wall + 0.1, wall + 6])
+            rotate([90, 0, 0])
+                vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
+
+        // Cooling — SoC direct vent on rear panel
+        translate([pi_enc_cx - soc_vent_sz/2,
+                   pi_enc_cy - soc_vent_sz/2,
+                   enc_d - wall - 0.1]) {
+            n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
+            for(i = [0:n_soc-1])
+                translate([i*(vent_w+vent_sp),
+                           soc_vent_sz/2 - vent_l/2, 0])
+                    slot(vent_l, vent_w, wall+0.2);
+        }
+
+        // Kickstand prong slots — bottom face ONLY.
+        // Slot Z: [ks_prong_z0-clr, ks_prong_z0+ks_prong_t+clr]
+        //       = [5.25, 10.75] mm — entirely past the rear wall (Z=0-4 mm).
+        // Rear face at Z=0 is untouched.
+        for(i = [0:ks_prong_n-1]) {
+            px = enc_w * (i+1) / (ks_prong_n+1);
+            translate([px, 0, ks_prong_z0])
+                prong_slot_cut();
+        }
+
+        // NOTE: All side-wall port cutouts removed — both left and right
+        // walls are solid. Access to Pi ports via short extension cables
+        // routed through user-drilled holes as needed for the installation.
+    }
+}
+
+// ============================================================
+// SCENE — three parts exploded for inspection
+// ============================================================
+
+// Front bezel — floated forward
+color("DarkSlateGray", 0.92)
+    translate([0, 0, enc_d + 14])
+        front_bezel();
+
+// Rear cover — at origin
+color("SlateGray", 0.88)
+    rear_cover();
+
+// Kickstand — floated below and behind to show it is separate
+// In real use: slide it up from below until prongs click into columns.
+color("DimGray", 0.85)
+    translate([0, -(ks_thick + ks_drop + 20), 0])
+        kickstand();

security_risks.md

@@ -0,0 +1,113 @@
+# Security Risks Review (mis-control-tower)
+
+This review focuses on the risks highlighted in the tweet you shared: backend-first architecture, trusting the client, column/role escalation, and missing rate limits.
+
+Good news: this project is backend-first and uses Prisma on the server, not direct-to-DB from the client. Prisma itself is not the core risk here. The main issues are around authorization scope, secret handling, and rate limiting.
+
+## Critical: Cross-org reminder trigger + weak auth fallback
+
+### What can go wrong
+Any logged-in user can trigger the reminders job if the secret is not set, and the job queries across all orgs. This can spam email reminders to users in other orgs.
+
+### Source
+- Auth fallback to "any session" when secret missing: `app/api/downtime/actions/reminders/route.ts:40`
+- Cross-org query (no `orgId` filter): `app/api/downtime/actions/reminders/route.ts:62`
+
+### Why this maps to the tweet
+This is a classic "missing backend guardrails" and "rate limits/abuse" problem.
+
+### Fix ideas
+- Require `DOWNTIME_ACTION_REMINDER_SECRET` in all environments (fail closed if missing).
+- If you want session-based access, also require:
+  - role check (OWNER/ADMIN), and
+  - explicit `orgId` scoping in the `findMany` query.
+- Consider also logging who triggered it.
+
+---
+
+## High: Invite token exposure + invite claim risk
+
+### What can go wrong
+A regular member can retrieve active invite tokens and then accept invites intended for other people.
+
+### Source
+- Members GET has no role check: `app/api/org/members/route.ts:23`
+- Members GET returns raw invite tokens: `app/api/org/members/route.ts:52`
+- Accepting an invite creates a user for the invite email and marks it verified based only on the token: `app/api/invites/[token]/route.ts:93`, `app/api/invites/[token]/route.ts:98`
+
+### Why this maps to the tweet
+This is a "hidden columns / privilege escalation" flavor of bug: sensitive fields (tokens) are being exposed to users who should not see them.
+
+### Fix ideas
+- Add a role check to `GET /api/org/members` (OWNER/ADMIN only).
+- Do not return invite tokens from the API (or only return to OWNER/ADMIN).
+- Optional hardening:
+  - Bind invites more tightly to identity (e.g., require proof of email ownership), or
+  - require the invite acceptance flow to complete a verification step before granting access.
+
+---
+
+## Medium: Pairing code brute force path to machine API keys
+
+### What can go wrong
+Pairing codes are short and the pairing endpoint returns the machine API key. Without rate limiting, attackers can attempt many codes and occasionally succeed.
+
+### Source
+- Pairing codes length = 5: `lib/pairingCode.ts:5`
+- Pair endpoint returns `apiKey`: `app/api/machines/pair/route.ts:56`
+
+### Why this maps to the tweet
+This aligns with "rate limits are not optional anymore" and "don’t trust defaults."
+
+### Fix ideas
+- Add rate limiting to `/api/machines/pair` (by IP and/or code prefix).
+- Increase pairing code entropy (length and/or attempt tracking).
+- Track failed attempts and temporarily disable pairing for a machine after too many failures.
+
+---
+
+## Medium: Missing rate limiting on high-abuse endpoints
+
+### What can go wrong
+Attackers can brute-force or abuse endpoints to consume resources and/or trigger unwanted actions.
+
+### Source (representative endpoints)
+- Login: `app/api/login/route.ts:20`
+- Signup: `app/api/signup/route.ts:26`
+- Pairing: `app/api/machines/pair/route.ts:12`
+- Ingest: `app/api/ingest/kpi/route.ts:35`, `app/api/ingest/heartbeat/route.ts:33`, `app/api/ingest/event/route.ts:60`, `app/api/ingest/reason/route.ts:11`
+
+### Why this maps to the tweet
+This is directly item #10 in the tweet: rate limits at auth, API routes, and webhooks/ingest.
+
+### Fix ideas
+- Apply rate limiting to:
+  - auth endpoints (`/api/login`, `/api/signup`, invite acceptance),
+  - pairing (`/api/machines/pair`),
+  - ingest endpoints (especially if publicly reachable).
+- Even a simple KV-based limiter or middleware-based limiter is a large improvement.
+
+---
+
+## Not the core risk: Prisma usage
+
+### Observation
+This project uses Prisma server-side via Next.js route handlers and server components. I did not see direct DB calls from the browser.
+
+### Source (representative)
+- Session enforcement in API routes: `lib/auth/requireSession.ts:42`
+- Server-side data access in routes: `app/api/machines/route.ts:31`, `app/api/settings/route.ts:146`
+
+### Why this matters
+This avoids the tweet’s main direct-to-DB + RLS pitfalls, but you still need strong authorization and rate limiting in your own backend.
+
+---
+
+## Quick fix priority order
+
+1. Lock down `POST /api/downtime/actions/reminders` (fail closed + org scoping).
+2. Lock down `GET /api/org/members` and stop exposing invite tokens.
+3. Add rate limiting to pairing and auth endpoints.
+4. Consider increasing pairing code entropy + attempt tracking.
+
+If you want, I can implement the first two fixes in small, safe patches.

snappy.md

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+# Snappy UX plan (Next.js)
+
+## Goals
+- Make every navigation feel instant (<50ms feedback) via loading UI and disabled re-clicks.
+- Reduce server and data latency for heavy pages (Overview, Reports).
+- Keep data accurate while allowing slight staleness for Settings/Financial (seconds).
+
+## Constraints
+- Data-heavy pages with large payloads and expensive queries.
+- Users click multiple times when no feedback is shown.
+
+## Success targets
+- Navigation feedback in <50ms (loading/skeleton/pending state).
+- P95 server response under 300-500ms for most queries; worst cases hidden behind progressive loading.
+- No multi-click queueing; one navigation at a time.
+
+---
+
+## Phase 1: Audit and baseline (completed)
+
+### What was instrumented
+- Server timing + payload logging on Overview, Reports, Reports Filters, Machines APIs.
+- Per-step timings inside `getOverviewData` (machines query, events query, normalize/filter).
+- Client nav timing hooks were added but not captured due to service env/build config.
+
+### Baseline results (from `/tmp/mis-control-tower.log`)
+- Aggregate stats (cold + warm averaged)
+  - Client nav (`perf.client` nav duration)
+    - Avg: ~38ms; p50: ~51ms; p95: ~67ms; min: ~5ms; max: ~82ms.
+  - Overview API (`/api/overview`) total
+    - Avg: ~3.07s; p50: ~1.73s; p95: ~8.61s; min: ~1.20s; max: ~21.54s.
+  - `getOverviewData` total
+    - Avg: ~1.29s; p50: ~1.26s; p95: ~1.35s; min: ~1.15s; max: ~2.41s.
+  - Machines query (inside Overview)
+    - Avg: ~1.27s; p50: ~1.25s; p95: ~1.33s; min: ~1.13s; max: ~2.38s.
+  - Machines API (`/api/machines`) total
+    - Avg: ~1.26s; p50: ~1.25s; p95: ~1.36s; min: ~1.13s; max: ~1.52s.
+  - Reports API (`/api/reports`) total
+    - Avg: ~3.81s; p50: ~468ms; p95: ~18.14s; min: ~168ms; max: ~26.56s.
+  - Reports filters (`/api/reports/filters`) total
+    - Avg: ~4.07s; p50: ~367ms; p95: ~16.61s; min: ~57ms; max: ~23.78s.
+  - Reports payload size
+    - Avg: ~406KB; p50: ~406KB; p95: ~407KB.
+
+- Overview (`/api/overview`)
+  - Total: ~1.3–2.5s across samples (best ~1.2s, spikes up to ~2.5s).
+  - `getOverviewData` total: ~1.15–1.36s typically; one sample ~2.4s.
+  - **Machines query dominates**: ~1.12–1.33s (primary bottleneck).
+  - Events query: ~5–35ms (minor).
+  - Payload: ~13KB.
+
+- Machines (`/api/machines`)
+  - Total: ~1.15–1.33s per call for 3 machines.
+  - **Machines query dominates**: ~1.15–1.33s.
+  - Payload: ~1.6KB.
+
+- Reports (`/api/reports`)
+  - Typical total: ~170–225ms (later runs), earlier spikes up to ~16s (pre-fix or cold).
+  - Query timings combined: ~130–200ms.
+  - Row counts: ~1.8k KPI rows, ~6.2k cycles, ~736 events.
+  - **Payload size ~406KB** (largest).
+
+- Reports filters (`/api/reports/filters`)
+  - Typical total: ~56–68ms (later runs), earlier spikes up to ~23s (pre-fix or cold).
+  - Query timings: ~30–40ms.
+  - Payload: ~51B.
+
+### Findings
+- The dominant latency contributor is the **machines query** used by Overview and Machines endpoints.
+- Reports payload is large (~406KB), which impacts UI responsiveness even when queries are moderate.
+- Large outliers (multi-second totals) likely come from non-query overhead (session lookup, DB connection wait, or cold start); these need targeted checks.
+- Reports and reports filters show totals that are far larger than the summed query timings, confirming significant overhead outside the measured DB queries.
+- Client end-to-end nav timing (`perf.client`) is now captured; p95 is ~67ms, slightly above the 50ms target.
+- Baseline summaries should average cold and warm samples together for now.
+
+### Data captured
+- Logs are stored at `/tmp/mis-control-tower.log`.
+- Events include: `perf.overview.api`, `perf.overview.getOverviewData`, `perf.machines.api`, `perf.reports.api`, `perf.reports.filters`.
+
+Update
+- Client nav timing is now captured via `/api/debug/perf` (`perf.client` events).
+- API timings now include auth/preQuery/postQuery with coldStart/uptimeMs when enabled.
+
+---
+
+## Phase 2: Instant feedback (UX)
+
+### 1) Global route loading
+- Add `app/(app)/loading.tsx` with a lightweight skeleton for the shell.
+- Ensure each heavy route also has its own `loading.tsx` for targeted skeletons.
+
+### 2) Sidebar pending state
+- Use `useTransition` to mark a pending navigation.
+- Disable repeated clicks and show a subtle spinner on the active item.
+- Optional: debounce repeated clicks for 300-500ms.
+
+### 3) Suspense boundaries
+- Wrap the slowest sections (events, charts, tables) in `<Suspense>` with skeletons.
+- Ensure initial shell renders immediately even if data is still loading.
+
+Deliverables
+- Users always see visual feedback within a single frame.
+- Double-clicks do not queue up extra navigations.
+
+Progress
+- Added route-level loading skeletons for the app shell and heavy routes.
+- Sidebar uses `useTransition` with a pending spinner and blocks repeat clicks.
+- Added Suspense + lazy loading for the Overview timeline and Reports charts.
+
+---
+
+## Phase 3: Split heavy pages (Overview + Reports)
+
+### Overview (split)
+- First paint: show lightweight summary data (machines list + latest heartbeat + tiny event count).
+- Defer: fetch full event stream and detailed KPIs via client API after initial render.
+- Use an explicit "Load more" or lazy loading for event details.
+
+Implementation sketch
+- Create a `getOverviewSummary` for the initial server render.
+- Create a client fetch (`/api/overview?detail=1`) for detailed events and charts.
+- Replace large data arrays with preview-sized payloads.
+
+Progress
+- Overview now uses `getOverviewSummary` for first paint, and `/api/overview?detail=1` for deferred detail fetch.
+- Summary responses are cached in-memory with TTL + in-flight de-dupe (`perf.overview.summary` shows cache hits).
+- Reports charts are lazy-loaded with placeholders; heavy chart blocks render after the shell.
+
+### Reports (split)
+- Render the report shell and filters immediately.
+- Lazy-load heavy charts with `next/dynamic` and loading placeholders.
+- Fetch chart data on demand (per chart or on viewport with IntersectionObserver).
+- Paginate any large tables or use virtualization.
+
+Deliverables
+- Overview/Reports initial response is fast and small.
+- Deep detail loads after the UI is already visible.
+
+---
+
+## Phase 4: Caching + data freshness
+
+### 1) Page-level caching
+- Remove `force-dynamic` where it is not required.
+- Use `revalidate` on pages that can be stale for a few seconds (Settings, Financial).
+
+### 2) Data cache for Prisma queries
+- Wrap stable fetchers in `unstable_cache` with short TTL and tags (per org).
+- Add manual refresh button on Settings/Financial to bypass cache when needed.
+
+### 3) API cache headers
+- Use `ETag` and `If-None-Match` where possible.
+- For logged-in data, use `private` caching with short max-age.
+
+Deliverables
+- Fewer full recomputes for repeated navigations.
+- Settings/Financial feel instant, but still correct.
+
+Progress
+- Added session cache + throttled `lastSeenAt` updates to reduce auth overhead spikes.
+- Added cached GETs with short TTL + per-org tags for Settings + Financial config/impact.
+- Added refresh bypass (`?refresh=1`) and a refresh button on Financial.
+- Added ETag + private cache headers for Settings + Financial config, plus private cache headers for Financial impact.
+- Restored `force-dynamic` on the authenticated layout to avoid static render errors from `cookies()`.
+
+---
+
+## Phase 5: Query + payload tuning
+
+- Reduce `select` fields to only what the UI needs on first render.
+- Cap `take` sizes with clear UI controls to load more.
+- Add indexes for `orgId + ts` combos used in orderBy filters.
+- Consider summary tables for expensive aggregations.
+
+Progress
+- Split machine fetch into base + latest heartbeat/KPI queries to avoid nested relation orderBy/take on large tables.
+- Added indexes for heartbeat tsServer lookup and machine ordering by orgId + createdAt.
+- Machines base query dropped to low ms; new hotspots are latest heartbeat (~250-300ms) and latest KPI (~800-900ms).
+- Overview/Machines now log `heartbeatsQuery` + `kpiQuery` to track the new bottlenecks.
+
+---
+
+## What helped most
+- Overview split + summary cache: repeat navigations are instant and detail loads later.
+- Route-level loading + pending state: immediate feedback reduced double-clicks.
+- Session cache + throttled lastSeen: reduced non-query overhead spikes.
+- Short TTL caches with refresh bypass: Settings/Financial feel instant without losing correctness.
+- Query shape changes: removed nested relation ordering and shifted load to targeted queries.
+
+## Methodology / optimization strategy
+- Instrument first, measure cold + warm, and store logs.
+- Use timing breakdowns to find the dominant step.
+- Improve perceived performance early (skeletons, pending state).
+- Split payloads into summary + deferred detail.
+- Cache low-risk data with short TTL + refresh bypass and ETag for 304s.
+- Tune queries with smaller selects, indexes, and safer query shapes; consider denormalizing if needed.
+
+## Validation
+- Measure navigation feedback time (click to loading UI). Goal: <50ms.
+- Track p95 TTFB and payload size for Overview and Reports before/after.
+- Confirm that repeated clicks no longer add latency or duplicated requests.
+
+---
+
+## Open opportunities
+- Optimize latest KPI query (index on `orgId + machineId + tsServer` or denormalize latest KPI onto `Machine`).
+- Reduce Reports payload size (trim fields, paginate, or virtualize tables).
+- Consider summary tables/materialized views for heavy aggregates.
+
+## Further implementation plan (later)
+1) Latest KPI/heartbeat acceleration
+   - Add index for KPI lookups by server time: `@@index([orgId, machineId, tsServer])`.
+   - Switch KPI “latest” ordering to `tsServer` to match index.
+   - Optional: denormalize `latestHeartbeat` + `latestKpi` onto `Machine` and update on ingest.
+   - Add background backfill job for legacy machines.
+
+2) Machines + Overview caching
+   - Increase summary cache TTL (30-60s) to raise hit rates.
+   - Add per-org cache invalidation when a heartbeat/KPI ingests.
+   - Add ETag handling to `/api/machines` (similar to overview detail).
+
+3) Reports payload trim
+   - Reduce fields in `reports` response to the chart/minimum.
+   - Add pagination for large tables (KPIs/cycles/scrap).
+   - Add “Download full dataset” endpoint separate from UI view.
+
+4) Connection + ORM tuning
+   - Enable Prisma query logging to identify slow SQL.
+   - Evaluate connection pool size and cold-start behavior in serverless.
+   - Move heavy aggregates to `GROUP BY` at DB level with indexes.
+
+5) UX refinements
+   - Add inline “last updated” timestamp in Overview/Reports headers.
+   - Show cache-hit badges when content is served from cache.
+   - Add optional “refresh” on the overview to re-fetch detail data.