Downtime catalog

2026-05-06 00:36:48 +00:00
parent 0491237bad
commit bfc1673d89
42 changed files with 8035 additions and 1093 deletions
--- a/app/api/settings/machines/[machineId]/route.ts
+++ b/app/api/settings/machines/[machineId]/route.ts
@@ -17,7 +17,7 @@ import {
  validateShiftOverrides,
  validateThresholds,
 } from "@/lib/settings";
-import { loadFallbackReasonCatalog, normalizeReasonCatalog, type ReasonCatalog } from "@/lib/reasonCatalog";
+import { effectiveReasonCatalogForOrg } from "@/lib/reasonCatalogDb";
 import { publishSettingsUpdate } from "@/lib/mqtt";
 import { z } from "zod";

@@ -46,21 +46,18 @@ 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;
-
+async function attachReasonCatalog(
+  orgId: string,
+  defaultsJson: unknown,
+  settingsVersion: number,
+  base: Record<string, unknown>
+): Promise<Record<string, unknown>> {
+  const catalog = await effectiveReasonCatalogForOrg(orgId, defaultsJson, settingsVersion);
  return {
    ...base,
-    reasonCatalog: parsed,
-    reasonCatalogData: parsed,
-    reasonCatalogVersion: Number(parsed.version || 1),
+    reasonCatalog: catalog,
+    reasonCatalogData: catalog,
+    reasonCatalogVersion: Number(catalog.version || 1),
  };
 }

@@ -164,9 +161,7 @@ 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.$transaction(async (tx) => {
+  const { orgRow, shifts, rawOverrides } = await prisma.$transaction(async (tx) => {
    const orgSettings = await ensureOrgSettings(tx, orgId as string, userId);
    if (!orgSettings?.settings) throw new Error("SETTINGS_NOT_FOUND");

@@ -175,25 +170,24 @@ export async function GET(
      select: { overridesJson: true },
    });

-    const orgPayload = withReasonCatalog(
-      buildSettingsPayload(orgSettings.settings, orgSettings.shifts ?? []),
-      fallbackCatalog
-    );
    const rawOverrides = pickAllowedOverrides(machineSettings?.overridesJson ?? {});
-    const effective = withReasonCatalog(
-      deepMerge(orgPayload, rawOverrides) as Record<string, unknown>,
-      fallbackCatalog
-    );
-
-    return { settings: { org: orgPayload, effective }, overrides: rawOverrides };
+    return {
+      orgRow: orgSettings.settings,
+      shifts: orgSettings.shifts ?? [],
+      rawOverrides,
+    };
  });

+  const baseOrg = buildSettingsPayload(orgRow, shifts) as Record<string, unknown>;
+  const orgPayload = await attachReasonCatalog(orgId as string, orgRow.defaultsJson, orgRow.version, baseOrg);
+  const effective = deepMerge(orgPayload, rawOverrides) as Record<string, unknown>;
+
  return NextResponse.json({
    ok: true,
    machineId,
-    orgSettings: settings.org,
-    effectiveSettings: settings.effective,
-    overrides,
+    orgSettings: orgPayload,
+    effectiveSettings: effective,
+    overrides: rawOverrides,
  });
 }

@@ -413,25 +407,23 @@ export async function PUT(
      },
    });

-    const fallbackCatalog = await loadFallbackReasonCatalog();
-    const orgPayload = withReasonCatalog(
-      buildSettingsPayload(orgSettings.settings, orgSettings.shifts ?? []),
-      fallbackCatalog
-    );
-    const overrides = pickAllowedOverrides(saved.overridesJson ?? {});
-    const effective = withReasonCatalog(
-      deepMerge(orgPayload, overrides) as Record<string, unknown>,
-      fallbackCatalog
-    );
-
    return {
-      orgPayload,
-      overrides,
-      effective,
+      orgSettingsRow: orgSettings.settings,
+      shifts: orgSettings.shifts ?? [],
+      overrides: pickAllowedOverrides(saved.overridesJson ?? {}),
      overridesUpdatedAt: saved.updatedAt,
    };
  });

+  const baseOrg = buildSettingsPayload(result.orgSettingsRow, result.shifts) as Record<string, unknown>;
+  const orgPayload = await attachReasonCatalog(
+    session.orgId,
+    result.orgSettingsRow.defaultsJson,
+    result.orgSettingsRow.version,
+    baseOrg
+  );
+  const effective = deepMerge(orgPayload, result.overrides) as Record<string, unknown>;
+
  const overridesUpdatedAt =
    result.overridesUpdatedAt && result.overridesUpdatedAt instanceof Date
      ? result.overridesUpdatedAt.toISOString()
@@ -440,7 +432,7 @@ export async function PUT(
    await publishSettingsUpdate({
      orgId: session.orgId,
      machineId,
-      version: Number(result.orgPayload.version ?? 0),
+      version: Number(result.orgSettingsRow.version ?? 0),
      source,
      overridesUpdatedAt,
    });
@@ -451,8 +443,8 @@ export async function PUT(
  return NextResponse.json({
    ok: true,
    machineId,
-    orgSettings: result.orgPayload,
-    effectiveSettings: result.effective,
+    orgSettings: orgPayload,
+    effectiveSettings: effective,
    overrides: result.overrides,
  });
 }
--- a/app/api/settings/reason-catalog/categories/[categoryId]/route.ts
+++ b/app/api/settings/reason-catalog/categories/[categoryId]/route.ts
@@ -0,0 +1,106 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+import { bumpOrgSettingsVersion, composeReasonCode } from "@/lib/reasonCatalogDb";
+import { z } from "zod";
+
+const PREFIX_RE = /^[A-Za-z][A-Za-z0-9-]*$/;
+
+const patchSchema = z.object({
+  name: z.string().trim().min(1).max(200).optional(),
+  codePrefix: z
+    .string()
+    .trim()
+    .min(1)
+    .max(32)
+    .transform((s) => s.toUpperCase())
+    .optional(),
+  sortOrder: z.number().int().optional(),
+  active: z.boolean().optional(),
+});
+
+export async function PATCH(
+  req: Request,
+  { params }: { params: Promise<{ categoryId: string }> }
+) {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const { categoryId } = await params;
+  const parsed = patchSchema.safeParse(await req.json().catch(() => null));
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid body", issues: parsed.error.flatten() }, { status: 400 });
+  }
+
+  const existing = await prisma.reasonCatalogCategory.findFirst({
+    where: { id: categoryId, orgId: auth.session.orgId },
+    include: { items: true },
+  });
+  if (!existing) return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+
+  const nextPrefix = parsed.data.codePrefix ?? existing.codePrefix;
+  if (parsed.data.codePrefix !== undefined && !PREFIX_RE.test(nextPrefix)) {
+    return NextResponse.json(
+      { ok: false, error: "codePrefix must start with a letter; letters, digits, hyphen allowed." },
+      { status: 400 }
+    );
+  }
+
+  if (parsed.data.codePrefix !== undefined && parsed.data.codePrefix !== existing.codePrefix) {
+    const proposed = new Set<string>();
+    for (const it of existing.items) {
+      proposed.add(composeReasonCode(nextPrefix, it.codeSuffix));
+    }
+    const codes = [...proposed];
+    const conflicts = await prisma.reasonCatalogItem.findMany({
+      where: {
+        orgId: auth.session.orgId,
+        reasonCode: { in: codes },
+        NOT: { categoryId: existing.id },
+      },
+      select: { reasonCode: true },
+    });
+    if (conflicts.length) {
+      return NextResponse.json(
+        { ok: false, error: "Prefix change would duplicate codes", conflicts: conflicts.map((c) => c.reasonCode) },
+        { status: 409 }
+      );
+    }
+  }
+
+  try {
+    await prisma.$transaction(async (tx) => {
+      await tx.reasonCatalogCategory.update({
+        where: { id: categoryId },
+        data: {
+          ...(parsed.data.name !== undefined ? { name: parsed.data.name } : {}),
+          ...(parsed.data.codePrefix !== undefined ? { codePrefix: parsed.data.codePrefix } : {}),
+          ...(parsed.data.sortOrder !== undefined ? { sortOrder: parsed.data.sortOrder } : {}),
+          ...(parsed.data.active !== undefined ? { active: parsed.data.active } : {}),
+        },
+      });
+
+      if (parsed.data.codePrefix !== undefined && parsed.data.codePrefix !== existing.codePrefix) {
+        for (const it of existing.items) {
+          const reasonCode = composeReasonCode(nextPrefix, it.codeSuffix);
+          await tx.reasonCatalogItem.update({
+            where: { id: it.id },
+            data: { reasonCode },
+          });
+        }
+      }
+
+      await bumpOrgSettingsVersion(tx, auth.session.orgId, auth.session.userId);
+    });
+
+    const updated = await prisma.reasonCatalogCategory.findUnique({
+      where: { id: categoryId },
+      include: { items: { orderBy: [{ sortOrder: "asc" }, { reasonCode: "asc" }] } },
+    });
+
+    return NextResponse.json({ ok: true, category: updated });
+  } catch (e) {
+    console.error("[reason-catalog category PATCH]", e);
+    return NextResponse.json({ ok: false, error: "Update failed" }, { status: 500 });
+  }
+}
--- a/app/api/settings/reason-catalog/categories/route.ts
+++ b/app/api/settings/reason-catalog/categories/route.ts
@@ -0,0 +1,64 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+import { bumpOrgSettingsVersion } from "@/lib/reasonCatalogDb";
+import { z } from "zod";
+
+const PREFIX_RE = /^[A-Za-z][A-Za-z0-9-]*$/;
+
+const bodySchema = z.object({
+  kind: z.enum(["downtime", "scrap"]),
+  name: z.string().trim().min(1).max(200),
+  codePrefix: z
+    .string()
+    .trim()
+    .min(1)
+    .max(32)
+    .transform((s) => s.toUpperCase()),
+});
+
+export async function POST(req: Request) {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const parsed = bodySchema.safeParse(await req.json().catch(() => null));
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid body", issues: parsed.error.flatten() }, { status: 400 });
+  }
+  const { kind, name, codePrefix } = parsed.data;
+  if (!PREFIX_RE.test(codePrefix)) {
+    return NextResponse.json(
+      { ok: false, error: "codePrefix must start with a letter; letters, digits, hyphen allowed." },
+      { status: 400 }
+    );
+  }
+
+  try {
+    const row = await prisma.$transaction(async (tx) => {
+      const last = await tx.reasonCatalogCategory.findFirst({
+        where: { orgId: auth.session.orgId, kind },
+        orderBy: { sortOrder: "desc" },
+        select: { sortOrder: true },
+      });
+      const sortOrder = (last?.sortOrder ?? -1) + 1;
+
+      const created = await tx.reasonCatalogCategory.create({
+        data: {
+          orgId: auth.session.orgId,
+          kind,
+          name,
+          codePrefix,
+          sortOrder,
+          active: true,
+        },
+      });
+      await bumpOrgSettingsVersion(tx, auth.session.orgId, auth.session.userId);
+      return created;
+    });
+
+    return NextResponse.json({ ok: true, category: row });
+  } catch (e) {
+    console.error("[reason-catalog categories POST]", e);
+    return NextResponse.json({ ok: false, error: "Create failed" }, { status: 500 });
+  }
+}
--- a/app/api/settings/reason-catalog/items/[itemId]/route.ts
+++ b/app/api/settings/reason-catalog/items/[itemId]/route.ts
@@ -0,0 +1,69 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+import { bumpOrgSettingsVersion, composeReasonCode, isNumericSuffix } from "@/lib/reasonCatalogDb";
+import { z } from "zod";
+
+const patchSchema = z.object({
+  name: z.string().trim().min(1).max(500).optional(),
+  codeSuffix: z.string().trim().min(1).max(32).optional(),
+  sortOrder: z.number().int().optional(),
+  active: z.boolean().optional(),
+});
+
+export async function PATCH(
+  req: Request,
+  { params }: { params: Promise<{ itemId: string }> }
+) {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const { itemId } = await params;
+  const parsed = patchSchema.safeParse(await req.json().catch(() => null));
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid body", issues: parsed.error.flatten() }, { status: 400 });
+  }
+
+  const existing = await prisma.reasonCatalogItem.findFirst({
+    where: { id: itemId, orgId: auth.session.orgId },
+    include: { category: true },
+  });
+  if (!existing) return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+
+  const nextSuffix = parsed.data.codeSuffix ?? existing.codeSuffix;
+  if (parsed.data.codeSuffix !== undefined && !isNumericSuffix(nextSuffix)) {
+    return NextResponse.json({ ok: false, error: "codeSuffix must be digits only" }, { status: 400 });
+  }
+
+  const reasonCode = composeReasonCode(existing.category.codePrefix, nextSuffix);
+  if (reasonCode !== existing.reasonCode) {
+    const conflict = await prisma.reasonCatalogItem.findFirst({
+      where: { orgId: auth.session.orgId, reasonCode, NOT: { id: itemId } },
+      select: { id: true },
+    });
+    if (conflict) {
+      return NextResponse.json({ ok: false, error: "Duplicate reasonCode for this organization" }, { status: 409 });
+    }
+  }
+
+  try {
+    await prisma.$transaction(async (tx) => {
+      await tx.reasonCatalogItem.update({
+        where: { id: itemId },
+        data: {
+          ...(parsed.data.name !== undefined ? { name: parsed.data.name } : {}),
+          ...(parsed.data.codeSuffix !== undefined ? { codeSuffix: nextSuffix, reasonCode } : {}),
+          ...(parsed.data.sortOrder !== undefined ? { sortOrder: parsed.data.sortOrder } : {}),
+          ...(parsed.data.active !== undefined ? { active: parsed.data.active } : {}),
+        },
+      });
+      await bumpOrgSettingsVersion(tx, auth.session.orgId, auth.session.userId);
+    });
+
+    const updated = await prisma.reasonCatalogItem.findUnique({ where: { id: itemId } });
+    return NextResponse.json({ ok: true, item: updated });
+  } catch (e) {
+    console.error("[reason-catalog item PATCH]", e);
+    return NextResponse.json({ ok: false, error: "Update failed" }, { status: 500 });
+  }
+}
--- a/app/api/settings/reason-catalog/items/route.ts
+++ b/app/api/settings/reason-catalog/items/route.ts
@@ -0,0 +1,71 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+import { bumpOrgSettingsVersion, composeReasonCode, isNumericSuffix } from "@/lib/reasonCatalogDb";
+import { z } from "zod";
+
+const bodySchema = z.object({
+  categoryId: z.string().uuid(),
+  codeSuffix: z.string().trim().min(1).max(32),
+  name: z.string().trim().min(1).max(500),
+  sortOrder: z.number().int().optional(),
+});
+
+export async function POST(req: Request) {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const parsed = bodySchema.safeParse(await req.json().catch(() => null));
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid body", issues: parsed.error.flatten() }, { status: 400 });
+  }
+
+  const { categoryId, codeSuffix, name, sortOrder } = parsed.data;
+  if (!isNumericSuffix(codeSuffix)) {
+    return NextResponse.json({ ok: false, error: "codeSuffix must be digits only" }, { status: 400 });
+  }
+
+  const category = await prisma.reasonCatalogCategory.findFirst({
+    where: { id: categoryId, orgId: auth.session.orgId },
+  });
+  if (!category) return NextResponse.json({ ok: false, error: "Category not found" }, { status: 404 });
+
+  const reasonCode = composeReasonCode(category.codePrefix, codeSuffix);
+
+  try {
+    const row = await prisma.$transaction(async (tx) => {
+      let nextOrder = sortOrder;
+      if (nextOrder === undefined) {
+        const last = await tx.reasonCatalogItem.findFirst({
+          where: { categoryId },
+          orderBy: { sortOrder: "desc" },
+          select: { sortOrder: true },
+        });
+        nextOrder = (last?.sortOrder ?? -1) + 1;
+      }
+
+      const created = await tx.reasonCatalogItem.create({
+        data: {
+          orgId: auth.session.orgId,
+          categoryId,
+          name,
+          codeSuffix,
+          reasonCode,
+          sortOrder: nextOrder,
+          active: true,
+        },
+      });
+      await bumpOrgSettingsVersion(tx, auth.session.orgId, auth.session.userId);
+      return created;
+    });
+
+    return NextResponse.json({ ok: true, item: row });
+  } catch (e: unknown) {
+    const code = typeof e === "object" && e && "code" in e ? (e as { code: string }).code : "";
+    if (code === "P2002") {
+      return NextResponse.json({ ok: false, error: "Duplicate reasonCode for this organization" }, { status: 409 });
+    }
+    console.error("[reason-catalog items POST]", e);
+    return NextResponse.json({ ok: false, error: "Create failed" }, { status: 500 });
+  }
+}
--- a/app/api/settings/reason-catalog/route.ts
+++ b/app/api/settings/reason-catalog/route.ts
@@ -0,0 +1,43 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+
+/** Full tree for Control Tower (includes inactive rows). */
+export async function GET() {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const orgSettings = await prisma.orgSettings.findUnique({
+    where: { orgId: auth.session.orgId },
+    select: { version: true },
+  });
+
+  const categories = await prisma.reasonCatalogCategory.findMany({
+    where: { orgId: auth.session.orgId },
+    include: {
+      items: { orderBy: [{ sortOrder: "asc" }, { reasonCode: "asc" }] },
+    },
+    orderBy: [{ kind: "asc" }, { sortOrder: "asc" }, { name: "asc" }],
+  });
+
+  return NextResponse.json({
+    ok: true,
+    catalogVersion: orgSettings?.version ?? 1,
+    categories: categories.map((c) => ({
+      id: c.id,
+      kind: c.kind,
+      name: c.name,
+      codePrefix: c.codePrefix,
+      sortOrder: c.sortOrder,
+      active: c.active,
+      items: c.items.map((it) => ({
+        id: it.id,
+        name: it.name,
+        codeSuffix: it.codeSuffix,
+        reasonCode: it.reasonCode,
+        sortOrder: it.sortOrder,
+        active: it.active,
+      })),
+    })),
+  });
+}
--- a/app/api/settings/route.ts
+++ b/app/api/settings/route.ts
@@ -19,7 +19,7 @@ import {
  validateShiftOverrides,
  validateThresholds,
 } from "@/lib/settings";
-import { loadFallbackReasonCatalog, normalizeReasonCatalog, type ReasonCatalog } from "@/lib/reasonCatalog";
+import { effectiveReasonCatalogForOrg } from "@/lib/reasonCatalogDb";
 import { publishSettingsUpdate } from "@/lib/mqtt";
 import { z } from "zod";

@@ -39,21 +39,18 @@ 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;
-
+async function attachReasonCatalog(
+  orgId: string,
+  defaultsJson: unknown,
+  settingsVersion: number,
+  base: Record<string, unknown>
+): Promise<Record<string, unknown>> {
+  const catalog = await effectiveReasonCatalogForOrg(orgId, defaultsJson, settingsVersion);
  return {
    ...base,
-    reasonCatalog: parsed,
-    reasonCatalogData: parsed,
-    reasonCatalogVersion: Number(parsed.version || 1),
+    reasonCatalog: catalog,
+    reasonCatalogData: catalog,
+    reasonCatalogVersion: Number(catalog.version || 1),
  };
 }

@@ -66,7 +63,6 @@ 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();
@@ -145,8 +141,13 @@ async function loadSettingsPayload(orgId: string, userId: string) {
    return found;
  });

-  const fallbackCatalog = await loadFallbackReasonCatalog();
-  const payload = withReasonCatalog(buildSettingsPayload(loaded.settings, loaded.shifts ?? []), fallbackCatalog);
+  const base = buildSettingsPayload(loaded.settings, loaded.shifts ?? []) as Record<string, unknown>;
+  const payload = await attachReasonCatalog(
+    orgId,
+    loaded.settings.defaultsJson,
+    loaded.settings.version,
+    base
+  );
  const defaultsRaw = isPlainObject(loaded.settings.defaultsJson) ? (loaded.settings.defaultsJson as any) : {};
  const modulesRaw = isPlainObject(defaultsRaw.modules) ? defaultsRaw.modules : {};
  const modules = { screenlessMode: modulesRaw.screenlessMode === true };
@@ -221,7 +222,6 @@ 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;

@@ -233,7 +233,6 @@ export async function PUT(req: Request) {
      thresholds === undefined &&
      alerts === undefined &&
      defaults === undefined &&
-      reasonCatalogRaw === undefined &&
      modules === undefined

    ) {
@@ -252,13 +251,6 @@ 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 });
    }
@@ -333,20 +325,16 @@ export async function PUT(req: Request) {
        : { ...currentModulesRaw, screenlessMode };

    // Write defaultsJson if either defaults changed OR modules changed
-    const shouldWriteDefaultsJson =
-      !!nextDefaultsCore || screenlessMode !== undefined || reasonCatalogRaw !== undefined;
+    const shouldWriteDefaultsJson = !!nextDefaultsCore || screenlessMode !== undefined;

    const nextDefaultsJson = shouldWriteDefaultsJson
      ? { ...(nextDefaultsCore ?? normalizeDefaults(currentDefaultsRaw)), modules: nextModules }
      : undefined;

-    if (nextDefaultsJson && reasonCatalogRaw !== undefined) {
+    if (nextDefaultsJson) {
      const defaultsTarget = nextDefaultsJson as Record<string, unknown>;
-      if (nextReasonCatalog === null) {
-        delete defaultsTarget.reasonCatalog;
-      } else if (nextReasonCatalog) {
-        defaultsTarget.reasonCatalog = nextReasonCatalog;
-      }
+      delete defaultsTarget.reasonCatalog;
+      delete defaultsTarget.reasonCatalogData;
    }


@@ -444,12 +432,18 @@ export async function PUT(req: Request) {
      return NextResponse.json({ ok: false, error: updated.error }, { status: 400 });
    }

-    const payload = buildSettingsPayload(updated.settings, updated.shifts ?? []);
+    const baseOut = buildSettingsPayload(updated.settings, updated.shifts ?? []) as Record<string, unknown>;
+    const payload = await attachReasonCatalog(
+      session.orgId,
+      updated.settings.defaultsJson,
+      updated.settings.version,
+      baseOut
+    );
    const updatedAt =
      typeof payload.updatedAt === "string"
        ? payload.updatedAt
        : payload.updatedAt
-        ? payload.updatedAt.toISOString()
+        ? (payload.updatedAt as Date).toISOString()
        : undefined;
    try {
      await publishSettingsUpdate({