Downtime catalog

lib/alerts/getAlertsInboxData.ts

@@ -38,6 +38,7 @@ type AlertsInboxEvent = {
   status?: string | null;
   shift?: string | null;
   alertId?: string | null;
+  incidentKey?: string | null;
   isUpdate?: boolean;
   isAutoAck?: boolean;
 };
@@ -224,29 +225,34 @@ function resolveShift(
 }
 
 function collapseAlertEvents(events: AlertsInboxEvent[]) {
-  const byAlert = new Map<string, AlertsInboxEvent>();
+  // Group by incidentKey (preferred — stable across the entire incident lifecycle)
+  // OR alertId (fallback — for older or non-stoppage events).
+  // Per group, keep AT MOST one "active" (oldest = when it first happened) and
+  // one "resolved" (newest = when it actually ended). Result: max 2 entries per incident.
+  const byGroup = new Map<string, AlertsInboxEvent>();
   const passthrough: AlertsInboxEvent[] = [];
 
   for (const ev of events) {
-    if (!ev.alertId) {
+    const groupId = ev.incidentKey ?? ev.alertId;
+    if (!groupId) {
       passthrough.push(ev);
       continue;
     }
     const statusKey = ev.status === "resolved" ? "resolved" : "active";
-    const key = `${ev.alertId}:${statusKey}`;
-    const existing = byAlert.get(key);
+    const key = `${groupId}:${statusKey}`;
+    const existing = byGroup.get(key);
     if (!existing) {
-      byAlert.set(key, ev);
+      byGroup.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);
+    if (shouldReplace) byGroup.set(key, ev);
   }
 
-  const combined = [...passthrough, ...byAlert.values()];
+  const combined = [...passthrough, ...byGroup.values()];
   combined.sort((a, b) => b.ts.getTime() - a.ts.getTime());
   return combined;
 }
@@ -325,7 +331,12 @@ export async function getAlertsInboxData(params: AlertsInboxParams) {
     const rawStatus = safeString(payload?.status ?? inner?.status);
     const isUpdate = safeBool(payload?.is_update ?? inner?.is_update);
     const isAutoAck = safeBool(payload?.is_auto_ack ?? inner?.is_auto_ack);
-    if (!includeUpdates && (isUpdate || isAutoAck)) continue;
+    // Drop only auto-ack pings (every-10s refresh noise).
+    // Keep is_update events: due to a Node-RED spread inheritance pattern,
+    // virtually all events carry is_update=true even legitimate first-emission
+    // and cycle-arrival resolved events. Dedup happens via collapseAlertEvents
+    // grouping by incidentKey below.
+    if (!includeUpdates && isAutoAck) continue;
 
     const shiftName = resolveShift(shifts, shiftOverrides, ev.ts, timeZone);
     if (normalizedShift && shiftName !== normalizedShift) continue;
@@ -349,6 +360,7 @@ export async function getAlertsInboxData(params: AlertsInboxParams) {
       status: statusLabel,
       shift: shiftName,
       alertId: safeString(payload?.alert_id ?? inner?.alert_id),
+      incidentKey: safeString(payload?.incidentKey ?? payload?.incident_key ?? inner?.incidentKey ?? inner?.incident_key),
       isUpdate,
       isAutoAck,
     });

lib/alerts/getAlertsInboxData.ts.bak

@@ -0,0 +1,363 @@
+import { normalizeShiftOverrides } from "@/lib/settings";
+import { prisma } from "@/lib/prisma";
+
+const RANGE_MS: Record<string, number> = {
+  "24h": 24 * 60 * 60 * 1000,
+  "7d": 7 * 24 * 60 * 60 * 1000,
+  "30d": 30 * 24 * 60 * 60 * 1000,
+};
+
+type AlertsInboxParams = {
+  orgId: string;
+  range?: string;
+  start?: Date | null;
+  end?: Date | null;
+  machineId?: string;
+  location?: string;
+  eventType?: string;
+  severity?: string;
+  status?: string;
+  shift?: string;
+  includeUpdates?: boolean;
+  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") {
+    const startFallback = new Date(now.getTime() - RANGE_MS["24h"]);
+    return {
+      range,
+      start: start ?? startFallback,
+      end: end ?? now,
+    };
+  }
+  const ms = RANGE_MS[range] ?? RANGE_MS["24h"];
+  return { range, start: new Date(now.getTime() - ms), end: now };
+}
+
+function safeString(value: unknown) {
+  if (typeof value !== "string") return null;
+  const trimmed = value.trim();
+  return trimmed ? trimmed : null;
+}
+
+function safeNumber(value: unknown) {
+  const n = typeof value === "number" ? value : Number(value);
+  return Number.isFinite(n) ? n : null;
+}
+
+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") {
+    try {
+      parsed = JSON.parse(raw);
+    } catch {
+      parsed = raw;
+    }
+  }
+  const payload =
+    parsed && typeof parsed === "object" && !Array.isArray(parsed)
+      ? (parsed as Record<string, unknown>)
+      : {};
+  const innerCandidate = payload.data;
+  const inner =
+    innerCandidate && typeof innerCandidate === "object" && !Array.isArray(innerCandidate)
+      ? (innerCandidate as Record<string, unknown>)
+      : payload;
+  return { payload, inner };
+}
+
+function extractDurationSec(raw: unknown) {
+  const { payload, inner } = parsePayload(raw);
+  const candidates = [
+    inner?.duration_seconds,
+    inner?.duration_sec,
+    inner?.stoppage_duration_seconds,
+    inner?.stop_duration_seconds,
+    payload?.duration_seconds,
+    payload?.duration_sec,
+    payload?.stoppage_duration_seconds,
+    payload?.stop_duration_seconds,
+  ];
+  for (const val of candidates) {
+    if (typeof val === "number" && Number.isFinite(val) && val >= 0) return val;
+  }
+  const msCandidates = [inner?.duration_ms, inner?.durationMs, payload?.duration_ms, payload?.durationMs];
+  for (const val of msCandidates) {
+    if (typeof val === "number" && Number.isFinite(val) && val >= 0) {
+      return Math.round(val / 1000);
+    }
+  }
+
+  const startMs = inner.start_ts ?? inner.startTs ?? payload.start_ts ?? payload.startTs ?? null;
+  const endMs = inner.end_ts ?? inner.endTs ?? payload.end_ts ?? payload.endTs ?? null;
+  if (typeof startMs === "number" && typeof endMs === "number" && endMs >= startMs) {
+    return Math.round((endMs - startMs) / 1000);
+  }
+
+  const actual = safeNumber(inner.actual_cycle_time ?? payload.actual_cycle_time);
+  const theoretical = safeNumber(inner.theoretical_cycle_time ?? payload.theoretical_cycle_time);
+  if (actual != null && theoretical != null) {
+    return Math.max(0, actual - theoretical);
+  }
+
+  return null;
+}
+
+function parseTimeMinutes(value?: string | null) {
+  if (!value || !/^\d{2}:\d{2}$/.test(value)) return null;
+  const [hh, mm] = value.split(":").map((n) => Number(n));
+  if (!Number.isFinite(hh) || !Number.isFinite(mm)) return null;
+  return hh * 60 + mm;
+}
+
+function getLocalMinutes(ts: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      hour: "2-digit",
+      minute: "2-digit",
+      hourCycle: "h23",
+    }).formatToParts(ts);
+    const hours = Number(parts.find((p) => p.type === "hour")?.value ?? "0");
+    const minutes = Number(parts.find((p) => p.type === "minute")?.value ?? "0");
+    return hours * 60 + minutes;
+  } catch {
+    return ts.getUTCHours() * 60 + ts.getUTCMinutes();
+  }
+}
+
+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: ShiftLike[],
+  overrides: Record<string, ShiftLike[]> | undefined,
+  ts: Date,
+  timeZone: string
+) {
+  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 activeShifts) {
+    if (shift.enabled === false) continue;
+    const start = parseTimeMinutes(shift.startTime ?? shift.start ?? null);
+    const end = parseTimeMinutes(shift.endTime ?? shift.end ?? null);
+    if (start == null || end == null) continue;
+    if (start <= end) {
+      if (nowMin >= start && nowMin < end) return shift.name;
+    } else {
+      if (nowMin >= start || nowMin < end) return shift.name;
+    }
+  }
+  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,
+    range = "24h",
+    start,
+    end,
+    machineId,
+    location,
+    eventType,
+    severity,
+    status,
+    shift,
+    includeUpdates = false,
+    limit = 200,
+  } = params;
+
+  const picked = pickRange(range, start, end);
+  const normalizedStatus = safeString(status)?.toLowerCase();
+  const normalizedShift = safeString(shift);
+  const safeLimit = Number.isFinite(limit) ? Math.min(Math.max(limit, 1), 500) : 200;
+
+  const where = {
+    orgId,
+    ts: { gte: picked.start, lte: picked.end },
+    ...(machineId ? { machineId } : {}),
+    ...(eventType ? { eventType } : {}),
+    ...(severity ? { severity } : {}),
+    ...(location ? { machine: { location } } : {}),
+  };
+
+  const [events, shifts, settings] = await Promise.all([
+    prisma.machineEvent.findMany({
+      where,
+      orderBy: { ts: "desc" },
+      take: safeLimit,
+      select: {
+        id: true,
+        ts: true,
+        eventType: true,
+        severity: true,
+        title: true,
+        description: true,
+        data: true,
+        machineId: true,
+        workOrderId: true,
+        sku: true,
+        machine: {
+          select: {
+            name: true,
+            location: true,
+          },
+        },
+      },
+    }),
+    prisma.orgShift.findMany({
+      where: { orgId },
+      orderBy: { sortOrder: "asc" },
+      select: { name: true, startTime: true, endTime: true, enabled: true },
+    }),
+    prisma.orgSettings.findUnique({
+      where: { orgId },
+      select: { timezone: true, shiftScheduleOverridesJson: true },
+    }),
+  ]);
+
+  const timeZone = settings?.timezone || "UTC";
+  const shiftOverrides = normalizeShiftOverrides(settings?.shiftScheduleOverridesJson);
+  const mapped: AlertsInboxEvent[] = [];
+
+  for (const ev of events) {
+    const { payload, inner } = parsePayload(ev.data);
+    const rawStatus = safeString(payload?.status ?? inner?.status);
+    const isUpdate = safeBool(payload?.is_update ?? inner?.is_update);
+    const isAutoAck = safeBool(payload?.is_auto_ack ?? inner?.is_auto_ack);
+    if (!includeUpdates && (isUpdate || isAutoAck)) continue;
+
+    const shiftName = resolveShift(shifts, shiftOverrides, ev.ts, timeZone);
+    if (normalizedShift && shiftName !== normalizedShift) continue;
+
+    const statusLabel = normalizeStatus(rawStatus) ?? "unknown";
+    if (normalizedStatus && statusLabel !== normalizedStatus) continue;
+
+    mapped.push({
+      id: ev.id,
+      ts: ev.ts,
+      eventType: ev.eventType,
+      severity: ev.severity,
+      title: ev.title,
+      description: ev.description,
+      machineId: ev.machineId,
+      machineName: ev.machine?.name ?? null,
+      location: ev.machine?.location ?? null,
+      workOrderId: ev.workOrderId ?? null,
+      sku: ev.sku ?? null,
+      durationSec: extractDurationSec(ev.data),
+      status: statusLabel,
+      shift: shiftName,
+      alertId: safeString(payload?.alert_id ?? inner?.alert_id),
+      isUpdate,
+      isAutoAck,
+    });
+  }
+
+  const finalEvents = includeUpdates ? mapped : collapseAlertEvents(mapped);
+
+  return {
+    range: { range: picked.range, start: picked.start, end: picked.end },
+    events: finalEvents,
+  };
+}

lib/auth/requireOrgAdminSession.ts

@@ -0,0 +1,25 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+
+export type OrgAdminSession = { orgId: string; userId: string };
+
+export async function requireOrgAdminSession(): Promise<
+  { ok: true; session: OrgAdminSession } | { ok: false; response: NextResponse }
+> {
+  const session = await requireSession();
+  if (!session) {
+    return {
+      ok: false,
+      response: NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 }),
+    };
+  }
+  const membership = await prisma.orgUser.findUnique({
+    where: { orgId_userId: { orgId: session.orgId, userId: session.userId } },
+    select: { role: true },
+  });
+  if (membership?.role !== "OWNER" && membership?.role !== "ADMIN") {
+    return { ok: false, response: NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 }) };
+  }
+  return { ok: true, session: { orgId: session.orgId, userId: session.userId } };
+}

lib/i18n/en.json

@@ -115,10 +115,7 @@
   "machines.status.stopped": "STOPPED",
   "machines.stoppedFor": "Stopped for {min} min",
   "recap.grid.title": "Machine recap",
-  "recap.status.dataLoss": "Data Loss",
   "recap.status.idle": "Idle",
-  "recap.card.dataLoss": "{count} untracked cycles — press START",
-  "recap.card.notStarted": "Operator hasn't pressed START",
   "recap.card.idle": "No active work order",
   "recap.grid.subtitle": "Last 24h · click to open details",
   "recap.grid.updatedAgo": "Updated {sec}s ago",
@@ -467,6 +464,7 @@
   "settings.tabs.alerts": "Alerts",
   "settings.tabs.financial": "Financial",
   "settings.tabs.team": "Team",
+  "settings.tabs.reasonCatalog": "Downtime & scrap",
   "settings.loading": "Loading settings...",
   "settings.loadingTeam": "Loading team...",
   "settings.refresh": "Refresh",
@@ -522,6 +520,46 @@
   "settings.thresholds.macroStoppage": "Macro stoppage multiplier",
   "settings.alerts": "Alerts",
   "settings.alertsSubtitle": "Choose which alerts to notify.",
+  "settings.reasonCatalog.title": "Downtime and scrap catalogs",
+  "settings.reasonCatalog.subtitle": "Catalogs are stored in MIS (categories + codes). Changes bump settings version so machines pick them up. Deactivate retired codes instead of deleting them.",
+  "settings.reasonCatalog.version": "Catalog version",
+  "settings.reasonCatalog.hint": "Increase version when you change codes so edge devices can detect updates. Use \"Active\" to hide a code from new selections while keeping history labels.",
+  "settings.reasonCatalog.downtime": "Downtime (stops)",
+  "settings.reasonCatalog.scrap": "Scrap",
+  "settings.reasonCatalog.addCategory": "Add category",
+  "settings.reasonCatalog.emptyKind": "No categories yet.",
+  "settings.reasonCatalog.categoryId": "Category id",
+  "settings.reasonCatalog.categoryLabel": "Category name",
+  "settings.reasonCatalog.reasons": "Reasons",
+  "settings.reasonCatalog.addReason": "Add reason",
+  "settings.reasonCatalog.removeCategory": "Remove category",
+  "settings.reasonCatalog.detailId": "Detail id",
+  "settings.reasonCatalog.reasonCode": "Printed code",
+  "settings.reasonCatalog.detailLabel": "Description",
+  "settings.reasonCatalog.active": "Active",
+  "settings.reasonCatalog.removeRow": "Remove",
+  "settings.reasonCatalog.removeDetailHint": "Prefer deactivating codes that were already used in production.",
+  "settings.reasonCatalog.newCategory": "New category",
+  "settings.reasonCatalog.newReason": "New reason",
+  "settings.reasonCatalog.dbVersionHint": "Settings version (includes catalog): {version}",
+  "settings.reasonCatalog.reload": "Reload",
+  "settings.reasonCatalog.stepKind": "1. Catalog type",
+  "settings.reasonCatalog.stepCategory": "2. Category and prefix",
+  "settings.reasonCatalog.pickCategory": "Category",
+  "settings.reasonCatalog.inactive": "inactive",
+  "settings.reasonCatalog.categoryNameEdit": "Category name",
+  "settings.reasonCatalog.codePrefixEdit": "Code prefix (letters; optional digits/hyphen after first letter)",
+  "settings.reasonCatalog.categoryActive": "Category active",
+  "settings.reasonCatalog.newCategorySection": "New category in this catalog type",
+  "settings.reasonCatalog.codePrefixField": "Prefix (shown before the number)",
+  "settings.reasonCatalog.stepReason": "3. Add reason (numbers only)",
+  "settings.reasonCatalog.digitsOnlyHint": "Enter only the numeric part; the full printed code is prefix + number.",
+  "settings.reasonCatalog.fullCodePreview": "Printed code",
+  "settings.reasonCatalog.numericSuffix": "Number",
+  "settings.reasonCatalog.reasonsInCategory": "Reasons in this category",
+  "settings.reasonCatalog.noItemsYet": "No reasons yet.",
+  "settings.reasonCatalog.prefixInvalid": "Prefix must start with a letter and use letters, digits, or hyphen.",
+
   "settings.alerts.oeeDrop": "OEE drop alerts",
   "settings.alerts.oeeDropHelper": "Notify when OEE falls below threshold",
   "settings.alerts.performanceDegradation": "Performance degradation alerts",

lib/i18n/es-MX.json

@@ -121,10 +121,7 @@
   "recap.card.stoppedFor": "Detenida hace {min} min",
   "machines.status.stopped": "DETENIDA",
   "machines.stoppedFor": "Detenida hace {min} min",
-  "recap.status.dataLoss": "Sin tracking",
   "recap.status.idle": "Inactiva",
-  "recap.card.dataLoss": "{count} ciclos sin tracking — presione INICIAR",
-  "recap.card.notStarted": "Operador no ha presionado INICIAR",
   "recap.card.idle": "Sin orden de trabajo activa",
   "recap.grid.title": "Resumen de máquinas",
   "recap.grid.subtitle": "Últimas 24h · click para ver detalle",
@@ -474,6 +471,7 @@
   "settings.tabs.alerts": "Alertas",
   "settings.tabs.financial": "Finanzas",
   "settings.tabs.team": "Equipo",
+  "settings.tabs.reasonCatalog": "Paros y scrap",
   "settings.loading": "Cargando configuración...",
   "settings.loadingTeam": "Cargando equipo...",
   "settings.refresh": "Actualizar",
@@ -529,6 +527,46 @@
   "settings.thresholds.macroStoppage": "Multiplicador de macroparo",
   "settings.alerts": "Alertas",
   "settings.alertsSubtitle": "Elige qué alertas notificar.",
+  "settings.reasonCatalog.title": "Catálogos de paros y scrap",
+  "settings.reasonCatalog.subtitle": "Los catálogos viven en MIS (categorías y códigos). Los cambios suben la versión de ajustes para que las máquinas los reciban. Desactiva códigos retirados en lugar de borrarlos.",
+  "settings.reasonCatalog.version": "Versión del catálogo",
+  "settings.reasonCatalog.hint": "Sube la versión cuando cambies códigos para que el borde detecte actualizaciones. Usa \"Activo\" para ocultar un código en nuevas capturas sin perder etiquetas en histórico.",
+  "settings.reasonCatalog.downtime": "Tiempo muerto (paros)",
+  "settings.reasonCatalog.scrap": "Scrap",
+  "settings.reasonCatalog.addCategory": "Agregar categoría",
+  "settings.reasonCatalog.emptyKind": "Aún no hay categorías.",
+  "settings.reasonCatalog.categoryId": "Id de categoría",
+  "settings.reasonCatalog.categoryLabel": "Nombre de categoría",
+  "settings.reasonCatalog.reasons": "Razones",
+  "settings.reasonCatalog.addReason": "Agregar razón",
+  "settings.reasonCatalog.removeCategory": "Quitar categoría",
+  "settings.reasonCatalog.detailId": "Id del detalle",
+  "settings.reasonCatalog.reasonCode": "Código impreso",
+  "settings.reasonCatalog.detailLabel": "Descripción",
+  "settings.reasonCatalog.active": "Activo",
+  "settings.reasonCatalog.removeRow": "Quitar",
+  "settings.reasonCatalog.removeDetailHint": "Para códigos ya usados en producción, preferir desactivar en lugar de quitar la fila.",
+  "settings.reasonCatalog.newCategory": "Nueva categoría",
+  "settings.reasonCatalog.newReason": "Nueva razón",
+  "settings.reasonCatalog.dbVersionHint": "Versión de ajustes (incluye catálogo): {version}",
+  "settings.reasonCatalog.reload": "Recargar",
+  "settings.reasonCatalog.stepKind": "1. Tipo de catálogo",
+  "settings.reasonCatalog.stepCategory": "2. Categoría y prefijo",
+  "settings.reasonCatalog.pickCategory": "Categoría",
+  "settings.reasonCatalog.inactive": "inactiva",
+  "settings.reasonCatalog.categoryNameEdit": "Nombre de categoría",
+  "settings.reasonCatalog.codePrefixEdit": "Prefijo de código (letras; opcional dígitos o guión después de la primera letra)",
+  "settings.reasonCatalog.categoryActive": "Categoría activa",
+  "settings.reasonCatalog.newCategorySection": "Nueva categoría en este tipo de catálogo",
+  "settings.reasonCatalog.codePrefixField": "Prefijo (se muestra antes del número)",
+  "settings.reasonCatalog.stepReason": "3. Agregar razón (solo números)",
+  "settings.reasonCatalog.digitsOnlyHint": "Captura solo la parte numérica; el código impreso completo es prefijo + número.",
+  "settings.reasonCatalog.fullCodePreview": "Código impreso",
+  "settings.reasonCatalog.numericSuffix": "Número",
+  "settings.reasonCatalog.reasonsInCategory": "Razones en esta categoría",
+  "settings.reasonCatalog.noItemsYet": "Aún no hay razones.",
+  "settings.reasonCatalog.prefixInvalid": "El prefijo debe empezar con letra y usar letras, dígitos o guión.",
+
   "settings.alerts.oeeDrop": "Alertas por caída de OEE",
   "settings.alerts.oeeDropHelper": "Notificar cuando OEE esté por debajo del umbral",
   "settings.alerts.performanceDegradation": "Alertas por baja de Performance",

lib/reasonCatalog.ts

@@ -1,6 +1,3 @@
-import { readFile } from "fs/promises";
-import path from "path";
-
 type AnyRecord = Record<string, unknown>;
 
 export type ReasonCatalogKind = "downtime" | "scrap";
@@ -8,6 +5,10 @@ export type ReasonCatalogKind = "downtime" | "scrap";
 export type ReasonCatalogDetail = {
   id: string;
   label: string;
+  /** Official code (e.g. DTPRC-01, MX001). When set, used as reasonCode instead of slug. */
+  reasonCode?: string;
+  /** When false, hidden from operator pickers but kept for historical label resolution. Default true. */
+  active?: boolean;
 };
 
 export type ReasonCatalogCategory = {
@@ -22,6 +23,11 @@ export type ReasonCatalog = {
   scrap: ReasonCatalogCategory[];
 };
 
+export type FlattenReasonCatalogOptions = {
+  /** If true, omit details with active === false (operator / tactile UI). */
+  activeOnly?: boolean;
+};
+
 function isPlainObject(value: unknown): value is AnyRecord {
   return !!value && typeof value === "object" && !Array.isArray(value);
 }
@@ -40,6 +46,17 @@ function buildReasonCode(categoryId: string, detailId: string) {
   return `${canonicalId(categoryId)}__${canonicalId(detailId)}`.toUpperCase();
 }
 
+/** Uppercase official or derived code for this detail row. */
+export function detailEffectiveReasonCode(category: ReasonCatalogCategory, detail: ReasonCatalogDetail): string {
+  const explicit = String(detail.reasonCode ?? "").trim();
+  if (explicit) return explicit.toUpperCase();
+  return buildReasonCode(category.id, detail.id);
+}
+
+export function isDetailActive(detail: ReasonCatalogDetail): boolean {
+  return detail.active !== false;
+}
+
 function toCategory(raw: unknown): ReasonCatalogCategory | null {
   if (!isPlainObject(raw)) return null;
   const labelRaw = String(raw.label ?? "").trim();
@@ -57,7 +74,16 @@ function toCategory(raw: unknown): ReasonCatalogCategory | null {
     const detailLabel = String(detailRaw.label ?? "").trim();
     if (!detailLabel) continue;
     const detailId = String(detailRaw.id ?? "").trim() || canonicalId(detailLabel, "detail");
-    details.push({ id: detailId, label: detailLabel });
+    const reasonCodeRaw = detailRaw.reasonCode ?? detailRaw.code;
+    const reasonCode =
+      reasonCodeRaw != null && String(reasonCodeRaw).trim() ? String(reasonCodeRaw).trim() : undefined;
+    const active = detailRaw.active === false ? false : true;
+    details.push({
+      id: detailId,
+      label: detailLabel,
+      ...(reasonCode ? { reasonCode } : {}),
+      ...(active ? {} : { active: false }),
+    });
   }
 
   if (!details.length) return null;
@@ -131,7 +157,7 @@ export function parseReasonCatalogMarkdown(markdown: string): ReasonCatalog {
         details: [] as ReasonCatalogDetail[],
       };
     if (!existing.details.some((d) => d.id === detailId)) {
-      existing.details.push({ id: detailId, label: detailLabel });
+      existing.details.push({ id: detailId, label: detailLabel, active: true });
     }
     buckets[activeKind].set(categoryId, existing);
   }
@@ -143,29 +169,35 @@ export function parseReasonCatalogMarkdown(markdown: string): ReasonCatalog {
   };
 }
 
-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,
+  options?: FlattenReasonCatalogOptions
+) {
+  const activeOnly = options?.activeOnly === true;
+  return (catalog[kind] ?? []).flatMap((category) =>
+    category.details
+      .filter((d) => !activeOnly || isDetailActive(d))
+      .map((detail) => ({
+        kind,
+        categoryId: category.id,
+        categoryLabel: category.label,
+        detailId: detail.id,
+        detailLabel: detail.label,
+        reasonCode: detailEffectiveReasonCode(category, detail),
+        reasonLabel: `${category.label} > ${detail.label}`,
+        active: isDetailActive(detail),
+      }))
+  );
 }
 
-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} > ${detail.label}`,
-    }))
-  );
+function canonicalText(value: unknown) {
+  return String(value ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
 }
 
 export function findCatalogReason(
@@ -187,11 +219,38 @@ export function findCatalogReason(
     categoryLabel: category.label,
     detailId: detail.id,
     detailLabel: detail.label,
-    reasonCode: buildReasonCode(category.id, detail.id),
+    reasonCode: detailEffectiveReasonCode(category, detail),
     reasonLabel: `${category.label} > ${detail.label}`,
   };
 }
 
+/** Resolve category/detail + labels by official or derived reasonCode (includes inactive details). */
+export function findCatalogReasonByReasonCode(
+  catalog: ReasonCatalog | null | undefined,
+  kind: ReasonCatalogKind,
+  reasonCode: string | null | undefined
+) {
+  if (!catalog) return null;
+  const needle = String(reasonCode ?? "").trim().toUpperCase();
+  if (!needle) return null;
+  for (const category of catalog[kind] ?? []) {
+    for (const detail of category.details) {
+      const rc = detailEffectiveReasonCode(category, detail);
+      if (rc === needle) {
+        return {
+          categoryId: category.id,
+          categoryLabel: category.label,
+          detailId: detail.id,
+          detailLabel: detail.label,
+          reasonCode: rc,
+          reasonLabel: `${category.label} > ${detail.label}`,
+        };
+      }
+    }
+  }
+  return null;
+}
+
 export function toReasonCode(categoryId: unknown, detailId: unknown) {
   const cat = canonicalId(categoryId, "");
   const det = canonicalId(detailId, "");

lib/reasonCatalogDb.ts

@@ -0,0 +1,98 @@
+import type { Prisma } from "@prisma/client";
+import { prisma } from "@/lib/prisma";
+import type { ReasonCatalog, ReasonCatalogCategory, ReasonCatalogDetail } from "@/lib/reasonCatalog";
+import { normalizeReasonCatalog } from "@/lib/reasonCatalog";
+import { loadFallbackReasonCatalog } from "@/lib/reasonCatalogFallback";
+
+function isPlainObject(value: unknown): value is Record<string, unknown> {
+  return !!value && typeof value === "object" && !Array.isArray(value);
+}
+
+/**
+ * Full printed code from category prefix + operator numeric suffix (or suffix digits from seed).
+ * Downtime-style keys use a hyphen before the numeric part (e.g. DTPRC-01); short scrap-style
+ * prefixes (e.g. MX) concatenate without hyphen (MX001).
+ */
+export function composeReasonCode(prefix: string, suffix: string): string {
+  const p = String(prefix ?? "").trim().toUpperCase();
+  const s = String(suffix ?? "").trim();
+  if (/^\d+$/.test(s) && p.length >= 3) {
+    return `${p}-${s}`.toUpperCase();
+  }
+  return `${p}${s}`.toUpperCase();
+}
+
+export function isNumericSuffix(value: string): boolean {
+  return /^\d+$/.test(String(value ?? "").trim());
+}
+
+function mapKind(kind: string): "downtime" | "scrap" | null {
+  const k = String(kind).toLowerCase();
+  if (k === "downtime" || k === "scrap") return k;
+  return null;
+}
+
+/**
+ * Load catalog from Postgres tables. Returns null if org has no catalog rows yet.
+ * Includes inactive rows for historical label resolution (same as prior JSON behavior).
+ */
+export async function loadReasonCatalogFromDb(
+  orgId: string,
+  catalogVersion: number
+): Promise<ReasonCatalog | null> {
+  const rows = await prisma.reasonCatalogCategory.findMany({
+    where: { orgId },
+    include: {
+      items: { orderBy: { sortOrder: "asc" } },
+    },
+    orderBy: [{ kind: "asc" }, { sortOrder: "asc" }],
+  });
+  if (!rows.length) return null;
+
+  const downtime: ReasonCatalogCategory[] = [];
+  const scrap: ReasonCatalogCategory[] = [];
+
+  for (const cat of rows) {
+    const k = mapKind(cat.kind);
+    if (!k) continue;
+    const details: ReasonCatalogDetail[] = cat.items.map((it) => ({
+      id: it.id,
+      label: it.name,
+      reasonCode: it.reasonCode,
+      active: it.active,
+    }));
+    const bucket: ReasonCatalogCategory = {
+      id: cat.id,
+      label: cat.name,
+      details,
+    };
+    if (k === "downtime") downtime.push(bucket);
+    else scrap.push(bucket);
+  }
+
+  if (!downtime.length && !scrap.length) return null;
+  return { version: Math.max(1, catalogVersion), downtime, scrap };
+}
+
+/** DB first, then legacy JSON in defaults, then file fallback. */
+export async function effectiveReasonCatalogForOrg(
+  orgId: string,
+  defaultsJson: unknown,
+  settingsVersion: number
+): Promise<ReasonCatalog> {
+  const fromDb = await loadReasonCatalogFromDb(orgId, settingsVersion);
+  if (fromDb) return fromDb;
+
+  const defs = isPlainObject(defaultsJson) ? defaultsJson : {};
+  const fromJson = normalizeReasonCatalog(defs.reasonCatalog ?? defs.reasonCatalogData);
+  if (fromJson) return fromJson;
+
+  return loadFallbackReasonCatalog();
+}
+
+export async function bumpOrgSettingsVersion(tx: Prisma.TransactionClient, orgId: string, userId: string) {
+  await tx.orgSettings.update({
+    where: { orgId },
+    data: { version: { increment: 1 }, updatedBy: userId },
+  });
+}

lib/reasonCatalogFallback.ts

@@ -0,0 +1,15 @@
+import { readFile } from "fs/promises";
+import path from "path";
+import { parseReasonCatalogMarkdown, type ReasonCatalog } from "@/lib/reasonCatalog";
+
+let catalogPromise: Promise<ReasonCatalog> | null = null;
+
+/** Server-only: reads downtime_menu.md from the repo root. */
+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;
+}

lib/recap/getRecapData.ts

@@ -289,6 +289,7 @@ async function computeRecap(params: Required<Pick<RecapQuery, "orgId">> & {
           ts: true,
           cycleCount: true,
           workOrderId: true,
+          theoreticalCycleTime: true,
           sku: true,
           goodDelta: true,
           scrapDelta: true,

lib/recap/machineState.ts

@@ -23,9 +23,6 @@ export type MachineStateName =
   | "idle"
   | "running";
 
-export type StoppedReason = "machine_fault" | "not_started";
-export type DataLossReason = "untracked";
-
 export type MachineStateResult =
   | { state: "offline"; lastSeenMs: number | null; offlineForMin: number }
   | {
@@ -35,17 +32,9 @@ export type MachineStateResult =
     }
   | {
       state: "stopped";
-      reason: StoppedReason;
       ongoingStopMin: number;
       stopStartedAtMs: number | null;
     }
-  | {
-      state: "data-loss";
-      reason: DataLossReason;
-      untrackedCycleCount: number;
-      untrackedSinceMs: number | null;
-      untrackedForMin: number;
-    }
   | { state: "idle" }
   | { state: "running" };
 
@@ -74,8 +63,6 @@ export type MachineStateInputs = {
    * Caller computes by counting MachineCycle rows in the last UNTRACKED_WINDOW_MS
    * where ts > latestKpi.ts (so they're "after" the tracking-off snapshot).
    */
-  untrackedCycles: { count: number; oldestTsMs: number | null };
-
   /**
    * Most recent cycle timestamp regardless of tracking — used as a sanity check
    * for IDLE classification.
@@ -84,8 +71,7 @@ export type MachineStateInputs = {
 };
 
 // Trigger thresholds — tunable
-const DATA_LOSS_MIN_CYCLES = 5;
-const DATA_LOSS_MIN_DURATION_MS = 10 * 60 * 1000; // 10 min
+
 const RECENT_CYCLE_MS = 15 * 60 * 1000; // for IDLE check — "no cycles in 15 min"
 
 export function classifyMachineState(
@@ -116,51 +102,22 @@ export function classifyMachineState(
   // 3. DATA_LOSS — tracking off but cycles arriving. Operator forgot START.
   // Check this BEFORE STOPPED because cycles ARE arriving (so the "no cycles" branch
   // would never fire), but we still want to flag it.
-  if (!inputs.trackingEnabled && inputs.untrackedCycles.count > 0) {
-    const oldest = inputs.untrackedCycles.oldestTsMs;
-    const durationMs = oldest != null ? nowMs - oldest : 0;
-    const tripped =
-      inputs.untrackedCycles.count >= DATA_LOSS_MIN_CYCLES ||
-      durationMs >= DATA_LOSS_MIN_DURATION_MS;
-
-    if (tripped) {
-      return {
-        state: "data-loss",
-        reason: "untracked",
-        untrackedCycleCount: inputs.untrackedCycles.count,
-        untrackedSinceMs: oldest,
-        untrackedForMin: Math.max(0, Math.floor(durationMs / 60000)),
-      };
-    }
-    // Not yet tripped — fall through to other checks (likely RUNNING since cycles are coming)
-  }
 
   // 4. STOPPED — should be producing, isn't. Two reasons:
   //    a) machine_fault: operator pressed START, macrostop event active → mechanical issue
   //    b) not_started: operator never pressed START but a WO is loaded
-  if (inputs.activeMacrostop && inputs.trackingEnabled) {
+// 4. STOPPED — machine should be producing, isn't.
+  // The Pi only emits macrostop events when tracking is on AND a WO is active,
+  // so the presence of an active macrostop event is sufficient.
+  if (inputs.activeMacrostop) {
     const startedAt = inputs.activeMacrostop.startedAtMs;
     return {
       state: "stopped",
-      reason: "machine_fault",
       ongoingStopMin: Math.max(0, Math.floor((nowMs - startedAt) / 60000)),
       stopStartedAtMs: startedAt,
     };
   }
 
-  if (inputs.hasActiveWorkOrder && !inputs.trackingEnabled) {
-    // Operator hasn't started production despite a loaded WO.
-    // We don't have a precise "since when" for this — best estimate is "since latest
-    // KPI snapshot reported trackingEnabled=false," but that's not in the inputs.
-    // For now, report ongoingStopMin=0 and let the caller refine if needed.
-    return {
-      state: "stopped",
-      reason: "not_started",
-      ongoingStopMin: 0,
-      stopStartedAtMs: null,
-    };
-  }
-
   // 5. IDLE — no one expects this machine to be doing anything right now.
   // No tracking, no WO, no recent cycles. Calm gray.
   const cycledRecently =

lib/recap/timeline.ts

@@ -44,6 +44,7 @@ export type TimelineCycleRow = {
   ts: Date;
   cycleCount: number | null;
   actualCycleTime: number;
+  theoreticalCycleTime: number | null;
   workOrderId: string | null;
   sku: string | null;
 };
@@ -554,19 +555,21 @@ export function buildTimelineSegments(input: {
   let currentProduction: RawSegment | null = null;
   for (const cycle of dedupedCycles) {
     if (!cycle.workOrderId) continue;
-    const cycleStartMs = cycle.ts.getTime();
+    // Pi stores cycle.ts at COMPLETION time; the cycle ran in [ts - actual, ts].
+    const completionMs = cycle.ts.getTime();
     const cycleDurationMs = Math.max(
       1000,
       Math.min(600000, Math.trunc((safeNum(cycle.actualCycleTime) ?? 1) * 1000))
     );
-    const cycleEndMs = cycleStartMs + cycleDurationMs;
+    const cycleStartMs = completionMs - cycleDurationMs;
+    const cycleEndMs = completionMs;
 
     if (
       currentProduction &&
       currentProduction.type === "production" &&
       currentProduction.workOrderId === cycle.workOrderId &&
       currentProduction.sku === cycle.sku &&
-      cycleStartMs <= currentProduction.endMs + 5 * 60 * 1000
+      cycleStartMs <= currentProduction.endMs + MERGE_GAP_MS
     ) {
       currentProduction.endMs = Math.max(currentProduction.endMs, cycleEndMs);
       continue;
@@ -652,7 +655,11 @@ export function buildTimelineSegments(input: {
     episode.firstTsMs = Math.min(episode.firstTsMs, tsMs);
     episode.lastTsMs = Math.max(episode.lastTsMs, tsMs);
 
-    const startMs = safeNum(data.start_ms) ?? safeNum(data.startMs);
+    const startMs =
+      safeNum(data.start_ms) ??
+      safeNum(data.startMs) ??
+      safeNum(data.last_cycle_timestamp) ??
+      safeNum(data.lastCycleTimestamp);
     const endMs = safeNum(data.end_ms) ?? safeNum(data.endMs);
     const durationSec =
       safeNum(data.duration_sec) ??
@@ -679,7 +686,7 @@ export function buildTimelineSegments(input: {
   }
 
   for (const episode of eventEpisodes.values()) {
-    const startMs = Math.trunc(episode.startMs ?? episode.firstTsMs);
+    let startMs = Math.trunc(episode.startMs ?? episode.firstTsMs);
     let endMs = Math.trunc(episode.endMs ?? episode.lastTsMs);
 
     if (episode.statusActive && !episode.statusResolved) {
@@ -694,7 +701,13 @@ export function buildTimelineSegments(input: {
         }
       }
     } else if (endMs <= startMs && episode.durationSec != null && episode.durationSec > 0) {
-      endMs = startMs + episode.durationSec * 1000;
+      // Event ts is end-of-stop; subtract duration to recover start.
+      // Only adjust if we don't already have an explicit startMs from data.
+      if (episode.startMs == null) {
+        startMs = endMs - episode.durationSec * 1000;
+      } else {
+        endMs = startMs + episode.durationSec * 1000;
+      }
     }
 
     if (endMs <= startMs) continue;
@@ -730,7 +743,35 @@ export function buildTimelineSegments(input: {
   const clustered = absorbMicroStopClusters(withIdle, MICRO_CLUSTER_GAP_MS);
   const normalized = fillGapsWithIdle(clustered, rangeStartMs, rangeEndMs);
   const absorbed = absorbShortSegments(normalized, ABSORB_SHORT_SEGMENT_MS);
-  const finalSegments = fillGapsWithIdle(absorbed, rangeStartMs, rangeEndMs);
+ const finalSegments = fillGapsWithIdle(absorbed, rangeStartMs, rangeEndMs);
+
+  // Live tail: machine cycling now, last cycle not yet completed.
+  // Extend production through right edge until microstop threshold passes.
+  const lastCycle = dedupedCycles[dedupedCycles.length - 1];
+  const idealCT = safeNum(lastCycle?.theoreticalCycleTime) ?? 120;
+  const MICRO_MS = idealCT * 1.5 * 1000;
+
+  // Live-tail: extend whatever the last real state was, until microstop threshold passes.
+  if (finalSegments.length >= 2) {
+    const last = finalSegments[finalSegments.length - 1];
+    const prev = finalSegments[finalSegments.length - 2];
+    if (last.type === "idle" && last.endMs >= rangeEndMs - 2000) {
+      const gapMs = last.endMs - prev.endMs;
+      let shouldExtend = false;
+      if (prev.type === "production" && gapMs < MICRO_MS) {
+        // mid-cycle: still running up to microstop threshold
+        shouldExtend = true;
+      } else if (prev.type === "microstop" || prev.type === "macrostop") {
+        // stoppage in progress: extend until resolved/next cycle
+        shouldExtend = true;
+      }
+      if (shouldExtend) {
+        prev.endMs = last.endMs;
+        prev.durationSec = Math.max(0, Math.trunc((prev.endMs - prev.startMs) / 1000));
+        finalSegments.pop();
+      }
+    }
+  }
 
   return finalSegments;
 }

lib/recap/timelineApi.ts

@@ -105,6 +105,7 @@ export async function getRecapTimelineForMachine(params: {
         ts: true,
         cycleCount: true,
         actualCycleTime: true,
+        theoreticalCycleTime: true,
         workOrderId: true,
         sku: true,
       },
@@ -151,10 +152,10 @@ export async function getRecapTimelineForMachine(params: {
     ts: row.ts,
     cycleCount: row.cycleCount,
     actualCycleTime: row.actualCycleTime,
+    theoreticalCycleTime: row.theoreticalCycleTime,
     workOrderId: row.workOrderId,
     sku: row.sku,
   }));
-
   const events: TimelineEventRow[] = eventsRaw.map((row) => ({
     ts: row.ts,
     eventType: row.eventType,

lib/recap/types.ts

@@ -121,23 +121,14 @@ export type RecapQuery = {
   shift?: string;
 };
 
-export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "data-loss" | "offline" | "idle";
-
-export type RecapStoppedReason = "machine_fault" | "not_started";
-export type RecapDataLossReason = "untracked";
+export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "offline" | "idle";
 
 /**
- * Reason context for STOPPED and DATA_LOSS states.
- * - When status is "stopped": stoppedReason is set, dataLossReason is null.
- * - When status is "data-loss": dataLossReason is set, stoppedReason is null.
- * - All other states: both are null.
+ * Reason context — currently empty in practice because the only STOPPED cause
+ * we can detect (given Node-RED's constraints) is machine_fault. Kept as a
+ * struct so future expansion doesn't require a type change downstream.
  */
-export type RecapStateContext = {
-  stoppedReason: RecapStoppedReason | null;
-  dataLossReason: RecapDataLossReason | null;
-  /** For data-loss: how many untracked cycles have been detected so far. */
-  untrackedCycleCount: number | null;
-};
+export type RecapStateContext = Record<string, never>;
 
 
 export type RecapSummaryMachine = {

lib/settings.ts

@@ -81,10 +81,6 @@ export function buildSettingsPayload(settings: SettingsRow, shifts: ShiftRow[])
   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,
@@ -105,9 +101,6 @@ export function buildSettingsPayload(settings: SettingsRow, shifts: ShiftRow[])
     },
     alerts: normalizeAlerts(settings.alertsJson),
     defaults,
-    reasonCatalog: reasonCatalog ?? undefined,
-    reasonCatalogData: reasonCatalog ?? undefined,
-    reasonCatalogVersion: Number((reasonCatalog as AnyRecord | null)?.version ?? 1),
     updatedAt: settings.updatedAt,
     updatedBy: settings.updatedBy,
   };