Mobile friendly, lint correction, typescript error clear
This commit is contained in:
Marcelo
418
lib/financial/impact.ts
Normal file
418
lib/financial/impact.ts
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import { prisma } from "@/lib/prisma";
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const COST_EVENT_TYPES = ["slow-cycle", "microstop", "macrostop", "quality-spike"] as const;
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type CostProfile = {
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currency: string;
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machineCostPerMin: number | null;
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operatorCostPerMin: number | null;
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ratedRunningKw: number | null;
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idleKw: number | null;
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kwhRate: number | null;
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energyMultiplier: number | null;
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energyCostPerMin: number | null;
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scrapCostPerUnit: number | null;
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rawMaterialCostPerUnit: number | null;
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};
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type CostProfileOverride = Omit<Partial<CostProfile>, "currency">;
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type Category = "slowCycle" | "microstop" | "macrostop" | "scrap";
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type Totals = { total: number } & Record<Category, number>;
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type DayRow = { day: string } & Totals;
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export type FinancialEventDetail = {
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id: string;
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ts: Date;
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eventType: string;
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status: string;
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severity: string;
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category: Category;
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machineId: string;
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machineName: string | null;
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location: string | null;
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workOrderId: string | null;
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sku: string | null;
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durationSec: number | null;
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costMachine: number;
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costOperator: number;
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costEnergy: number;
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costScrap: number;
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costRawMaterial: number;
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costTotal: number;
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currency: string;
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};
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export type FinancialImpactSummary = {
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currency: string;
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totals: Totals;
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byDay: DayRow[];
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};
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export type FinancialImpactResult = {
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range: { start: Date; end: Date };
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currencySummaries: FinancialImpactSummary[];
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eventsEvaluated: number;
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eventsIncluded: number;
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events: FinancialEventDetail[];
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filters: {
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machineId?: string;
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location?: string;
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sku?: string;
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currency?: string;
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};
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};
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export type FinancialImpactParams = {
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orgId: string;
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start: Date;
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end: Date;
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machineId?: string;
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location?: string;
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sku?: string;
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currency?: string;
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includeEvents?: boolean;
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};
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function safeNumber(value: unknown) {
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const n = typeof value === "number" ? value : Number(value);
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return Number.isFinite(n) ? n : null;
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}
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function parseBlob(raw: unknown) {
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let parsed: unknown = raw;
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if (typeof raw === "string") {
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try {
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parsed = JSON.parse(raw);
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} catch {
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parsed = raw;
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}
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}
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const blob = Array.isArray(parsed) ? parsed[0] : parsed;
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const blobRecord = typeof blob === "object" && blob !== null ? (blob as Record<string, unknown>) : null;
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const innerCandidate = blobRecord?.data ?? blobRecord ?? {};
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const inner =
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typeof innerCandidate === "object" && innerCandidate !== null
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? (innerCandidate as Record<string, unknown>)
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: {};
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return { blob: blobRecord, inner } as const;
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}
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function dateKey(ts: Date) {
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return ts.toISOString().slice(0, 10);
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}
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function applyOverride(
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base: CostProfile,
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override?: CostProfileOverride | null,
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currency?: string | null
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) {
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const out: CostProfile = { ...base };
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if (currency) out.currency = currency;
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if (!override) return out;
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if (override.machineCostPerMin != null) out.machineCostPerMin = override.machineCostPerMin;
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if (override.operatorCostPerMin != null) out.operatorCostPerMin = override.operatorCostPerMin;
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if (override.ratedRunningKw != null) out.ratedRunningKw = override.ratedRunningKw;
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if (override.idleKw != null) out.idleKw = override.idleKw;
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if (override.kwhRate != null) out.kwhRate = override.kwhRate;
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if (override.energyMultiplier != null) out.energyMultiplier = override.energyMultiplier;
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if (override.energyCostPerMin != null) out.energyCostPerMin = override.energyCostPerMin;
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if (override.scrapCostPerUnit != null) out.scrapCostPerUnit = override.scrapCostPerUnit;
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if (override.rawMaterialCostPerUnit != null) out.rawMaterialCostPerUnit = override.rawMaterialCostPerUnit;
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return out;
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}
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function computeEnergyCostPerMin(profile: CostProfile, mode: "running" | "idle") {
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if (profile.energyCostPerMin != null) return profile.energyCostPerMin;
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const kw = mode === "running" ? profile.ratedRunningKw : profile.idleKw;
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const rate = profile.kwhRate;
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if (kw == null || rate == null) return null;
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const multiplier = profile.energyMultiplier ?? 1;
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return (kw / 60) * rate * multiplier;
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}
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export async function computeFinancialImpact(params: FinancialImpactParams): Promise<FinancialImpactResult> {
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const { orgId, start, end, machineId, location, sku, currency, includeEvents } = params;
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const machines = await prisma.machine.findMany({
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where: { orgId },
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select: { id: true, name: true, location: true },
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});
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const machineMap = new Map(machines.map((m) => [m.id, m]));
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let machineIds = machines.map((m) => m.id);
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if (location) {
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machineIds = machines.filter((m) => m.location === location).map((m) => m.id);
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}
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if (machineId) {
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machineIds = machineIds.includes(machineId) ? [machineId] : [];
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}
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if (!machineIds.length) {
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return {
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range: { start, end },
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currencySummaries: [],
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eventsEvaluated: 0,
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eventsIncluded: 0,
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events: [],
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filters: { machineId, location, sku, currency },
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};
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}
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const events = await prisma.machineEvent.findMany({
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where: {
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orgId,
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ts: { gte: start, lte: end },
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machineId: { in: machineIds },
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eventType: { in: COST_EVENT_TYPES as unknown as string[] },
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},
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orderBy: { ts: "asc" },
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select: {
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id: true,
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ts: true,
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eventType: true,
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data: true,
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machineId: true,
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workOrderId: true,
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sku: true,
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severity: true,
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},
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});
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const missingSkuPairs = events
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.filter((e) => !e.sku && e.workOrderId)
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.map((e) => ({ machineId: e.machineId, workOrderId: e.workOrderId as string }));
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const workOrderIds = Array.from(new Set(missingSkuPairs.map((p) => p.workOrderId)));
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const workOrderMachines = Array.from(new Set(missingSkuPairs.map((p) => p.machineId)));
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const workOrders = workOrderIds.length
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? await prisma.machineWorkOrder.findMany({
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where: {
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orgId,
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workOrderId: { in: workOrderIds },
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machineId: { in: workOrderMachines },
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},
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select: { machineId: true, workOrderId: true, sku: true },
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})
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: [];
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const workOrderSku = new Map<string, string>();
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for (const row of workOrders) {
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if (row.sku) {
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workOrderSku.set(`${row.machineId}:${row.workOrderId}`, row.sku);
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}
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}
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const [orgProfileRaw, locationOverrides, machineOverrides, productOverrides] = await Promise.all([
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prisma.orgFinancialProfile.findUnique({ where: { orgId } }),
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prisma.locationFinancialOverride.findMany({ where: { orgId } }),
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prisma.machineFinancialOverride.findMany({ where: { orgId } }),
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prisma.productCostOverride.findMany({ where: { orgId } }),
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]);
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const orgProfile: CostProfile = {
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currency: orgProfileRaw?.defaultCurrency ?? "USD",
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machineCostPerMin: orgProfileRaw?.machineCostPerMin ?? null,
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operatorCostPerMin: orgProfileRaw?.operatorCostPerMin ?? null,
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ratedRunningKw: orgProfileRaw?.ratedRunningKw ?? null,
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idleKw: orgProfileRaw?.idleKw ?? null,
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kwhRate: orgProfileRaw?.kwhRate ?? null,
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energyMultiplier: orgProfileRaw?.energyMultiplier ?? 1,
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energyCostPerMin: orgProfileRaw?.energyCostPerMin ?? null,
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scrapCostPerUnit: orgProfileRaw?.scrapCostPerUnit ?? null,
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rawMaterialCostPerUnit: orgProfileRaw?.rawMaterialCostPerUnit ?? null,
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};
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const locationMap = new Map(locationOverrides.map((o) => [o.location, o]));
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const machineOverrideMap = new Map(machineOverrides.map((o) => [o.machineId, o]));
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const productMap = new Map(productOverrides.map((o) => [o.sku, o]));
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const summaries = new Map<
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string,
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{
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currency: string;
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totals: Totals;
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byDay: Map<string, DayRow>;
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}
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>();
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const detailed: FinancialEventDetail[] = [];
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let eventsIncluded = 0;
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for (const ev of events) {
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const eventType = String(ev.eventType ?? "").toLowerCase();
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const { blob, inner } = parseBlob(ev.data);
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const status = String(blob?.status ?? inner?.status ?? "").toLowerCase();
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const severity = String(ev.severity ?? "").toLowerCase();
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const isAutoAck = Boolean(blob?.is_auto_ack ?? inner?.is_auto_ack);
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const isUpdate = Boolean(blob?.is_update ?? inner?.is_update);
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const machine = machineMap.get(ev.machineId);
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const locationName = machine?.location ?? null;
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const skuResolved =
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ev.sku ??
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(ev.workOrderId ? workOrderSku.get(`${ev.machineId}:${ev.workOrderId}`) : null) ??
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null;
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if (sku && skuResolved !== sku) continue;
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if (isAutoAck || isUpdate) continue;
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const locationOverride = locationName ? locationMap.get(locationName) : null;
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const machineOverride = machineOverrideMap.get(ev.machineId) ?? null;
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let profile = applyOverride(orgProfile, locationOverride, locationOverride?.currency ?? null);
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profile = applyOverride(profile, machineOverride, machineOverride?.currency ?? null);
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const productOverride = skuResolved ? productMap.get(skuResolved) : null;
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if (productOverride?.rawMaterialCostPerUnit != null) {
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profile.rawMaterialCostPerUnit = productOverride.rawMaterialCostPerUnit;
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}
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if (productOverride?.currency) {
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profile.currency = productOverride.currency;
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}
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let category: Category | null = null;
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let durationSec: number | null = null;
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let costMachine = 0;
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let costOperator = 0;
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let costEnergy = 0;
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let costScrap = 0;
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let costRawMaterial = 0;
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if (eventType === "slow-cycle") {
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const actual =
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safeNumber(inner?.actual_cycle_time ?? blob?.actual_cycle_time ?? inner?.actualCycleTime ?? blob?.actualCycleTime) ??
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null;
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const theoretical =
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safeNumber(
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inner?.theoretical_cycle_time ??
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blob?.theoretical_cycle_time ??
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inner?.theoreticalCycleTime ??
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blob?.theoreticalCycleTime
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) ?? null;
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if (actual == null || theoretical == null) continue;
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durationSec = Math.max(0, actual - theoretical);
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if (!durationSec) continue;
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const durationMin = durationSec / 60;
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costMachine = durationMin * (profile.machineCostPerMin ?? 0);
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costOperator = durationMin * (profile.operatorCostPerMin ?? 0);
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costEnergy = durationMin * (computeEnergyCostPerMin(profile, "running") ?? 0);
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category = "slowCycle";
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} else if (eventType === "microstop" || eventType === "macrostop") {
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//future activestoppage handling
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if (status === "active") continue;
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const rawDurationSec =
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safeNumber(
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inner?.stoppage_duration_seconds ??
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blob?.stoppage_duration_seconds ??
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inner?.stop_duration_seconds ??
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blob?.stop_duration_seconds
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) ?? 0;
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if (!rawDurationSec || rawDurationSec <= 0) continue;
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const theoreticalSec =
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safeNumber(
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inner?.theoretical_cycle_time ??
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blob?.theoretical_cycle_time ??
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inner?.theoreticalCycleTime ??
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blob?.theoreticalCycleTime
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) ?? null;
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const lastCycleTimestamp = safeNumber(inner?.last_cycle_timestamp ?? blob?.last_cycle_timestamp);
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const isCycleGapStop = theoreticalSec != null && theoreticalSec > 0 && lastCycleTimestamp == null;
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durationSec = isCycleGapStop ? Math.max(0, rawDurationSec - theoreticalSec) : rawDurationSec;
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if (!durationSec || durationSec <= 0) continue;
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const durationMin = durationSec / 60;
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costMachine = durationMin * (profile.machineCostPerMin ?? 0);
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costOperator = durationMin * (profile.operatorCostPerMin ?? 0);
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costEnergy = durationMin * (computeEnergyCostPerMin(profile, "idle") ?? 0);
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category = eventType === "macrostop" ? "macrostop" : "microstop";
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} else if (eventType === "quality-spike") {
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if (severity === "info" || status === "resolved") continue;
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const scrapParts =
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safeNumber(
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inner?.scrap_parts ??
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blob?.scrap_parts ??
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inner?.scrapParts ??
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blob?.scrapParts
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) ?? 0;
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if (scrapParts <= 0) continue;
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costScrap = scrapParts * (profile.scrapCostPerUnit ?? 0);
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costRawMaterial = scrapParts * (profile.rawMaterialCostPerUnit ?? 0);
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category = "scrap";
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}
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if (!category) continue;
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const costTotal = costMachine + costOperator + costEnergy + costScrap + costRawMaterial;
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if (costTotal <= 0) continue;
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if (currency && profile.currency !== currency) continue;
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const key = profile.currency || "USD";
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const bucket = summaries.get(key) ?? {
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currency: key,
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totals: { total: 0, slowCycle: 0, microstop: 0, macrostop: 0, scrap: 0 },
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byDay: new Map<string, DayRow>(),
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};
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bucket.totals.total += costTotal;
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bucket.totals[category] += costTotal;
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const day = dateKey(ev.ts);
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const dayRow: DayRow = bucket.byDay.get(day) ?? {
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day,
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total: 0,
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slowCycle: 0,
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microstop: 0,
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macrostop: 0,
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scrap: 0,
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};
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dayRow.total += costTotal;
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dayRow[category] += costTotal;
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bucket.byDay.set(day, dayRow);
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summaries.set(key, bucket);
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eventsIncluded += 1;
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if (includeEvents) {
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detailed.push({
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id: ev.id,
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ts: ev.ts,
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eventType,
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status,
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severity,
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category,
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machineId: ev.machineId,
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machineName: machine?.name ?? null,
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location: locationName,
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workOrderId: ev.workOrderId ?? null,
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sku: skuResolved,
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durationSec,
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costMachine,
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costOperator,
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costEnergy,
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costScrap,
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costRawMaterial,
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costTotal,
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currency: key,
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});
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}
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}
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const currencySummaries = Array.from(summaries.values()).map((summary) => {
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const byDay = Array.from(summary.byDay.values()).sort((a, b) => {
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return String(a.day).localeCompare(String(b.day));
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});
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return { currency: summary.currency, totals: summary.totals, byDay };
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});
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return {
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range: { start, end },
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currencySummaries,
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eventsEvaluated: events.length,
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eventsIncluded,
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events: detailed,
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filters: { machineId, location, sku, currency },
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};
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}
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