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Marcelo Dares
368
app/api/reports/route.ts
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368
app/api/reports/route.ts
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import { NextResponse } from "next/server";
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import type { NextRequest } from "next/server";
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import { prisma } from "@/lib/prisma";
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import { requireSession } from "@/lib/auth/requireSession";
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const RANGE_MS: Record<string, number> = {
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"24h": 24 * 60 * 60 * 1000,
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"7d": 7 * 24 * 60 * 60 * 1000,
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"30d": 30 * 24 * 60 * 60 * 1000,
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};
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function parseDate(input?: string | null) {
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if (!input) return null;
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const n = Number(input);
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if (!Number.isNaN(n)) return new Date(n);
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const d = new Date(input);
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return Number.isNaN(d.getTime()) ? null : d;
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}
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function pickRange(req: NextRequest) {
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const url = new URL(req.url);
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const range = url.searchParams.get("range") ?? "24h";
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const now = new Date();
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if (range === "custom") {
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const start = parseDate(url.searchParams.get("start")) ?? new Date(now.getTime() - RANGE_MS["24h"]);
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const end = parseDate(url.searchParams.get("end")) ?? now;
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return { start, end };
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}
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const ms = RANGE_MS[range] ?? RANGE_MS["24h"];
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return { start: new Date(now.getTime() - ms), end: now };
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}
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function safeNum(v: unknown) {
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return typeof v === "number" && Number.isFinite(v) ? v : null;
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}
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export async function GET(req: NextRequest) {
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const session = await requireSession();
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if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
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const url = new URL(req.url);
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const machineId = url.searchParams.get("machineId") ?? undefined;
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const { start, end } = pickRange(req);
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const workOrderId = url.searchParams.get("workOrderId") ?? undefined;
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const sku = url.searchParams.get("sku") ?? undefined;
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const baseWhere = {
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orgId: session.orgId,
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...(machineId ? { machineId } : {}),
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...(workOrderId ? { workOrderId } : {}),
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...(sku ? { sku } : {}),
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};
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const kpiRows = await prisma.machineKpiSnapshot.findMany({
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where: { ...baseWhere, ts: { gte: start, lte: end } },
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orderBy: { ts: "asc" },
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select: {
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ts: true,
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oee: true,
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availability: true,
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performance: true,
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quality: true,
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good: true,
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scrap: true,
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target: true,
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machineId: true,
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},
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});
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let oeeSum = 0;
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let oeeCount = 0;
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let availSum = 0;
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let availCount = 0;
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let perfSum = 0;
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let perfCount = 0;
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let qualSum = 0;
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let qualCount = 0;
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for (const k of kpiRows) {
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if (safeNum(k.oee) != null) {
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oeeSum += Number(k.oee);
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oeeCount += 1;
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}
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if (safeNum(k.availability) != null) {
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availSum += Number(k.availability);
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availCount += 1;
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}
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if (safeNum(k.performance) != null) {
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perfSum += Number(k.performance);
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perfCount += 1;
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}
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if (safeNum(k.quality) != null) {
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qualSum += Number(k.quality);
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qualCount += 1;
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}
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}
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const cycles = await prisma.machineCycle.findMany({
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where: { ...baseWhere, ts: { gte: start, lte: end } },
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select: { goodDelta: true, scrapDelta: true },
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});
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let goodTotal = 0;
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let scrapTotal = 0;
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for (const c of cycles) {
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if (safeNum(c.goodDelta) != null) goodTotal += Number(c.goodDelta);
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if (safeNum(c.scrapDelta) != null) scrapTotal += Number(c.scrapDelta);
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}
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const kpiAgg = await prisma.machineKpiSnapshot.groupBy({
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by: ["machineId"],
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where: { ...baseWhere, ts: { gte: start, lte: end } },
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_max: { good: true, scrap: true, target: true },
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_min: { good: true, scrap: true },
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_count: { _all: true },
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});
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let targetTotal = 0;
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if (goodTotal === 0 && scrapTotal === 0) {
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let goodFallback = 0;
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let scrapFallback = 0;
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for (const row of kpiAgg) {
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const count = row._count._all ?? 0;
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const maxGood = safeNum(row._max.good);
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const minGood = safeNum(row._min.good);
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const maxScrap = safeNum(row._max.scrap);
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const minScrap = safeNum(row._min.scrap);
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if (count > 1 && maxGood != null && minGood != null) {
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goodFallback += Math.max(0, maxGood - minGood);
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} else if (maxGood != null) {
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goodFallback += maxGood;
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}
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if (count > 1 && maxScrap != null && minScrap != null) {
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scrapFallback += Math.max(0, maxScrap - minScrap);
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} else if (maxScrap != null) {
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scrapFallback += maxScrap;
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}
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}
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goodTotal = goodFallback;
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scrapTotal = scrapFallback;
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}
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for (const row of kpiAgg) {
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const maxTarget = safeNum(row._max.target);
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if (maxTarget != null) targetTotal += maxTarget;
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}
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const events = await prisma.machineEvent.findMany({
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where: { ...baseWhere, ts: { gte: start, lte: end } },
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select: { eventType: true, data: true },
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});
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let macrostopSec = 0;
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let microstopSec = 0;
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let slowCycleCount = 0;
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let qualitySpikeCount = 0;
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let performanceDegradationCount = 0;
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let oeeDropCount = 0;
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for (const e of events) {
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const type = String(e.eventType ?? "").toLowerCase();
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let blob: any = e.data;
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if (typeof blob === "string") {
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try {
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blob = JSON.parse(blob);
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} catch {
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blob = null;
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}
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}
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const inner = blob?.data ?? blob ?? {};
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const stopSec =
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(typeof inner?.stoppage_duration_seconds === "number" && inner.stoppage_duration_seconds) ||
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(typeof inner?.stop_duration_seconds === "number" && inner.stop_duration_seconds) ||
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0;
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if (type === "macrostop") macrostopSec += Number(stopSec) || 0;
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else if (type === "microstop") microstopSec += Number(stopSec) || 0;
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else if (type === "slow-cycle") slowCycleCount += 1;
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else if (type === "quality-spike") qualitySpikeCount += 1;
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else if (type === "performance-degradation") performanceDegradationCount += 1;
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else if (type === "oee-drop") oeeDropCount += 1;
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}
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type TrendPoint = { t: string; v: number };
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const trend: {
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oee: TrendPoint[];
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availability: TrendPoint[];
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performance: TrendPoint[];
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quality: TrendPoint[];
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scrapRate: TrendPoint[];
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} = {
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oee: [],
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availability: [],
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performance: [],
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quality: [],
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scrapRate: [],
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};
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for (const k of kpiRows) {
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const t = k.ts.toISOString();
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if (safeNum(k.oee) != null) trend.oee.push({ t, v: Number(k.oee) });
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if (safeNum(k.availability) != null) trend.availability.push({ t, v: Number(k.availability) });
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if (safeNum(k.performance) != null) trend.performance.push({ t, v: Number(k.performance) });
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if (safeNum(k.quality) != null) trend.quality.push({ t, v: Number(k.quality) });
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const good = safeNum(k.good);
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const scrap = safeNum(k.scrap);
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if (good != null && scrap != null && good + scrap > 0) {
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trend.scrapRate.push({ t, v: (scrap / (good + scrap)) * 100 });
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}
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}
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const cycleRows = await prisma.machineCycle.findMany({
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where: { ...baseWhere, ts: { gte: start, lte: end } },
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select: { actualCycleTime: true },
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});
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const values = cycleRows
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.map((c) => Number(c.actualCycleTime))
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.filter((v) => Number.isFinite(v) && v > 0)
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.sort((a, b) => a - b);
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let cycleTimeBins: {
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label: string;
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count: number;
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rangeStart?: number;
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rangeEnd?: number;
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overflow?: "low" | "high";
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minValue?: number;
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maxValue?: number;
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}[] = [];
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if (values.length) {
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const pct = (p: number) => {
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const idx = Math.max(0, Math.min(values.length - 1, Math.floor(p * (values.length - 1))));
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return values[idx];
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};
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const p5 = pct(0.05);
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const p95 = pct(0.95);
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const inRange = values.filter((v) => v >= p5 && v <= p95);
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const low = values.filter((v) => v < p5);
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const high = values.filter((v) => v > p95);
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const binCount = 10;
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const span = Math.max(0.1, p95 - p5);
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const step = span / binCount;
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const counts = new Array(binCount).fill(0);
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for (const v of inRange) {
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const idx = Math.min(binCount - 1, Math.floor((v - p5) / step));
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counts[idx] += 1;
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}
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const decimals = step < 0.1 ? 2 : step < 1 ? 1 : 0;
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cycleTimeBins = counts.map((count, i) => {
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const a = p5 + step * i;
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const b = p5 + step * (i + 1);
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return {
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label: `${a.toFixed(decimals)}-${b.toFixed(decimals)}s`,
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count,
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rangeStart: a,
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rangeEnd: b,
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};
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});
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if (low.length) {
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cycleTimeBins.unshift({
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label: `< ${p5.toFixed(1)}s`,
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count: low.length,
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rangeEnd: p5,
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overflow: "low",
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minValue: low[0],
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maxValue: low[low.length - 1],
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});
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}
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if (high.length) {
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cycleTimeBins.push({
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label: `> ${p95.toFixed(1)}s`,
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count: high.length,
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rangeStart: p95,
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overflow: "high",
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minValue: high[0],
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maxValue: high[high.length - 1],
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});
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}
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}
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const scrapRate =
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goodTotal + scrapTotal > 0 ? (scrapTotal / (goodTotal + scrapTotal)) * 100 : null;
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// top scrap SKU / work order (from cycles)
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const scrapBySku = new Map<string, number>();
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const scrapByWo = new Map<string, number>();
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const scrapRows = await prisma.machineCycle.findMany({
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where: { ...baseWhere, ts: { gte: start, lte: end } },
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select: { sku: true, workOrderId: true, scrapDelta: true },
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});
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for (const row of scrapRows) {
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const scrap = safeNum(row.scrapDelta);
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if (scrap == null || scrap <= 0) continue;
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if (row.sku) scrapBySku.set(row.sku, (scrapBySku.get(row.sku) ?? 0) + scrap);
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if (row.workOrderId) scrapByWo.set(row.workOrderId, (scrapByWo.get(row.workOrderId) ?? 0) + scrap);
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}
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const topScrapSku = [...scrapBySku.entries()].sort((a, b) => b[1] - a[1])[0]?.[0] ?? null;
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const topScrapWorkOrder = [...scrapByWo.entries()].sort((a, b) => b[1] - a[1])[0]?.[0] ?? null;
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const oeeAvg = oeeCount ? oeeSum / oeeCount : null;
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const availabilityAvg = availCount ? availSum / availCount : null;
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const performanceAvg = perfCount ? perfSum / perfCount : null;
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const qualityAvg = qualCount ? qualSum / qualCount : null;
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// insights
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const insights: string[] = [];
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if (scrapRate != null && scrapRate > 5) insights.push(`Scrap rate is ${scrapRate.toFixed(1)}% (above 5%).`);
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if (performanceAvg != null && performanceAvg < 85) insights.push("Performance below 85%.");
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if (availabilityAvg != null && availabilityAvg < 85) insights.push("Availability below 85%.");
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if (oeeAvg != null && oeeAvg < 85) insights.push("OEE below 85%.");
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if (macrostopSec > 1800) insights.push("Macrostop time exceeds 30 minutes in this range.");
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return NextResponse.json({
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ok: true,
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summary: {
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oeeAvg,
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availabilityAvg,
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performanceAvg,
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qualityAvg,
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goodTotal,
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scrapTotal,
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targetTotal,
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scrapRate,
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topScrapSku,
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topScrapWorkOrder,
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},
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downtime: {
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macrostopSec,
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microstopSec,
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slowCycleCount,
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qualitySpikeCount,
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performanceDegradationCount,
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oeeDropCount,
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},
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trend,
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insights,
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distribution: {
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cycleTime: cycleTimeBins
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},
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});
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}
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