Downtime catalog

MACHINE_STATE_PROGRESS.md

@@ -0,0 +1,43 @@
+# Machine State Progress
+
+## Final State Model (5 states + sub-reasons)
+
+| State | Color | Trigger |
+|---|---|---|
+| OFFLINE | dark gray | Heartbeat dead >2 min |
+| STOPPED | red, pulse >5min | Active WO + no cycles (regardless of tracking) |
+| - reason `machine_fault` | | Tracking on, macrostop event active |
+| - reason `not_started` | | Tracking off, has WO |
+| DATA_LOSS | red + icon, pulse | Tracking off + cycles arriving (>5 cycles or >10 min) |
+| MOLD_CHANGE | blue | Active mold-change event |
+| - sub at >3h | yellow accent | (Round 2) |
+| - sub at >5h | red accent | (Round 2) |
+| IDLE | calm gray | No tracking, no WO, no cycles |
+| RUNNING | green | Tracking + WO + recent cycles |
+
+## Round 1 — Foundation: classifier + IDLE + STOPPED collapse + DATA_LOSS
+- [x] Step 1: Add `"idle"` and `"data-loss"` to `RecapMachineStatus` union
+- [x] Step 2: Create `lib/recap/machineState.ts` shared classifier with all reasons
+- [x] Step 3: Refactor `statusFromMachine` in redesign.ts to call classifier
+- [x] Step 4: Plumb new fields (status reason, ongoing min) through types/responses
+- [x] Step 5: UI rendering: IDLE (calm gray) on /recap, /machines, detail
+- [x] Step 6: UI rendering: DATA_LOSS (red + icon) on all surfaces
+- [x] Step 7: STOPPED reason text: show `not_started` vs `machine_fault` distinction
+- [x] Step 8: i18n keys (en + es-MX)
+- [x] Step 9: End-to-end verify each state transitions correctly
+
+## Round 2 — Mold change duration escalation (CT-only)
+- [ ] MOLD_CHANGE >3h yellow accent
+- [ ] MOLD_CHANGE >5h red accent
+- [ ] i18n strings
+
+## Notes / parked items
+- Prisma drift on (orgId,machineId,seq) unique indexes — pre-existing, not related to this work. Address as separate housekeeping task.
+- Node-RED incidentKey rotation behavior verified: 10 distinct keys per real stoppage = correct.
+
+## Path A — dead state cleanup (post Round 1)
+- [x] Removed `not_started` and `data-loss` branches from classifier
+- [x] Removed `RecapStoppedReason` and `RecapDataLossReason` types
+- [x] Simplified `RecapStateContext` to empty struct (kept for future use)
+- [x] Updated UI rendering: 5 states only (offline/stopped/mold-change/idle/running)
+- [x] i18n: removed dead keys

app/(app)/machines/MachinesClient.tsx

@@ -19,6 +19,12 @@ type MachineRow = {
     ip?: string | null;
     fwVersion?: string | null;
   };
+  latestMacrostop?: null | {
+    machineId: string;
+    ts: string;
+    status: "active" | "resolved" | "unknown";
+    startedAtMs: number;
+  };
 };
 const LIVE_REFRESH_MS = 5000;
 const OFFLINE_MS = RECAP_HEARTBEAT_STALE_MS;
@@ -51,6 +57,21 @@ function badgeClass(status?: string, offline?: boolean) {
   return "bg-white/10 text-white";
 }
 
+const MACROSTOP_FRESH_MS = 2 * 60 * 1000;
+
+function isMacrostopActive(macrostop: MachineRow["latestMacrostop"]) {
+  if (!macrostop) return false;
+  if (macrostop.status !== "active") return false;
+  // Fresh if last refresh was within 2 min — Node-RED refreshes every 10s,
+  // so anything older means the stoppage already ended without resolution event.
+  return Date.now() - new Date(macrostop.ts).getTime() <= MACROSTOP_FRESH_MS;
+}
+
+function ongoingMacrostopMin(macrostop: MachineRow["latestMacrostop"]) {
+  if (!macrostop) return 0;
+  return Math.max(0, Math.floor((Date.now() - macrostop.startedAtMs) / 60000));
+}
+
 export default function MachinesClient({ initialMachines = [] }: { initialMachines?: MachineRow[] }) {
   const { t, locale } = useI18n();
   const router = useRouter();
@@ -292,9 +313,28 @@ export default function MachinesClient({ initialMachines = [] }: { initialMachin
           const hbTs = hb?.tsServer ?? hb?.ts;
           const offline = isOffline(hbTs);
           const normalizedStatus = normalizeStatus(hb?.status);
-          const statusLabel = offline ? t("machines.status.offline") : (normalizedStatus || t("machines.status.unknown"));
           const lastSeen = secondsAgo(hbTs, locale, t("common.never"));
 
+          const macrostopActive = isMacrostopActive(m.latestMacrostop);
+          const stoppedMin = macrostopActive ? ongoingMacrostopMin(m.latestMacrostop) : 0;
+
+          // Production-state badge: STOPPED if active macrostop, else heartbeat-based.
+          const productionBadgeLabel = offline
+            ? t("machines.status.offline")
+            : macrostopActive
+            ? t("machines.status.stopped")
+            : (normalizedStatus || t("machines.status.unknown"));
+
+          const productionBadgeClass = offline
+            ? "bg-white/10 text-zinc-300"
+            : macrostopActive
+            ? "bg-red-500/20 text-red-200 ring-2 ring-red-500/50 animate-pulse"
+            : badgeClass(normalizedStatus, offline);
+
+          const cardClass = macrostopActive
+            ? "cursor-pointer rounded-2xl border border-red-500/60 bg-red-500/10 p-5 ring-2 ring-red-500/40 animate-pulse hover:bg-red-500/15"
+            : "cursor-pointer rounded-2xl border border-white/10 bg-white/5 p-5 hover:bg-white/10";
+
           return (
             <div
               key={m.id}
@@ -302,7 +342,7 @@ export default function MachinesClient({ initialMachines = [] }: { initialMachin
               tabIndex={0}
               onClick={() => router.push(`/machines/${m.id}`)}
               onKeyDown={(event) => handleCardKeyDown(event, m.id)}
-              className="cursor-pointer rounded-2xl border border-white/10 bg-white/5 p-5 hover:bg-white/10"
+              className={cardClass}
             >
               <div className="flex items-center justify-between gap-3">
                 <div className="min-w-0">
@@ -310,15 +350,17 @@ export default function MachinesClient({ initialMachines = [] }: { initialMachin
                   <div className="mt-1 text-xs text-zinc-400">
                     {m.code ? m.code : t("common.na")} - {t("machines.lastSeen", { time: lastSeen })}
                   </div>
+                  {macrostopActive ? (
+                    <div className="mt-1 text-xs font-semibold text-red-200">
+                      {t("machines.stoppedFor", { min: stoppedMin })}
+                    </div>
+                  ) : null}
                 </div>
 
                 <span
-                  className={`shrink-0 rounded-full px-3 py-1 text-xs ${badgeClass(
-                    normalizedStatus,
-                    offline
-                  )}`}
+                  className={`shrink-0 rounded-full px-3 py-1 text-xs ${productionBadgeClass}`}
                 >
-                  {statusLabel}
+                  {productionBadgeLabel}
                 </span>
               </div>
 

app/(app)/machines/MachinesClient.tsx.bak

@@ -4,6 +4,7 @@ import Link from "next/link";
 import { useRouter } from "next/navigation";
 import { useEffect, useState, type KeyboardEvent } from "react";
 import { useI18n } from "@/lib/i18n/useI18n";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
 
 type MachineRow = {
   id: string;
@@ -20,6 +21,7 @@ type MachineRow = {
   };
 };
 const LIVE_REFRESH_MS = 5000;
+const OFFLINE_MS = RECAP_HEARTBEAT_STALE_MS;
 
 function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
   if (!ts) return fallback;
@@ -31,7 +33,7 @@ function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
 
 function isOffline(ts?: string) {
   if (!ts) return true;
-  return Date.now() - new Date(ts).getTime() > 30000; // 30s threshold
+  return Date.now() - new Date(ts).getTime() > OFFLINE_MS;
 }
 
 function normalizeStatus(status?: string) {

app/(app)/recap/RecapGridClient.tsx

@@ -13,6 +13,7 @@ function statusLabel(status: RecapMachineStatus, t: (key: string) => string) {
   if (status === "running") return t("recap.status.running");
   if (status === "mold-change") return t("recap.status.moldChange");
   if (status === "stopped") return t("recap.status.stopped");
+  if (status === "idle") return t("recap.status.idle");
   return t("recap.status.offline");
 }
 
@@ -110,7 +111,7 @@ export default function RecapGridClient({ initialData }: Props) {
               className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
             >
               <option value="all">{t("recap.filter.allStatuses")}</option>
-              {(["running", "mold-change", "stopped", "offline"] as const).map((status) => (
+              {(["running", "mold-change", "stopped", "idle", "offline"] as const).map((status) => (
                 <option key={status} value={status}>
                   {statusLabel(status, t)}
                 </option>

app/(app)/recap/RecapGridClient.tsx.bak.step5

@@ -0,0 +1,153 @@
+"use client";
+
+import { useEffect, useMemo, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+import type { RecapMachineStatus, RecapSummaryResponse } from "@/lib/recap/types";
+import RecapMachineCard from "@/components/recap/RecapMachineCard";
+
+type Props = {
+  initialData: RecapSummaryResponse;
+};
+
+function statusLabel(status: RecapMachineStatus, t: (key: string) => string) {
+  if (status === "running") return t("recap.status.running");
+  if (status === "mold-change") return t("recap.status.moldChange");
+  if (status === "stopped") return t("recap.status.stopped");
+  return t("recap.status.offline");
+}
+
+export default function RecapGridClient({ initialData }: Props) {
+  const { t } = useI18n();
+
+  const [data, setData] = useState<RecapSummaryResponse>(initialData);
+  const [loading, setLoading] = useState(false);
+  const [locationFilter, setLocationFilter] = useState("all");
+  const [statusFilter, setStatusFilter] = useState<"all" | RecapMachineStatus>("all");
+  const [nowMs, setNowMs] = useState(() => Date.now());
+
+  useEffect(() => {
+    const timer = window.setInterval(() => setNowMs(Date.now()), 1000);
+    return () => window.clearInterval(timer);
+  }, []);
+
+  useEffect(() => {
+    let alive = true;
+
+    async function refresh() {
+      setLoading(true);
+      try {
+        const res = await fetch(`/api/recap/summary?hours=${data.range.hours}`, { cache: "no-store" });
+        const json = await res.json().catch(() => null);
+        if (!alive || !json || !res.ok) return;
+        setData(json as RecapSummaryResponse);
+      } finally {
+        if (alive) setLoading(false);
+      }
+    }
+
+    const onFocus = () => {
+      void refresh();
+    };
+
+    const interval = window.setInterval(onFocus, 60000);
+    window.addEventListener("focus", onFocus);
+
+    return () => {
+      alive = false;
+      window.clearInterval(interval);
+      window.removeEventListener("focus", onFocus);
+    };
+  }, [data.range.hours]);
+
+  const locationOptions = useMemo(() => {
+    const set = new Set<string>();
+    for (const machine of data.machines) {
+      if (machine.location) set.add(machine.location);
+    }
+    return [...set].sort((a, b) => a.localeCompare(b));
+  }, [data.machines]);
+
+  const filteredMachines = useMemo(() => {
+    return data.machines.filter((machine) => {
+      if (locationFilter !== "all" && machine.location !== locationFilter) return false;
+      if (statusFilter !== "all" && machine.status !== statusFilter) return false;
+      return true;
+    });
+  }, [data.machines, locationFilter, statusFilter]);
+
+  const generatedAtMs = new Date(data.generatedAt).getTime();
+  const freshAgeSec = Number.isFinite(generatedAtMs) ? Math.max(0, Math.floor((nowMs - generatedAtMs) / 1000)) : null;
+
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-4 rounded-2xl border border-white/10 bg-black/40 p-4">
+        <div className="flex flex-col gap-4 lg:flex-row lg:items-center lg:justify-between">
+          <div>
+            <h1 className="text-2xl font-semibold text-white">{t("recap.grid.title")}</h1>
+            <p className="text-sm text-zinc-400">{t("recap.grid.subtitle")}</p>
+            {freshAgeSec != null ? (
+              <p className="mt-1 text-xs text-zinc-500">{t("recap.grid.updatedAgo", { sec: freshAgeSec })}</p>
+            ) : null}
+          </div>
+
+          <div className="flex flex-wrap gap-2 text-sm">
+            <select
+              value={locationFilter}
+              onChange={(event) => setLocationFilter(event.target.value)}
+              className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
+            >
+              <option value="all">{t("recap.filter.allLocations")}</option>
+              {locationOptions.map((location) => (
+                <option key={location} value={location}>
+                  {location}
+                </option>
+              ))}
+            </select>
+
+            <select
+              value={statusFilter}
+              onChange={(event) => setStatusFilter(event.target.value as "all" | RecapMachineStatus)}
+              className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
+            >
+              <option value="all">{t("recap.filter.allStatuses")}</option>
+              {(["running", "mold-change", "stopped", "offline"] as const).map((status) => (
+                <option key={status} value={status}>
+                  {statusLabel(status, t)}
+                </option>
+              ))}
+            </select>
+          </div>
+        </div>
+      </div>
+
+      {loading && data.machines.length === 0 ? (
+        <div className="grid grid-cols-1 gap-4 sm:grid-cols-2 xl:grid-cols-3">
+          {Array.from({ length: 6 }).map((_, idx) => (
+            <div key={idx} className="h-[220px] animate-pulse rounded-2xl border border-white/10 bg-white/5" />
+          ))}
+        </div>
+      ) : null}
+
+      {loading && data.machines.length > 0 ? (
+        <div className="mb-3 text-xs text-zinc-500">{t("common.loading")}</div>
+      ) : null}
+
+      {filteredMachines.length === 0 ? (
+        <div className="rounded-2xl border border-white/10 bg-black/30 p-4 text-sm text-zinc-400">
+          {t("recap.grid.empty")}
+        </div>
+      ) : (
+        <div className="grid grid-cols-1 gap-4 sm:grid-cols-2 xl:grid-cols-3">
+          {filteredMachines.map((machine) => (
+            <RecapMachineCard
+              key={machine.machineId}
+              machine={machine}
+              rangeStart={data.range.start}
+              rangeEnd={data.range.end}
+            />
+          ))}
+        </div>
+      )}
+    </div>
+  );
+}

app/(app)/recap/[machineId]/RecapDetailClient.tsx.bak

@@ -0,0 +1,240 @@
+"use client";
+
+import Link from "next/link";
+import { useEffect, useState, useTransition } from "react";
+import { usePathname, useRouter, useSearchParams } from "next/navigation";
+import { useI18n } from "@/lib/i18n/useI18n";
+import type { RecapDetailResponse, RecapRangeMode, RecapTimelineResponse } from "@/lib/recap/types";
+import RecapBanners from "@/components/recap/RecapBanners";
+import RecapKpiRow from "@/components/recap/RecapKpiRow";
+import RecapProductionBySku from "@/components/recap/RecapProductionBySku";
+import RecapDowntimeTop from "@/components/recap/RecapDowntimeTop";
+import RecapWorkOrders from "@/components/recap/RecapWorkOrders";
+import RecapMachineStatus from "@/components/recap/RecapMachineStatus";
+import RecapFullTimeline from "@/components/recap/RecapFullTimeline";
+
+type Props = {
+  machineId: string;
+  initialData: RecapDetailResponse;
+};
+
+function toInputDate(value: string) {
+  const d = new Date(value);
+  const pad = (n: number) => String(n).padStart(2, "0");
+  return `${d.getFullYear()}-${pad(d.getMonth() + 1)}-${pad(d.getDate())}T${pad(d.getHours())}:${pad(d.getMinutes())}`;
+}
+
+function normalizeInputDate(value: string) {
+  const d = new Date(value);
+  if (!Number.isFinite(d.getTime())) return null;
+  return d.toISOString();
+}
+
+export default function RecapDetailClient({ machineId, initialData }: Props) {
+  const { t, locale } = useI18n();
+  const router = useRouter();
+  const pathname = usePathname();
+  const searchParams = useSearchParams();
+  const [isPending, startTransition] = useTransition();
+  const [timeline, setTimeline] = useState<RecapTimelineResponse | null>(null);
+  const [timelineLoading, setTimelineLoading] = useState(true);
+  const [nowMs, setNowMs] = useState(() => Date.now());
+
+  const [customStart, setCustomStart] = useState(toInputDate(initialData.range.start));
+  const [customEnd, setCustomEnd] = useState(toInputDate(initialData.range.end));
+
+  const requestedRange =
+    (searchParams.get("range") as RecapRangeMode | null) ?? initialData.range.requestedMode ?? initialData.range.mode;
+  const selectedRange = requestedRange;
+  const shiftAvailable = initialData.range.shiftAvailable ?? true;
+  const shiftFallbackReason = initialData.range.fallbackReason;
+  const shiftFallbackActive = selectedRange === "shift" && initialData.range.mode !== "shift";
+
+  function pushRange(nextRange: RecapRangeMode, start?: string, end?: string) {
+    const params = new URLSearchParams(searchParams.toString());
+    params.set("range", nextRange);
+
+    if (nextRange === "custom" && start && end) {
+      params.set("start", start);
+      params.set("end", end);
+    } else {
+      params.delete("start");
+      params.delete("end");
+    }
+
+    startTransition(() => {
+      router.push(`${pathname}?${params.toString()}`);
+    });
+  }
+
+  function applyCustomRange() {
+    const start = normalizeInputDate(customStart);
+    const end = normalizeInputDate(customEnd);
+    if (!start || !end || end <= start) return;
+    pushRange("custom", start, end);
+  }
+
+  const machine = initialData.machine;
+  const generatedAtMs = new Date(initialData.generatedAt).getTime();
+  const freshAgeSec = Number.isFinite(generatedAtMs) ? Math.max(0, Math.floor((nowMs - generatedAtMs) / 1000)) : null;
+  const timelineStart = timeline?.range.start ?? initialData.range.start;
+  const timelineEnd = timeline?.range.end ?? initialData.range.end;
+  const timelineSegments = timeline?.segments ?? [];
+  const timelineHasData = timeline?.hasData ?? false;
+
+  useEffect(() => {
+    let alive = true;
+    setTimeline(null);
+    setTimelineLoading(true);
+
+    async function loadTimeline() {
+      try {
+        const params = new URLSearchParams({
+          start: initialData.range.start,
+          end: initialData.range.end,
+        });
+        const res = await fetch(`/api/recap/${machineId}/timeline?${params.toString()}`, { cache: "no-store" });
+        const json = await res.json().catch(() => null);
+        if (!alive || !res.ok || !json) return;
+        setTimeline(json as RecapTimelineResponse);
+      } catch {
+      } finally {
+        if (alive) setTimelineLoading(false);
+      }
+    }
+
+    void loadTimeline();
+    return () => {
+      alive = false;
+    };
+  }, [initialData.range.end, initialData.range.start, machineId]);
+
+  useEffect(() => {
+    const timer = window.setInterval(() => setNowMs(Date.now()), 1000);
+    return () => window.clearInterval(timer);
+  }, []);
+
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-4 flex flex-col gap-3 lg:flex-row lg:items-start lg:justify-between">
+        <div>
+          <Link href="/recap" className="text-sm text-zinc-400 hover:text-zinc-200">
+            {`← ${t("recap.detail.back")}`}
+          </Link>
+          <h1 className="mt-1 text-2xl font-semibold text-white">{machine.name || machineId}</h1>
+          <div className="text-sm text-zinc-400">{machine.location || t("common.na")}</div>
+          {freshAgeSec != null ? (
+            <div className="mt-1 text-xs text-zinc-500">{t("recap.grid.updatedAgo", { sec: freshAgeSec })}</div>
+          ) : null}
+        </div>
+
+        <div className="flex flex-wrap gap-2 text-sm">
+          {(["24h", "shift", "yesterday", "custom"] as const).map((range) => (
+            <button
+              key={range}
+              type="button"
+              disabled={range === "shift" && !shiftAvailable}
+              onClick={() => {
+                if (range === "shift" && !shiftAvailable) return;
+                if (range === "custom") {
+                  pushRange("custom", normalizeInputDate(customStart) ?? undefined, normalizeInputDate(customEnd) ?? undefined);
+                  return;
+                }
+                pushRange(range);
+              }}
+              className={`rounded-xl border px-3 py-2 ${
+                selectedRange === range
+                  ? "border-emerald-300/60 bg-emerald-500/20 text-emerald-100"
+                  : "border-white/10 bg-black/40 text-zinc-200"
+              } ${range === "shift" && !shiftAvailable ? "cursor-not-allowed opacity-60" : ""}`}
+            >
+              {range === "24h" ? t("recap.range.24h") : null}
+              {range === "shift" ? t("recap.range.shiftCurrent") : null}
+              {range === "yesterday" ? t("recap.range.yesterday") : null}
+              {range === "custom" ? t("recap.range.custom") : null}
+            </button>
+          ))}
+        </div>
+      </div>
+
+      {!shiftAvailable ? (
+        <div className="mb-4 rounded-xl border border-amber-400/40 bg-amber-400/10 px-3 py-2 text-xs text-amber-100">
+          {t("recap.range.shiftUnavailable")}
+        </div>
+      ) : null}
+
+      {shiftFallbackActive ? (
+        <div className="mb-4 rounded-xl border border-amber-400/40 bg-amber-400/10 px-3 py-2 text-xs text-amber-100">
+          {shiftFallbackReason === "shift-inactive" ? t("recap.range.shiftFallbackInactive") : t("recap.range.shiftFallbackUnavailable")}
+        </div>
+      ) : null}
+
+      {selectedRange === "custom" ? (
+        <div className="mb-4 flex flex-wrap gap-2 text-sm">
+          <input
+            type="datetime-local"
+            value={customStart}
+            onChange={(event) => setCustomStart(event.target.value)}
+            className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
+          />
+          <input
+            type="datetime-local"
+            value={customEnd}
+            onChange={(event) => setCustomEnd(event.target.value)}
+            className="rounded-xl border border-white/10 bg-black/40 px-3 py-2 text-zinc-200"
+          />
+          <button
+            type="button"
+            onClick={applyCustomRange}
+            className="rounded-xl border border-emerald-300/50 bg-emerald-500/20 px-3 py-2 text-emerald-100"
+          >
+            {t("recap.range.apply")}
+          </button>
+        </div>
+      ) : null}
+
+      {isPending ? <div className="mb-3 text-xs text-zinc-500">{t("common.loading")}</div> : null}
+
+      <div className="mb-4">
+        <RecapBanners
+          moldChangeStartMs={machine.moldChange?.active ? machine.moldChange.startMs : null}
+          offlineForMin={machine.offlineForMin}
+          ongoingStopMin={machine.ongoingStopMin}
+        />
+      </div>
+
+      <RecapKpiRow
+        oeeAvg={machine.oee}
+        goodParts={machine.goodParts}
+        totalStops={Math.round(machine.stopMinutes)}
+        scrapParts={machine.scrap}
+        rangeMode={initialData.range.mode}
+      />
+
+      <div className="mt-4">
+        <RecapFullTimeline
+          rangeStart={timelineStart}
+          rangeEnd={timelineEnd}
+          segments={timelineSegments}
+          hasData={timelineHasData}
+          loading={timelineLoading}
+          locale={locale}
+          rangeMode={initialData.range.mode}
+        />
+      </div>
+
+      <div className="mt-4 grid grid-cols-1 gap-4 xl:grid-cols-2">
+        <RecapProductionBySku rows={machine.productionBySku} />
+        <RecapDowntimeTop rows={machine.downtimeTop} />
+      </div>
+
+      <div className="mt-4">
+        <RecapWorkOrders workOrders={machine.workOrders} />
+      </div>
+
+      <div className="mt-4">
+        <RecapMachineStatus heartbeat={machine.heartbeat} />
+      </div>
+    </div>
+  );
+}

app/(app)/settings/page.tsx

@@ -3,6 +3,7 @@
 import { useCallback, useEffect, useMemo, useRef, useState } from "react";
 import { AlertsConfig } from "@/components/settings/AlertsConfig";
 import { FinancialCostConfig } from "@/components/settings/FinancialCostConfig";
+import { ReasonCatalogConfig } from "@/components/settings/ReasonCatalogConfig";
 import { useI18n } from "@/lib/i18n/useI18n";
 import { SHIFT_OVERRIDE_DAYS, type ShiftOverrideDay } from "@/lib/settings";
 import { useScreenlessMode } from "@/lib/ui/screenlessMode";
@@ -122,6 +123,7 @@ const SETTINGS_TABS = [
   { id: "thresholds", labelKey: "settings.tabs.thresholds" },
   { id: "alerts", labelKey: "settings.tabs.alerts" },
   { id: "financial", labelKey: "settings.tabs.financial" },
+  { id: "reasonCatalog", labelKey: "settings.tabs.reasonCatalog" },
   { id: "team", labelKey: "settings.tabs.team" },
 ] as const;
 
@@ -239,7 +241,6 @@ function normalizeSettings(raw: unknown, fallbackName: (index: number) => string
   const thresholds = asRecord(record.thresholds) ?? {};
   const alerts = asRecord(record.alerts) ?? {};
   const defaults = asRecord(record.defaults) ?? {};
-
   return {
     orgId: String(record.orgId ?? ""),
     version: Number(record.version ?? 0),
@@ -1276,6 +1277,18 @@ export default function SettingsPage() {
         </div>
       )}
 
+      {activeTab === "reasonCatalog" && (
+        <div className="space-y-6">
+          <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+            <div className="text-sm font-semibold text-white">{t("settings.reasonCatalog.title")}</div>
+            <p className="mt-1 text-xs text-zinc-400">{t("settings.reasonCatalog.subtitle")}</p>
+            <div className="mt-4">
+              <ReasonCatalogConfig disabled={saving} />
+            </div>
+          </div>
+        </div>
+      )}
+
       {activeTab === "team" && (
         <div className="grid grid-cols-1 gap-4 xl:grid-cols-2">
           <div className="rounded-2xl border border-white/10 bg-white/5 p-5">

app/api/ingest/event/route.ts

@@ -5,13 +5,14 @@ import { z } from "zod";
 import { evaluateAlertsForEvent } from "@/lib/alerts/engine";
 import { toJsonValue } from "@/lib/prismaJson";
 import {
+  detailEffectiveReasonCode,
   findCatalogReason,
-  loadFallbackReasonCatalog,
-  normalizeReasonCatalog,
+  findCatalogReasonByReasonCode,
   toReasonCode,
   type ReasonCatalog,
   type ReasonCatalogKind,
 } from "@/lib/reasonCatalog";
+import { effectiveReasonCatalogForOrg } from "@/lib/reasonCatalogDb";
 
 const normalizeType = (t: unknown) =>
   String(t ?? "")
@@ -169,7 +170,7 @@ function findCatalogReasonFlexible(
         categoryLabel: category.label,
         detailId: detail.id,
         detailLabel: detail.label,
-        reasonCode: toReasonCode(category.id, detail.id),
+        reasonCode: detailEffectiveReasonCode(category, detail),
         reasonLabel: `${category.label} > ${detail.label}`,
       };
     }
@@ -177,12 +178,6 @@ function findCatalogReasonFlexible(
   return null;
 }
 
-function getCatalogFromDefaults(defaultsJson: unknown) {
-  const defaults = asRecord(defaultsJson);
-  if (!defaults) return null;
-  return normalizeReasonCatalog(defaults.reasonCatalog ?? defaults.reasonCatalogData);
-}
-
 function resolveReason(
   raw: Record<string, unknown>,
   kind: ReasonCatalogKind,
@@ -193,7 +188,13 @@ function resolveReason(
   const reasonTextPath = parseReasonTextPath(raw.reasonText);
   const categoryIdRaw = clampText(raw.categoryId ?? reasonPath.category ?? reasonTextPath.category, 64);
   const detailIdRaw = clampText(raw.detailId ?? reasonPath.detail ?? reasonTextPath.detail, 64);
-  const fromCatalog = findCatalogReasonFlexible(catalog, kind, categoryIdRaw, detailIdRaw);
+  const fromCatalogFlexible = findCatalogReasonFlexible(catalog, kind, categoryIdRaw, detailIdRaw);
+  const rawReasonCodeEarly = clampText(raw.reasonCode, 64);
+  const fromCatalogByCode =
+    !fromCatalogFlexible && rawReasonCodeEarly
+      ? findCatalogReasonByReasonCode(catalog, kind, rawReasonCodeEarly)
+      : null;
+  const fromCatalog = fromCatalogFlexible ?? fromCatalogByCode;
 
   const categoryLabelRaw = clampText(raw.categoryLabel ?? reasonPath.category ?? reasonTextPath.category, 120);
   const detailLabelRaw = clampText(raw.detailLabel ?? reasonPath.detail ?? reasonTextPath.detail, 120);
@@ -282,11 +283,13 @@ export async function POST(req: Request) {
 
   const orgSettings = await prisma.orgSettings.findUnique({
     where: { orgId: machine.orgId },
-    select: { stoppageMultiplier: true, macroStoppageMultiplier: true, defaultsJson: true },
+    select: { stoppageMultiplier: true, macroStoppageMultiplier: true, defaultsJson: true, version: true },
   });
-  const fallbackCatalog = await loadFallbackReasonCatalog();
-  const settingsCatalog = getCatalogFromDefaults(orgSettings?.defaultsJson);
-  const reasonCatalog = settingsCatalog ?? fallbackCatalog;
+  const reasonCatalog = await effectiveReasonCatalogForOrg(
+    machine.orgId,
+    orgSettings?.defaultsJson ?? null,
+    orgSettings?.version ?? 1
+  );
 
   const defaultMicroMultiplier = Number(orgSettings?.stoppageMultiplier ?? 1.5);
   const defaultMacroMultiplier = Math.max(

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

@@ -258,14 +258,65 @@ export async function GET(req: NextRequest, { params }: { params: Promise<{ mach
         })
       : allowed;
 
-  const seen = new Set<string>();
-  const deduped = filtered.filter((event) => {
-    const key = `${event.eventType}-${event.ts ?? ""}-${event.title}`;
-    if (seen.has(key)) return false;
-    seen.add(key);
-    return true;
+  // Build a lookup of raw event metadata (incidentKey, status, is_auto_ack)
+  // by event id, so we can collapse the normalized events down to one
+  // "active" + one "resolved" per incident.
+  const rawMetaById = new Map<string, { incidentKey: string | null; status: string | null; isAutoAck: boolean }>();
+  for (const row of rawEvents) {
+    let parsed: unknown = row.data;
+    if (typeof parsed === "string") {
+      try { parsed = JSON.parse(parsed); } catch { parsed = null; }
+    }
+    const data: Record<string, unknown> =
+      parsed && typeof parsed === "object" && !Array.isArray(parsed)
+        ? (parsed as Record<string, unknown>)
+        : {};
+    const isAutoAck =
+      data.is_auto_ack === true ||
+      data.isAutoAck === true ||
+      data.is_auto_ack === "true" ||
+      data.isAutoAck === "true";
+    const incidentKey =
+      typeof data.incidentKey === "string" ? data.incidentKey :
+      typeof data.incident_key === "string" ? data.incident_key : null;
+    const status = typeof data.status === "string" ? data.status.toLowerCase() : null;
+    rawMetaById.set(row.id, { incidentKey, status, isAutoAck });
+  }
+
+  // Drop pure auto-ack refresh pings.
+  const filteredNoAutoAck = filtered.filter((event) => {
+    const meta = rawMetaById.get(event.id);
+    return !meta?.isAutoAck;
   });
 
+  // Group by incidentKey: keep at most one "active" (oldest = original happen)
+  // and one "resolved" (newest = actual end) per incident. Events without
+  // incidentKey pass through unchanged (mold-change, edge-case events).
+  const byGroup = new Map<string, typeof filteredNoAutoAck[number]>();
+  const passthrough: typeof filteredNoAutoAck = [];
+
+  for (const event of filteredNoAutoAck) {
+    const meta = rawMetaById.get(event.id);
+    const groupId = meta?.incidentKey;
+    if (!groupId) {
+      passthrough.push(event);
+      continue;
+    }
+    const statusKey = meta.status === "resolved" ? "resolved" : "active";
+    const key = `${groupId}:${statusKey}`;
+    const existing = byGroup.get(key);
+    if (!existing) {
+      byGroup.set(key, event);
+      continue;
+    }
+    const existingTs = existing.ts ? existing.ts.getTime() : 0;
+    const eventTs = event.ts ? event.ts.getTime() : 0;
+    const pickNewest = statusKey === "resolved";
+    const shouldReplace = pickNewest ? eventTs > existingTs : eventTs < existingTs;
+    if (shouldReplace) byGroup.set(key, event);
+  }
+
+  const deduped = [...passthrough, ...byGroup.values()];
   deduped.sort((a, b) => {
     const at = a.ts ? a.ts.getTime() : 0;
     const bt = b.ts ? b.ts.getTime() : 0;

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

@@ -0,0 +1,492 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { Prisma } from "@prisma/client";
+import { z } from "zod";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { normalizeEvent } from "@/lib/events/normalizeEvent";
+import { invalidateMachineAuth } from "@/lib/machineAuthCache";
+
+const machineIdSchema = z.string().uuid();
+
+const ALLOWED_EVENT_TYPES = new Set([
+  "slow-cycle",
+  "microstop",
+  "macrostop",
+  "offline",
+  "error",
+  "oee-drop",
+  "quality-spike",
+  "performance-degradation",
+  "predictive-oee-decline",
+  "alert-delivery-failed",
+]);
+
+function canManageMachines(role?: string | null) {
+  return role === "OWNER" || role === "ADMIN";
+}
+
+function isPlainObject(value: unknown): value is Record<string, unknown> {
+  return !!value && typeof value === "object" && !Array.isArray(value);
+}
+
+function parseNumber(value: string | null, fallback: number) {
+  if (value == null || value === "") return fallback;
+  const parsed = Number(value);
+  return Number.isFinite(parsed) ? parsed : fallback;
+}
+
+type MachineFkReference = {
+  tableName: string;
+  columnName: string;
+  deleteRule: string;
+};
+
+function quoteIdent(identifier: string) {
+  return `"${identifier.replace(/"/g, "\"\"")}"`;
+}
+
+async function cleanupMachineReferences(machineId: string) {
+  const refs = await prisma.$queryRaw<MachineFkReference[]>`
+    SELECT DISTINCT
+      tc.table_name AS "tableName",
+      kcu.column_name AS "columnName",
+      rc.delete_rule AS "deleteRule"
+    FROM information_schema.table_constraints tc
+    JOIN information_schema.key_column_usage kcu
+      ON tc.constraint_name = kcu.constraint_name
+     AND tc.table_schema = kcu.table_schema
+    JOIN information_schema.referential_constraints rc
+      ON tc.constraint_name = rc.constraint_name
+     AND tc.table_schema = rc.constraint_schema
+    WHERE tc.constraint_type = 'FOREIGN KEY'
+      AND tc.table_schema = 'public'
+      AND rc.unique_constraint_schema = 'public'
+      AND rc.unique_constraint_name IN (
+        SELECT constraint_name
+        FROM information_schema.table_constraints
+        WHERE table_schema = 'public'
+          AND table_name = 'Machine'
+          AND constraint_type IN ('PRIMARY KEY', 'UNIQUE')
+      )
+  `;
+
+  for (const ref of refs) {
+    if (ref.tableName === "Machine") continue;
+    const table = quoteIdent(ref.tableName);
+    const column = quoteIdent(ref.columnName);
+    const rule = String(ref.deleteRule ?? "").toUpperCase();
+
+    if (rule === "CASCADE") continue;
+
+    if (rule === "SET NULL") {
+      await prisma.$executeRawUnsafe(`UPDATE ${table} SET ${column} = NULL WHERE ${column} = $1`, machineId);
+      continue;
+    }
+
+    await prisma.$executeRawUnsafe(`DELETE FROM ${table} WHERE ${column} = $1`, machineId);
+  }
+}
+
+export async function GET(req: NextRequest, { params }: { params: Promise<{ machineId: string }> }) {
+  const session = await requireSession();
+  if (!session) {
+    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  }
+
+  const { machineId } = await params;
+  if (!machineIdSchema.safeParse(machineId).success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine id" }, { status: 400 });
+  }
+
+  const url = new URL(req.url);
+  const windowSec = Math.max(0, parseNumber(url.searchParams.get("windowSec"), 3600));
+  const eventsWindowSec = Math.max(0, parseNumber(url.searchParams.get("eventsWindowSec"), 21600));
+  const eventsMode = url.searchParams.get("events") ?? "critical";
+  const eventsOnly = url.searchParams.get("eventsOnly") === "1";
+
+  const [machineRow, orgSettings, machineSettings] = await Promise.all([
+    prisma.machine.findFirst({
+      where: { id: machineId, orgId: session.orgId },
+      select: {
+        id: true,
+        name: true,
+        code: true,
+        location: true,
+        createdAt: true,
+        updatedAt: true,
+        heartbeats: {
+          orderBy: { tsServer: "desc" },
+          take: 1,
+          select: { ts: true, tsServer: true, status: true, message: true, ip: true, fwVersion: true },
+        },
+        kpiSnapshots: {
+          orderBy: { ts: "desc" },
+          take: 1,
+          select: {
+            ts: true,
+            oee: true,
+            availability: true,
+            performance: true,
+            quality: true,
+            workOrderId: true,
+            sku: true,
+            good: true,
+            scrap: true,
+            target: true,
+            cycleTime: true,
+          },
+        },
+      },
+    }),
+    prisma.orgSettings.findUnique({
+      where: { orgId: session.orgId },
+      select: { stoppageMultiplier: true, macroStoppageMultiplier: true },
+    }),
+    prisma.machineSettings.findUnique({
+      where: { machineId },
+      select: { overridesJson: true },
+    }),
+  ]);
+
+  if (!machineRow) {
+    return NextResponse.json({ ok: false, error: "Machine not found" }, { status: 404 });
+  }
+
+  const overrides = isPlainObject(machineSettings?.overridesJson) ? machineSettings?.overridesJson : {};
+  const thresholdsOverride = isPlainObject(overrides.thresholds) ? overrides.thresholds : {};
+  const stoppageMultiplier =
+    typeof thresholdsOverride.stoppageMultiplier === "number"
+      ? thresholdsOverride.stoppageMultiplier
+      : Number(orgSettings?.stoppageMultiplier ?? 1.5);
+  const macroStoppageMultiplier =
+    typeof thresholdsOverride.macroStoppageMultiplier === "number"
+      ? thresholdsOverride.macroStoppageMultiplier
+      : Number(orgSettings?.macroStoppageMultiplier ?? 5);
+
+  const thresholds = {
+    stoppageMultiplier,
+    macroStoppageMultiplier,
+  };
+
+  const machine = {
+    ...machineRow,
+    effectiveCycleTime: null,
+    latestHeartbeat: machineRow.heartbeats[0] ?? null,
+    latestKpi: machineRow.kpiSnapshots[0] ?? null,
+    heartbeats: undefined,
+    kpiSnapshots: undefined,
+  };
+
+  const cycles = eventsOnly
+    ? []
+    : await prisma.machineCycle.findMany({
+        where: {
+          orgId: session.orgId,
+          machineId,
+          ts: { gte: new Date(Date.now() - windowSec * 1000) },
+        },
+        orderBy: { ts: "asc" },
+        select: {
+          ts: true,
+          tsServer: true,
+          cycleCount: true,
+          actualCycleTime: true,
+          theoreticalCycleTime: true,
+          workOrderId: true,
+          sku: true,
+        },
+      });
+
+  const cyclesOut = cycles.map((row) => {
+    const ts = row.tsServer ?? row.ts;
+    return {
+      ts,
+      t: ts.getTime(),
+      cycleCount: row.cycleCount ?? null,
+      actual: row.actualCycleTime,
+      ideal: row.theoreticalCycleTime ?? null,
+      workOrderId: row.workOrderId ?? null,
+      sku: row.sku ?? null,
+    };
+  });
+
+  const eventWindowStart = new Date(Date.now() - eventsWindowSec * 1000);
+  const criticalSeverities = ["critical", "error", "high"];
+  const eventWhereBase = {
+    orgId: session.orgId,
+    machineId,
+    ts: { gte: eventWindowStart },
+  };
+
+  const [rawEvents, eventsCountAll] = await Promise.all([
+    prisma.machineEvent.findMany({
+      where: eventWhereBase,
+      orderBy: { ts: "desc" },
+      take: eventsOnly ? 300 : 120,
+      select: {
+        id: true,
+        ts: true,
+        topic: true,
+        eventType: true,
+        severity: true,
+        title: true,
+        description: true,
+        requiresAck: true,
+        data: true,
+        workOrderId: true,
+      },
+    }),
+    prisma.machineEvent.count({ where: eventWhereBase }),
+  ]);
+
+  const normalized = rawEvents.map((row) =>
+    normalizeEvent(row, { microMultiplier: stoppageMultiplier, macroMultiplier: macroStoppageMultiplier })
+  );
+
+  const allowed = normalized.filter((event) => ALLOWED_EVENT_TYPES.has(event.eventType));
+  const criticalEventTypes = new Set(["macrostop", "microstop", "slow-cycle", "offline", "error"]);
+  const filtered =
+    eventsMode === "critical"
+      ? allowed.filter((event) => {
+          const severity = String(event.severity ?? "").toLowerCase();
+          return (
+            criticalEventTypes.has(event.eventType) ||
+            event.requiresAck === true ||
+            criticalSeverities.includes(severity)
+          );
+        })
+      : allowed;
+
+  const seen = new Set<string>();
+  const deduped = filtered.filter((event) => {
+    const key = `${event.eventType}-${event.ts ?? ""}-${event.title}`;
+    if (seen.has(key)) return false;
+    seen.add(key);
+    return true;
+  });
+
+  deduped.sort((a, b) => {
+    const at = a.ts ? a.ts.getTime() : 0;
+    const bt = b.ts ? b.ts.getTime() : 0;
+    return bt - at;
+  });
+
+  return NextResponse.json({
+    ok: true,
+    machine,
+    events: deduped,
+    eventsCountAll,
+    cycles: cyclesOut,
+    thresholds,
+    activeStoppage: null,
+  });
+}
+
+export async function DELETE(_req: Request, { params }: { params: Promise<{ machineId: string }> }) {
+  const session = await requireSession();
+  if (!session) {
+    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  }
+
+  const { machineId } = await params;
+  if (!machineIdSchema.safeParse(machineId).success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine id" }, { status: 400 });
+  }
+
+  const membership = await prisma.orgUser.findUnique({
+    where: {
+      orgId_userId: {
+        orgId: session.orgId,
+        userId: session.userId,
+      },
+    },
+    select: { role: true },
+  });
+
+  if (!canManageMachines(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  for (let attempt = 0; attempt < 3; attempt += 1) {
+    try {
+      if (attempt === 0) {
+        // Revoke credentials first in a committed write so ingest auth fails immediately.
+        const revoked = await prisma.machine.updateMany({
+          where: {
+            id: machineId,
+            orgId: session.orgId,
+          },
+          data: {
+            apiKey: null,
+          },
+        });
+
+        if (revoked.count === 0) {
+          return NextResponse.json({ ok: false, error: "Machine not found" }, { status: 404 });
+        }
+
+        invalidateMachineAuth(machineId);
+      }
+
+      // Avoid long interactive transactions on very large history tables (P2028 timeout).
+      // This sequence is idempotent and safe to retry because apiKey is revoked first.
+      await prisma.machineCycle.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineHeartbeat.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineKpiSnapshot.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineEvent.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineWorkOrder.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineSettings.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.settingsAudit.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.alertNotification.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.machineFinancialOverride.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.reasonEntry.deleteMany({
+        where: {
+          machineId,
+        },
+      });
+
+      await prisma.downtimeAction.updateMany({
+        where: {
+          machineId,
+        },
+        data: {
+          machineId: null,
+        },
+      });
+
+      const result = await prisma.machine.deleteMany({
+        where: {
+          id: machineId,
+          orgId: session.orgId,
+        },
+      });
+
+      if (result.count === 0) {
+        return NextResponse.json({ ok: false, error: "Machine not found" }, { status: 404 });
+      }
+
+      invalidateMachineAuth(machineId);
+      return NextResponse.json({ ok: true });
+    } catch (err: unknown) {
+      const code = err instanceof Prisma.PrismaClientKnownRequestError ? err.code : undefined;
+      const message = err instanceof Error ? err.message : String(err);
+      console.error("DELETE /api/machines/[machineId] failed", {
+        machineId,
+        orgId: session.orgId,
+        attempt,
+        code,
+        message,
+      });
+
+      if (code === "P2003") {
+        if (attempt < 2) {
+          try {
+            await cleanupMachineReferences(machineId);
+          } catch (cleanupErr: unknown) {
+            const cleanupMessage = cleanupErr instanceof Error ? cleanupErr.message : String(cleanupErr);
+            console.error("DELETE /api/machines/[machineId] cleanup failed", {
+              machineId,
+              orgId: session.orgId,
+              attempt,
+              cleanupMessage,
+            });
+          }
+          await new Promise((resolve) => setTimeout(resolve, (attempt + 1) * 150));
+          continue;
+        }
+
+        return NextResponse.json(
+          {
+            ok: false,
+            error: "Machine has dependent records and could not be removed",
+            code,
+          },
+          { status: 409 }
+        );
+      }
+
+      if (code === "P2022") {
+        return NextResponse.json(
+          {
+            ok: false,
+            error: "Server schema is out of date for machine delete",
+            code,
+          },
+          { status: 500 }
+        );
+      }
+
+      if (code === "P2028") {
+        return NextResponse.json(
+          {
+            ok: false,
+            error: "Delete timed out while removing machine history",
+            code,
+          },
+          { status: 503 }
+        );
+      }
+
+      if (code) {
+        return NextResponse.json(
+          {
+            ok: false,
+            error: "Delete failed due to database error",
+            code,
+          },
+          { status: 500 }
+        );
+      }
+
+      return NextResponse.json({ ok: false, error: "Delete failed" }, { status: 500 });
+    }
+  }
+
+  return NextResponse.json({ ok: false, error: "Delete failed", code: "DELETE_RETRY_EXHAUSTED" }, { status: 500 });
+}

app/api/machines/route.ts

@@ -9,6 +9,7 @@ import { requireSession } from "@/lib/auth/requireSession";
 import {
   fetchLatestHeartbeats,
   fetchLatestKpis,
+  fetchLatestMacrostops,
   fetchMachineBase,
   mergeMachineOverviewRows,
 } from "@/lib/machines/withLatest";
@@ -58,6 +59,10 @@ export async function GET(req: Request) {
     if (perfEnabled) timings.kpiQuery = elapsedMs(kpiStart);
   }
 
+  const macrostopStart = nowMs();
+  const macrostops = await fetchLatestMacrostops(session.orgId, machineIds);
+  if (perfEnabled) timings.macrostopsQuery = elapsedMs(macrostopStart);
+
   const postQueryStart = nowMs();
 
   // flatten latest heartbeat for UI convenience
@@ -65,6 +70,7 @@ export async function GET(req: Request) {
     machines,
     heartbeats,
     kpis,
+    macrostops,
     includeKpi,
   });
 

app/api/machines/route.ts.bak

@@ -0,0 +1,161 @@
+import { NextResponse } from "next/server";
+import { randomBytes } from "crypto";
+import { prisma } from "@/lib/prisma";
+import { generatePairingCode } from "@/lib/pairingCode";
+import { z } from "zod";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, formatServerTiming, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+import { requireSession } from "@/lib/auth/requireSession";
+import {
+  fetchLatestHeartbeats,
+  fetchLatestKpis,
+  fetchMachineBase,
+  mergeMachineOverviewRows,
+} from "@/lib/machines/withLatest";
+
+let machinesColdStart = true;
+
+function getColdStartInfo() {
+  const coldStart = machinesColdStart;
+  machinesColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
+
+const createMachineSchema = z.object({
+  name: z.string().trim().min(1).max(80),
+  code: z.string().trim().max(40).optional(),
+  location: z.string().trim().max(80).optional(),
+});
+
+export async function GET(req: Request) {
+  const perfEnabled = PERF_LOGS_ENABLED;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+  const { coldStart, uptimeMs } = getColdStartInfo();
+  const url = new URL(req.url);
+  const includeKpi = url.searchParams.get("includeKpi") === "1";
+
+  const authStart = nowMs();
+  const session = await requireSession();
+  if (perfEnabled) timings.auth = elapsedMs(authStart);
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const preQueryStart = nowMs();
+  const machinesStart = nowMs();
+  if (perfEnabled) timings.preQuery = elapsedMs(preQueryStart);
+  const machines = await fetchMachineBase(session.orgId);
+  if (perfEnabled) timings.machinesQuery = elapsedMs(machinesStart);
+
+  const heartbeatStart = nowMs();
+  const machineIds = machines.map((machine) => machine.id);
+  const heartbeats = await fetchLatestHeartbeats(session.orgId, machineIds);
+  if (perfEnabled) timings.heartbeatsQuery = elapsedMs(heartbeatStart);
+
+  let kpis: Awaited<ReturnType<typeof fetchLatestKpis>> = [];
+  if (includeKpi) {
+    const kpiStart = nowMs();
+    kpis = await fetchLatestKpis(session.orgId, machineIds);
+    if (perfEnabled) timings.kpiQuery = elapsedMs(kpiStart);
+  }
+
+  const postQueryStart = nowMs();
+
+  // flatten latest heartbeat for UI convenience
+  const out = mergeMachineOverviewRows({
+    machines,
+    heartbeats,
+    kpis,
+    includeKpi,
+  });
+
+  const payload = { ok: true, machines: out };
+
+  const responseHeaders = new Headers();
+  if (perfEnabled) {
+    timings.postQuery = elapsedMs(postQueryStart);
+    timings.total = elapsedMs(totalStart);
+    responseHeaders.set("Server-Timing", formatServerTiming(timings));
+    const payloadBytes = Buffer.byteLength(JSON.stringify(payload));
+    logLine("perf.machines.api", {
+      orgId: session.orgId,
+      coldStart,
+      uptimeMs,
+      timings,
+      counts: { machines: out.length },
+      payloadBytes,
+    });
+  }
+
+  return NextResponse.json(payload, { headers: responseHeaders });
+}
+
+export async function POST(req: Request) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const body = await req.json().catch(() => ({}));
+  const parsed = createMachineSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine payload" }, { status: 400 });
+  }
+
+  const name = parsed.data.name;
+  const codeRaw = parsed.data.code ?? "";
+  const locationRaw = parsed.data.location ?? "";
+
+  const existing = await prisma.machine.findFirst({
+    where: { orgId: session.orgId, name },
+    select: { id: true },
+  });
+
+  if (existing) {
+    return NextResponse.json({ ok: false, error: "Machine name already exists" }, { status: 409 });
+  }
+
+  const apiKey = randomBytes(24).toString("hex");
+  const pairingExpiresAt = new Date(Date.now() + 24 * 60 * 60 * 1000);
+
+  let machine = null as null | {
+    id: string;
+    name: string;
+    code?: string | null;
+    location?: string | null;
+    pairingCode?: string | null;
+    pairingCodeExpiresAt?: Date | null;
+  };
+
+  for (let attempt = 0; attempt < 5; attempt += 1) {
+    const pairingCode = generatePairingCode();
+    try {
+      machine = await prisma.machine.create({
+        data: {
+          orgId: session.orgId,
+          name,
+          code: codeRaw || null,
+          location: locationRaw || null,
+          apiKey,
+          pairingCode,
+          pairingCodeExpiresAt: pairingExpiresAt,
+        },
+        select: {
+          id: true,
+          name: true,
+          code: true,
+          location: true,
+          pairingCode: true,
+          pairingCodeExpiresAt: true,
+        },
+      });
+      break;
+    } catch (err: unknown) {
+      const code = typeof err === "object" && err !== null ? (err as { code?: string }).code : undefined;
+      if (code !== "P2002") throw err;
+    }
+  }
+
+  if (!machine?.pairingCode) {
+    return NextResponse.json({ ok: false, error: "Failed to generate pairing code" }, { status: 500 });
+  }
+
+  return NextResponse.json({ ok: true, machine });
+}

app/api/reasons/catalog/route.ts

@@ -1,12 +1,8 @@
 import { NextResponse } from "next/server";
 import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
-import {
-  flattenReasonCatalog,
-  loadFallbackReasonCatalog,
-  normalizeReasonCatalog,
-  type ReasonCatalogKind,
-} from "@/lib/reasonCatalog";
+import { flattenReasonCatalog, normalizeReasonCatalog, type ReasonCatalogKind } from "@/lib/reasonCatalog";
+import { effectiveReasonCatalogForOrg, loadReasonCatalogFromDb } from "@/lib/reasonCatalogDb";
 
 function asKind(value: string | null): ReasonCatalogKind | null {
   const kind = String(value ?? "").toLowerCase();
@@ -26,20 +22,30 @@ export async function GET(req: Request) {
 
   const orgSettings = await prisma.orgSettings.findUnique({
     where: { orgId: session.orgId },
-    select: { defaultsJson: true },
+    select: { defaultsJson: true, version: true },
   });
-  const defaultsJson =
-    orgSettings?.defaultsJson && typeof orgSettings.defaultsJson === "object" && !Array.isArray(orgSettings.defaultsJson)
-      ? (orgSettings.defaultsJson as Record<string, unknown>)
+  const version = orgSettings?.version ?? 1;
+  const defaultsJson = orgSettings?.defaultsJson ?? null;
+
+  const fromDb = await loadReasonCatalogFromDb(session.orgId, version);
+  const catalog = await effectiveReasonCatalogForOrg(session.orgId, defaultsJson, version);
+
+  const defs =
+    defaultsJson && typeof defaultsJson === "object" && !Array.isArray(defaultsJson)
+      ? (defaultsJson as Record<string, unknown>)
       : {};
-  const settingsCatalog = normalizeReasonCatalog(defaultsJson.reasonCatalog ?? defaultsJson.reasonCatalogData);
-  const fallbackCatalog = await loadFallbackReasonCatalog();
-  const catalog = settingsCatalog ?? fallbackCatalog;
-  const rows = flattenReasonCatalog(catalog, kind);
+  const legacyJson = normalizeReasonCatalog(defs.reasonCatalog ?? defs.reasonCatalogData);
+
+  let source: "db" | "legacy" | "fallback";
+  if (fromDb) source = "db";
+  else if (legacyJson) source = "legacy";
+  else source = "fallback";
+
+  const rows = flattenReasonCatalog(catalog, kind, { activeOnly: true });
 
   return NextResponse.json({
     ok: true,
-    source: settingsCatalog ? "settings" : "fallback",
+    source,
     kind,
     catalogVersion: catalog.version,
     categories: catalog[kind],

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

@@ -17,7 +17,7 @@ import {
   validateShiftOverrides,
   validateThresholds,
 } from "@/lib/settings";
-import { loadFallbackReasonCatalog, normalizeReasonCatalog, type ReasonCatalog } from "@/lib/reasonCatalog";
+import { effectiveReasonCatalogForOrg } from "@/lib/reasonCatalogDb";
 import { publishSettingsUpdate } from "@/lib/mqtt";
 import { z } from "zod";
 
@@ -46,21 +46,18 @@ function pickAllowedOverrides(raw: unknown) {
   return out;
 }
 
-function withReasonCatalog<T extends Record<string, unknown>>(payload: T, fallbackCatalog: ReasonCatalog) {
-  const base = (isPlainObject(payload) ? { ...payload } : {}) as T;
-  const defaults = isPlainObject(base.defaults) ? base.defaults : {};
-  const parsed =
-    normalizeReasonCatalog(base.reasonCatalog) ??
-    normalizeReasonCatalog(base.reasonCatalogData) ??
-    normalizeReasonCatalog(defaults.reasonCatalog) ??
-    normalizeReasonCatalog(defaults.reasonCatalogData) ??
-    fallbackCatalog;
-
+async function attachReasonCatalog(
+  orgId: string,
+  defaultsJson: unknown,
+  settingsVersion: number,
+  base: Record<string, unknown>
+): Promise<Record<string, unknown>> {
+  const catalog = await effectiveReasonCatalogForOrg(orgId, defaultsJson, settingsVersion);
   return {
     ...base,
-    reasonCatalog: parsed,
-    reasonCatalogData: parsed,
-    reasonCatalogVersion: Number(parsed.version || 1),
+    reasonCatalog: catalog,
+    reasonCatalogData: catalog,
+    reasonCatalogVersion: Number(catalog.version || 1),
   };
 }
 
@@ -164,9 +161,7 @@ export async function GET(
     if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
     orgId = machine.orgId;
   }
-  const fallbackCatalog = await loadFallbackReasonCatalog();
-
-  const { settings, overrides } = await prisma.$transaction(async (tx) => {
+  const { orgRow, shifts, rawOverrides } = await prisma.$transaction(async (tx) => {
     const orgSettings = await ensureOrgSettings(tx, orgId as string, userId);
     if (!orgSettings?.settings) throw new Error("SETTINGS_NOT_FOUND");
 
@@ -175,25 +170,24 @@ export async function GET(
       select: { overridesJson: true },
     });
 
-    const orgPayload = withReasonCatalog(
-      buildSettingsPayload(orgSettings.settings, orgSettings.shifts ?? []),
-      fallbackCatalog
-    );
     const rawOverrides = pickAllowedOverrides(machineSettings?.overridesJson ?? {});
-    const effective = withReasonCatalog(
-      deepMerge(orgPayload, rawOverrides) as Record<string, unknown>,
-      fallbackCatalog
-    );
-
-    return { settings: { org: orgPayload, effective }, overrides: rawOverrides };
+    return {
+      orgRow: orgSettings.settings,
+      shifts: orgSettings.shifts ?? [],
+      rawOverrides,
+    };
   });
 
+  const baseOrg = buildSettingsPayload(orgRow, shifts) as Record<string, unknown>;
+  const orgPayload = await attachReasonCatalog(orgId as string, orgRow.defaultsJson, orgRow.version, baseOrg);
+  const effective = deepMerge(orgPayload, rawOverrides) as Record<string, unknown>;
+
   return NextResponse.json({
     ok: true,
     machineId,
-    orgSettings: settings.org,
-    effectiveSettings: settings.effective,
-    overrides,
+    orgSettings: orgPayload,
+    effectiveSettings: effective,
+    overrides: rawOverrides,
   });
 }
 
@@ -413,25 +407,23 @@ export async function PUT(
       },
     });
 
-    const fallbackCatalog = await loadFallbackReasonCatalog();
-    const orgPayload = withReasonCatalog(
-      buildSettingsPayload(orgSettings.settings, orgSettings.shifts ?? []),
-      fallbackCatalog
-    );
-    const overrides = pickAllowedOverrides(saved.overridesJson ?? {});
-    const effective = withReasonCatalog(
-      deepMerge(orgPayload, overrides) as Record<string, unknown>,
-      fallbackCatalog
-    );
-
     return {
-      orgPayload,
-      overrides,
-      effective,
+      orgSettingsRow: orgSettings.settings,
+      shifts: orgSettings.shifts ?? [],
+      overrides: pickAllowedOverrides(saved.overridesJson ?? {}),
       overridesUpdatedAt: saved.updatedAt,
     };
   });
 
+  const baseOrg = buildSettingsPayload(result.orgSettingsRow, result.shifts) as Record<string, unknown>;
+  const orgPayload = await attachReasonCatalog(
+    session.orgId,
+    result.orgSettingsRow.defaultsJson,
+    result.orgSettingsRow.version,
+    baseOrg
+  );
+  const effective = deepMerge(orgPayload, result.overrides) as Record<string, unknown>;
+
   const overridesUpdatedAt =
     result.overridesUpdatedAt && result.overridesUpdatedAt instanceof Date
       ? result.overridesUpdatedAt.toISOString()
@@ -440,7 +432,7 @@ export async function PUT(
     await publishSettingsUpdate({
       orgId: session.orgId,
       machineId,
-      version: Number(result.orgPayload.version ?? 0),
+      version: Number(result.orgSettingsRow.version ?? 0),
       source,
       overridesUpdatedAt,
     });
@@ -451,8 +443,8 @@ export async function PUT(
   return NextResponse.json({
     ok: true,
     machineId,
-    orgSettings: result.orgPayload,
-    effectiveSettings: result.effective,
+    orgSettings: orgPayload,
+    effectiveSettings: effective,
     overrides: result.overrides,
   });
 }

app/api/settings/reason-catalog/categories/[categoryId]/route.ts

@@ -0,0 +1,106 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+import { bumpOrgSettingsVersion, composeReasonCode } from "@/lib/reasonCatalogDb";
+import { z } from "zod";
+
+const PREFIX_RE = /^[A-Za-z][A-Za-z0-9-]*$/;
+
+const patchSchema = z.object({
+  name: z.string().trim().min(1).max(200).optional(),
+  codePrefix: z
+    .string()
+    .trim()
+    .min(1)
+    .max(32)
+    .transform((s) => s.toUpperCase())
+    .optional(),
+  sortOrder: z.number().int().optional(),
+  active: z.boolean().optional(),
+});
+
+export async function PATCH(
+  req: Request,
+  { params }: { params: Promise<{ categoryId: string }> }
+) {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const { categoryId } = await params;
+  const parsed = patchSchema.safeParse(await req.json().catch(() => null));
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid body", issues: parsed.error.flatten() }, { status: 400 });
+  }
+
+  const existing = await prisma.reasonCatalogCategory.findFirst({
+    where: { id: categoryId, orgId: auth.session.orgId },
+    include: { items: true },
+  });
+  if (!existing) return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+
+  const nextPrefix = parsed.data.codePrefix ?? existing.codePrefix;
+  if (parsed.data.codePrefix !== undefined && !PREFIX_RE.test(nextPrefix)) {
+    return NextResponse.json(
+      { ok: false, error: "codePrefix must start with a letter; letters, digits, hyphen allowed." },
+      { status: 400 }
+    );
+  }
+
+  if (parsed.data.codePrefix !== undefined && parsed.data.codePrefix !== existing.codePrefix) {
+    const proposed = new Set<string>();
+    for (const it of existing.items) {
+      proposed.add(composeReasonCode(nextPrefix, it.codeSuffix));
+    }
+    const codes = [...proposed];
+    const conflicts = await prisma.reasonCatalogItem.findMany({
+      where: {
+        orgId: auth.session.orgId,
+        reasonCode: { in: codes },
+        NOT: { categoryId: existing.id },
+      },
+      select: { reasonCode: true },
+    });
+    if (conflicts.length) {
+      return NextResponse.json(
+        { ok: false, error: "Prefix change would duplicate codes", conflicts: conflicts.map((c) => c.reasonCode) },
+        { status: 409 }
+      );
+    }
+  }
+
+  try {
+    await prisma.$transaction(async (tx) => {
+      await tx.reasonCatalogCategory.update({
+        where: { id: categoryId },
+        data: {
+          ...(parsed.data.name !== undefined ? { name: parsed.data.name } : {}),
+          ...(parsed.data.codePrefix !== undefined ? { codePrefix: parsed.data.codePrefix } : {}),
+          ...(parsed.data.sortOrder !== undefined ? { sortOrder: parsed.data.sortOrder } : {}),
+          ...(parsed.data.active !== undefined ? { active: parsed.data.active } : {}),
+        },
+      });
+
+      if (parsed.data.codePrefix !== undefined && parsed.data.codePrefix !== existing.codePrefix) {
+        for (const it of existing.items) {
+          const reasonCode = composeReasonCode(nextPrefix, it.codeSuffix);
+          await tx.reasonCatalogItem.update({
+            where: { id: it.id },
+            data: { reasonCode },
+          });
+        }
+      }
+
+      await bumpOrgSettingsVersion(tx, auth.session.orgId, auth.session.userId);
+    });
+
+    const updated = await prisma.reasonCatalogCategory.findUnique({
+      where: { id: categoryId },
+      include: { items: { orderBy: [{ sortOrder: "asc" }, { reasonCode: "asc" }] } },
+    });
+
+    return NextResponse.json({ ok: true, category: updated });
+  } catch (e) {
+    console.error("[reason-catalog category PATCH]", e);
+    return NextResponse.json({ ok: false, error: "Update failed" }, { status: 500 });
+  }
+}

app/api/settings/reason-catalog/categories/route.ts

@@ -0,0 +1,64 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+import { bumpOrgSettingsVersion } from "@/lib/reasonCatalogDb";
+import { z } from "zod";
+
+const PREFIX_RE = /^[A-Za-z][A-Za-z0-9-]*$/;
+
+const bodySchema = z.object({
+  kind: z.enum(["downtime", "scrap"]),
+  name: z.string().trim().min(1).max(200),
+  codePrefix: z
+    .string()
+    .trim()
+    .min(1)
+    .max(32)
+    .transform((s) => s.toUpperCase()),
+});
+
+export async function POST(req: Request) {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const parsed = bodySchema.safeParse(await req.json().catch(() => null));
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid body", issues: parsed.error.flatten() }, { status: 400 });
+  }
+  const { kind, name, codePrefix } = parsed.data;
+  if (!PREFIX_RE.test(codePrefix)) {
+    return NextResponse.json(
+      { ok: false, error: "codePrefix must start with a letter; letters, digits, hyphen allowed." },
+      { status: 400 }
+    );
+  }
+
+  try {
+    const row = await prisma.$transaction(async (tx) => {
+      const last = await tx.reasonCatalogCategory.findFirst({
+        where: { orgId: auth.session.orgId, kind },
+        orderBy: { sortOrder: "desc" },
+        select: { sortOrder: true },
+      });
+      const sortOrder = (last?.sortOrder ?? -1) + 1;
+
+      const created = await tx.reasonCatalogCategory.create({
+        data: {
+          orgId: auth.session.orgId,
+          kind,
+          name,
+          codePrefix,
+          sortOrder,
+          active: true,
+        },
+      });
+      await bumpOrgSettingsVersion(tx, auth.session.orgId, auth.session.userId);
+      return created;
+    });
+
+    return NextResponse.json({ ok: true, category: row });
+  } catch (e) {
+    console.error("[reason-catalog categories POST]", e);
+    return NextResponse.json({ ok: false, error: "Create failed" }, { status: 500 });
+  }
+}

app/api/settings/reason-catalog/items/[itemId]/route.ts

@@ -0,0 +1,69 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+import { bumpOrgSettingsVersion, composeReasonCode, isNumericSuffix } from "@/lib/reasonCatalogDb";
+import { z } from "zod";
+
+const patchSchema = z.object({
+  name: z.string().trim().min(1).max(500).optional(),
+  codeSuffix: z.string().trim().min(1).max(32).optional(),
+  sortOrder: z.number().int().optional(),
+  active: z.boolean().optional(),
+});
+
+export async function PATCH(
+  req: Request,
+  { params }: { params: Promise<{ itemId: string }> }
+) {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const { itemId } = await params;
+  const parsed = patchSchema.safeParse(await req.json().catch(() => null));
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid body", issues: parsed.error.flatten() }, { status: 400 });
+  }
+
+  const existing = await prisma.reasonCatalogItem.findFirst({
+    where: { id: itemId, orgId: auth.session.orgId },
+    include: { category: true },
+  });
+  if (!existing) return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+
+  const nextSuffix = parsed.data.codeSuffix ?? existing.codeSuffix;
+  if (parsed.data.codeSuffix !== undefined && !isNumericSuffix(nextSuffix)) {
+    return NextResponse.json({ ok: false, error: "codeSuffix must be digits only" }, { status: 400 });
+  }
+
+  const reasonCode = composeReasonCode(existing.category.codePrefix, nextSuffix);
+  if (reasonCode !== existing.reasonCode) {
+    const conflict = await prisma.reasonCatalogItem.findFirst({
+      where: { orgId: auth.session.orgId, reasonCode, NOT: { id: itemId } },
+      select: { id: true },
+    });
+    if (conflict) {
+      return NextResponse.json({ ok: false, error: "Duplicate reasonCode for this organization" }, { status: 409 });
+    }
+  }
+
+  try {
+    await prisma.$transaction(async (tx) => {
+      await tx.reasonCatalogItem.update({
+        where: { id: itemId },
+        data: {
+          ...(parsed.data.name !== undefined ? { name: parsed.data.name } : {}),
+          ...(parsed.data.codeSuffix !== undefined ? { codeSuffix: nextSuffix, reasonCode } : {}),
+          ...(parsed.data.sortOrder !== undefined ? { sortOrder: parsed.data.sortOrder } : {}),
+          ...(parsed.data.active !== undefined ? { active: parsed.data.active } : {}),
+        },
+      });
+      await bumpOrgSettingsVersion(tx, auth.session.orgId, auth.session.userId);
+    });
+
+    const updated = await prisma.reasonCatalogItem.findUnique({ where: { id: itemId } });
+    return NextResponse.json({ ok: true, item: updated });
+  } catch (e) {
+    console.error("[reason-catalog item PATCH]", e);
+    return NextResponse.json({ ok: false, error: "Update failed" }, { status: 500 });
+  }
+}

app/api/settings/reason-catalog/items/route.ts

@@ -0,0 +1,71 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+import { bumpOrgSettingsVersion, composeReasonCode, isNumericSuffix } from "@/lib/reasonCatalogDb";
+import { z } from "zod";
+
+const bodySchema = z.object({
+  categoryId: z.string().uuid(),
+  codeSuffix: z.string().trim().min(1).max(32),
+  name: z.string().trim().min(1).max(500),
+  sortOrder: z.number().int().optional(),
+});
+
+export async function POST(req: Request) {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const parsed = bodySchema.safeParse(await req.json().catch(() => null));
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid body", issues: parsed.error.flatten() }, { status: 400 });
+  }
+
+  const { categoryId, codeSuffix, name, sortOrder } = parsed.data;
+  if (!isNumericSuffix(codeSuffix)) {
+    return NextResponse.json({ ok: false, error: "codeSuffix must be digits only" }, { status: 400 });
+  }
+
+  const category = await prisma.reasonCatalogCategory.findFirst({
+    where: { id: categoryId, orgId: auth.session.orgId },
+  });
+  if (!category) return NextResponse.json({ ok: false, error: "Category not found" }, { status: 404 });
+
+  const reasonCode = composeReasonCode(category.codePrefix, codeSuffix);
+
+  try {
+    const row = await prisma.$transaction(async (tx) => {
+      let nextOrder = sortOrder;
+      if (nextOrder === undefined) {
+        const last = await tx.reasonCatalogItem.findFirst({
+          where: { categoryId },
+          orderBy: { sortOrder: "desc" },
+          select: { sortOrder: true },
+        });
+        nextOrder = (last?.sortOrder ?? -1) + 1;
+      }
+
+      const created = await tx.reasonCatalogItem.create({
+        data: {
+          orgId: auth.session.orgId,
+          categoryId,
+          name,
+          codeSuffix,
+          reasonCode,
+          sortOrder: nextOrder,
+          active: true,
+        },
+      });
+      await bumpOrgSettingsVersion(tx, auth.session.orgId, auth.session.userId);
+      return created;
+    });
+
+    return NextResponse.json({ ok: true, item: row });
+  } catch (e: unknown) {
+    const code = typeof e === "object" && e && "code" in e ? (e as { code: string }).code : "";
+    if (code === "P2002") {
+      return NextResponse.json({ ok: false, error: "Duplicate reasonCode for this organization" }, { status: 409 });
+    }
+    console.error("[reason-catalog items POST]", e);
+    return NextResponse.json({ ok: false, error: "Create failed" }, { status: 500 });
+  }
+}

app/api/settings/reason-catalog/route.ts

@@ -0,0 +1,43 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireOrgAdminSession } from "@/lib/auth/requireOrgAdminSession";
+
+/** Full tree for Control Tower (includes inactive rows). */
+export async function GET() {
+  const auth = await requireOrgAdminSession();
+  if (!auth.ok) return auth.response;
+
+  const orgSettings = await prisma.orgSettings.findUnique({
+    where: { orgId: auth.session.orgId },
+    select: { version: true },
+  });
+
+  const categories = await prisma.reasonCatalogCategory.findMany({
+    where: { orgId: auth.session.orgId },
+    include: {
+      items: { orderBy: [{ sortOrder: "asc" }, { reasonCode: "asc" }] },
+    },
+    orderBy: [{ kind: "asc" }, { sortOrder: "asc" }, { name: "asc" }],
+  });
+
+  return NextResponse.json({
+    ok: true,
+    catalogVersion: orgSettings?.version ?? 1,
+    categories: categories.map((c) => ({
+      id: c.id,
+      kind: c.kind,
+      name: c.name,
+      codePrefix: c.codePrefix,
+      sortOrder: c.sortOrder,
+      active: c.active,
+      items: c.items.map((it) => ({
+        id: it.id,
+        name: it.name,
+        codeSuffix: it.codeSuffix,
+        reasonCode: it.reasonCode,
+        sortOrder: it.sortOrder,
+        active: it.active,
+      })),
+    })),
+  });
+}

app/api/settings/route.ts

@@ -19,7 +19,7 @@ import {
   validateShiftOverrides,
   validateThresholds,
 } from "@/lib/settings";
-import { loadFallbackReasonCatalog, normalizeReasonCatalog, type ReasonCatalog } from "@/lib/reasonCatalog";
+import { effectiveReasonCatalogForOrg } from "@/lib/reasonCatalogDb";
 import { publishSettingsUpdate } from "@/lib/mqtt";
 import { z } from "zod";
 
@@ -39,21 +39,18 @@ function canManageSettings(role?: string | null) {
   return role === "OWNER" || role === "ADMIN";
 }
 
-function withReasonCatalog<T extends Record<string, unknown>>(payload: T, fallbackCatalog: ReasonCatalog) {
-  const base = (isPlainObject(payload) ? { ...payload } : {}) as T;
-  const defaults = isPlainObject(base.defaults) ? base.defaults : {};
-  const parsed =
-    normalizeReasonCatalog(base.reasonCatalog) ??
-    normalizeReasonCatalog(base.reasonCatalogData) ??
-    normalizeReasonCatalog(defaults.reasonCatalog) ??
-    normalizeReasonCatalog(defaults.reasonCatalogData) ??
-    fallbackCatalog;
-
+async function attachReasonCatalog(
+  orgId: string,
+  defaultsJson: unknown,
+  settingsVersion: number,
+  base: Record<string, unknown>
+): Promise<Record<string, unknown>> {
+  const catalog = await effectiveReasonCatalogForOrg(orgId, defaultsJson, settingsVersion);
   return {
     ...base,
-    reasonCatalog: parsed,
-    reasonCatalogData: parsed,
-    reasonCatalogVersion: Number(parsed.version || 1),
+    reasonCatalog: catalog,
+    reasonCatalogData: catalog,
+    reasonCatalogVersion: Number(catalog.version || 1),
   };
 }
 
@@ -66,7 +63,6 @@ const settingsPayloadSchema = z
     thresholds: z.any().optional(),
     alerts: z.any().optional(),
     defaults: z.any().optional(),
-    reasonCatalog: z.any().optional(),
     version: z.union([z.number(), z.string()]).optional(),
   })
   .passthrough();
@@ -145,8 +141,13 @@ async function loadSettingsPayload(orgId: string, userId: string) {
     return found;
   });
 
-  const fallbackCatalog = await loadFallbackReasonCatalog();
-  const payload = withReasonCatalog(buildSettingsPayload(loaded.settings, loaded.shifts ?? []), fallbackCatalog);
+  const base = buildSettingsPayload(loaded.settings, loaded.shifts ?? []) as Record<string, unknown>;
+  const payload = await attachReasonCatalog(
+    orgId,
+    loaded.settings.defaultsJson,
+    loaded.settings.version,
+    base
+  );
   const defaultsRaw = isPlainObject(loaded.settings.defaultsJson) ? (loaded.settings.defaultsJson as any) : {};
   const modulesRaw = isPlainObject(defaultsRaw.modules) ? defaultsRaw.modules : {};
   const modules = { screenlessMode: modulesRaw.screenlessMode === true };
@@ -221,7 +222,6 @@ export async function PUT(req: Request) {
     const thresholds = parsed.data.thresholds;
     const alerts = parsed.data.alerts;
     const defaults = parsed.data.defaults;
-    const reasonCatalogRaw = parsed.data.reasonCatalog;
     const expectedVersion = parsed.data.version;
     const modules = parsed.data.modules;
 
@@ -233,7 +233,6 @@ export async function PUT(req: Request) {
       thresholds === undefined &&
       alerts === undefined &&
       defaults === undefined &&
-      reasonCatalogRaw === undefined &&
       modules === undefined
 
     ) {
@@ -252,13 +251,6 @@ export async function PUT(req: Request) {
     if (defaults !== undefined && !isPlainObject(defaults)) {
       return NextResponse.json({ ok: false, error: "defaults must be an object" }, { status: 400 });
     }
-    const nextReasonCatalog =
-      reasonCatalogRaw === undefined || reasonCatalogRaw === null
-        ? reasonCatalogRaw
-        : normalizeReasonCatalog(reasonCatalogRaw);
-    if (reasonCatalogRaw !== undefined && reasonCatalogRaw !== null && !nextReasonCatalog) {
-      return NextResponse.json({ ok: false, error: "reasonCatalog must be a valid catalog payload" }, { status: 400 });
-    }
     if (modules !== undefined && !isPlainObject(modules)) {
       return NextResponse.json({ ok: false, error: "Invalid modules payload" }, { status: 400 });
     }
@@ -333,20 +325,16 @@ export async function PUT(req: Request) {
         : { ...currentModulesRaw, screenlessMode };
 
     // Write defaultsJson if either defaults changed OR modules changed
-    const shouldWriteDefaultsJson =
-      !!nextDefaultsCore || screenlessMode !== undefined || reasonCatalogRaw !== undefined;
+    const shouldWriteDefaultsJson = !!nextDefaultsCore || screenlessMode !== undefined;
 
     const nextDefaultsJson = shouldWriteDefaultsJson
       ? { ...(nextDefaultsCore ?? normalizeDefaults(currentDefaultsRaw)), modules: nextModules }
       : undefined;
 
-    if (nextDefaultsJson && reasonCatalogRaw !== undefined) {
+    if (nextDefaultsJson) {
       const defaultsTarget = nextDefaultsJson as Record<string, unknown>;
-      if (nextReasonCatalog === null) {
       delete defaultsTarget.reasonCatalog;
-      } else if (nextReasonCatalog) {
-        defaultsTarget.reasonCatalog = nextReasonCatalog;
-      }
+      delete defaultsTarget.reasonCatalogData;
     }
 
 
@@ -444,12 +432,18 @@ export async function PUT(req: Request) {
       return NextResponse.json({ ok: false, error: updated.error }, { status: 400 });
     }
 
-    const payload = buildSettingsPayload(updated.settings, updated.shifts ?? []);
+    const baseOut = buildSettingsPayload(updated.settings, updated.shifts ?? []) as Record<string, unknown>;
+    const payload = await attachReasonCatalog(
+      session.orgId,
+      updated.settings.defaultsJson,
+      updated.settings.version,
+      baseOut
+    );
     const updatedAt =
       typeof payload.updatedAt === "string"
         ? payload.updatedAt
         : payload.updatedAt
-        ? payload.updatedAt.toISOString()
+        ? (payload.updatedAt as Date).toISOString()
         : undefined;
     try {
       await publishSettingsUpdate({

components/recap/RecapFullTimeline.tsx

@@ -90,18 +90,19 @@ export default function RecapFullTimeline({
                   locale
                 )} · ${formatDuration(segment.startMs, segment.endMs)}${segment.label ? ` · ${segment.label}` : ""}`;
 
+                const showLabel = widthPct > LABEL_MIN_WIDTH_PCT;
                 return (
                   <div
                     key={`${segment.type}:${segment.startMs}:${segment.endMs}:${segment.label}`}
-                    className={`flex h-full shrink-0 items-center justify-center truncate px-2 text-xs font-semibold ${
-                      TIMELINE_COLORS[segment.type]
-                    } ${index === 0 ? "rounded-l-xl" : ""} ${
-                      index === normalized.length - 1 ? "rounded-r-xl" : ""
-                    }`}
+                    className={`flex h-full items-center justify-center overflow-hidden text-xs font-semibold ${
+                      showLabel ? "truncate px-2" : ""
+                    } ${TIMELINE_COLORS[segment.type]} ${
+                      index === 0 ? "rounded-l-xl" : ""
+                    } ${index === normalized.length - 1 ? "rounded-r-xl" : ""}`}
                     style={{ width: `${Math.max(0, widthPct)}%` }}
                     title={title}
                   >
-                    {widthPct > LABEL_MIN_WIDTH_PCT ? segment.label : ""}
+                    {showLabel ? segment.label : ""}
                   </div>
                 );
               })}

components/recap/RecapMachineCard.tsx

@@ -17,12 +17,14 @@ const STATUS_DOT: Record<RecapSummaryMachine["status"], string> = {
   "mold-change": "bg-amber-400",
   stopped: "bg-red-500",
   offline: "bg-zinc-500",
+  idle: "bg-zinc-400",
 };
 
 function statusLabel(status: RecapSummaryMachine["status"], t: (key: string) => string) {
   if (status === "running") return t("recap.status.running");
   if (status === "mold-change") return t("recap.status.moldChange");
   if (status === "stopped") return t("recap.status.stopped");
+  if (status === "idle") return t("recap.status.idle");
   return t("recap.status.offline");
 }
 
@@ -37,6 +39,9 @@ export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Prop
 
   const zeroActivity = machine.goodParts === 0 && machine.scrap === 0 && machine.stopsCount === 0;
   const primaryMetric = machine.oee == null ? "—" : `${machine.oee.toFixed(1)}%`;
+  const ongoingStopMin = machine.ongoingStopMin ?? 0;
+  const isUrgent = machine.status === "stopped" && ongoingStopMin >= 5;
+  const isCalm = machine.status === "idle";
   const timelineSegments = timeline?.segments ?? machine.miniTimeline;
   const timelineStart = timeline?.range.start ?? rangeStart;
   const timelineEnd = timeline?.range.end ?? rangeEnd;
@@ -59,7 +64,7 @@ export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Prop
     async function loadTimeline() {
       try {
         const res = await fetch(
-          `/api/recap/${machine.machineId}/timeline?range=24h&compact=1&maxSegments=60`,
+          `/api/recap/${machine.machineId}/timeline?range=24h`,
           { cache: "no-store" }
         );
         const json = await res.json().catch(() => null);
@@ -83,7 +88,13 @@ export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Prop
   return (
     <Link
       href={`/recap/${machine.machineId}`}
-      className="rounded-2xl border border-white/10 bg-white/5 p-4 transition hover:bg-white/10 focus-visible:outline-none focus-visible:ring-2 focus-visible:ring-emerald-300/80"
+      className={`rounded-2xl border p-4 transition focus-visible:outline-none focus-visible:ring-2 focus-visible:ring-emerald-300/80 ${
+        isUrgent
+          ? "border-red-500/60 bg-red-500/10 hover:bg-red-500/15 ring-2 ring-red-500/40 animate-pulse"
+          : isCalm
+          ? "border-white/5 bg-white/[0.02] hover:bg-white/[0.04] opacity-70"
+          : "border-white/10 bg-white/5 hover:bg-white/10"
+      }`}
     >
       <div className="flex items-start justify-between gap-3">
         <div className="min-w-0">
@@ -136,7 +147,14 @@ export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Prop
         </div>
       ) : null}
 
-      <div className="mt-3 text-xs text-zinc-400">{footerText}</div>
+      <div className={`mt-3 text-xs ${isUrgent ? "text-red-200 font-semibold" : isCalm ? "text-zinc-500" : "text-zinc-400"}`}>
+        {isUrgent
+          ? t("recap.card.stoppedFor", { min: ongoingStopMin })
+              + (machine.activeWorkOrderId ? ` · WO ${machine.activeWorkOrderId}` : "")
+          : machine.status === "idle"
+          ? t("recap.card.idle")
+          : footerText}
+      </div>
     </Link>
   );
 }

components/recap/RecapMachineCard.tsx.bak

@@ -0,0 +1,142 @@
+"use client";
+
+import Link from "next/link";
+import { useEffect, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+import type { RecapSummaryMachine, RecapTimelineResponse } from "@/lib/recap/types";
+import RecapMiniTimeline from "@/components/recap/RecapMiniTimeline";
+
+type Props = {
+  machine: RecapSummaryMachine;
+  rangeStart: string;
+  rangeEnd: string;
+};
+
+const STATUS_DOT: Record<RecapSummaryMachine["status"], string> = {
+  running: "bg-emerald-400",
+  "mold-change": "bg-amber-400",
+  stopped: "bg-red-500",
+  offline: "bg-zinc-500",
+};
+
+function statusLabel(status: RecapSummaryMachine["status"], t: (key: string) => string) {
+  if (status === "running") return t("recap.status.running");
+  if (status === "mold-change") return t("recap.status.moldChange");
+  if (status === "stopped") return t("recap.status.stopped");
+  return t("recap.status.offline");
+}
+
+function toInt(value: number | null | undefined) {
+  if (value == null || Number.isNaN(value)) return 0;
+  return Math.max(0, Math.round(value));
+}
+
+export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Props) {
+  const { t, locale } = useI18n();
+  const [timeline, setTimeline] = useState<RecapTimelineResponse | null>(null);
+
+  const zeroActivity = machine.goodParts === 0 && machine.scrap === 0 && machine.stopsCount === 0;
+  const primaryMetric = machine.oee == null ? "—" : `${machine.oee.toFixed(1)}%`;
+  const timelineSegments = timeline?.segments ?? machine.miniTimeline;
+  const timelineStart = timeline?.range.start ?? rangeStart;
+  const timelineEnd = timeline?.range.end ?? rangeEnd;
+  const hasTimelineData = timeline?.hasData ?? timelineSegments.length > 0;
+
+  const lastSeenLabel =
+    machine.lastActivityMin == null
+      ? t("common.never")
+      : t("recap.card.lastActivity", { min: toInt(machine.lastActivityMin) });
+
+  const footerText = machine.activeWorkOrderId
+    ? t("recap.card.activeWorkOrder", { id: machine.activeWorkOrderId })
+    : lastSeenLabel;
+
+  const moldMinutes = machine.moldChange?.active ? machine.moldChange.elapsedMin : null;
+
+  useEffect(() => {
+    let alive = true;
+
+    async function loadTimeline() {
+      try {
+        const res = await fetch(
+          `/api/recap/${machine.machineId}/timeline?range=24h&compact=1&maxSegments=60`,
+          { cache: "no-store" }
+        );
+        const json = await res.json().catch(() => null);
+        if (!alive || !res.ok || !json) return;
+        setTimeline(json as RecapTimelineResponse);
+      } catch {
+      }
+    }
+
+    void loadTimeline();
+    const timer = window.setInterval(() => {
+      void loadTimeline();
+    }, 60000);
+
+    return () => {
+      alive = false;
+      window.clearInterval(timer);
+    };
+  }, [machine.machineId]);
+
+  return (
+    <Link
+      href={`/recap/${machine.machineId}`}
+      className="rounded-2xl border border-white/10 bg-white/5 p-4 transition hover:bg-white/10 focus-visible:outline-none focus-visible:ring-2 focus-visible:ring-emerald-300/80"
+    >
+      <div className="flex items-start justify-between gap-3">
+        <div className="min-w-0">
+          <div className="truncate text-lg font-semibold text-white">{machine.name}</div>
+          <div className="mt-1 truncate text-xs text-zinc-400">{machine.location || t("common.na")}</div>
+        </div>
+        <span className="inline-flex items-center gap-2 rounded-full border border-white/10 px-2 py-1 text-xs text-zinc-200">
+          <span
+            className={`inline-block h-2.5 w-2.5 rounded-full ${STATUS_DOT[machine.status]}`}
+            aria-label={statusLabel(machine.status, t)}
+          />
+          {statusLabel(machine.status, t)}
+        </span>
+      </div>
+
+      <div className="mt-4 flex items-baseline gap-2">
+        <div className={`text-3xl font-semibold ${machine.oee == null ? "text-zinc-400" : "text-white"}`}>{primaryMetric}</div>
+        <div className="text-xs uppercase tracking-wide text-zinc-400">{t("recap.card.oee")}</div>
+      </div>
+      {machine.oee == null ? <div className="mt-1 text-xs text-zinc-500">{t("recap.kpi.noData")}</div> : null}
+
+      {zeroActivity ? <div className="mt-1 text-xs text-zinc-500">{t("recap.card.noProduction")}</div> : null}
+
+      <div className="mt-3 flex flex-wrap items-center gap-x-3 gap-y-1 text-xs text-zinc-300">
+        <span>{t("recap.card.good")}: {machine.goodParts}</span>
+        <span>{t("recap.card.scrap")}: {machine.scrap}</span>
+        <span>{t("recap.card.stops")}: {machine.stopsCount}</span>
+      </div>
+
+      <div className="mt-3">
+        <RecapMiniTimeline
+          rangeStart={timelineStart}
+          rangeEnd={timelineEnd}
+          segments={timelineSegments}
+          locale={locale}
+          hasData={hasTimelineData}
+          muted={zeroActivity}
+        />
+      </div>
+
+      {machine.moldChange?.active ? (
+        <div className="mt-3 rounded-lg border border-amber-400/40 bg-amber-400/10 px-2 py-1.5 text-xs text-amber-200">
+          {t("recap.card.moldChangeActive", { min: toInt(moldMinutes) })}
+        </div>
+      ) : null}
+
+      {machine.offlineForMin != null && machine.offlineForMin > 10 ? (
+        <div className="mt-2 rounded-lg border border-red-500/40 bg-red-500/10 px-2 py-1.5 text-xs text-red-200">
+          {t("recap.banner.offline", { min: toInt(machine.offlineForMin) })}
+        </div>
+      ) : null}
+
+      <div className="mt-3 text-xs text-zinc-400">{footerText}</div>
+    </Link>
+  );
+}

components/recap/RecapMachineCard.tsx.bak.step5

@@ -0,0 +1,153 @@
+"use client";
+
+import Link from "next/link";
+import { useEffect, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+import type { RecapSummaryMachine, RecapTimelineResponse } from "@/lib/recap/types";
+import RecapMiniTimeline from "@/components/recap/RecapMiniTimeline";
+
+type Props = {
+  machine: RecapSummaryMachine;
+  rangeStart: string;
+  rangeEnd: string;
+};
+
+const STATUS_DOT: Record<RecapSummaryMachine["status"], string> = {
+  running: "bg-emerald-400",
+  "mold-change": "bg-amber-400",
+  stopped: "bg-red-500",
+  offline: "bg-zinc-500",
+};
+
+function statusLabel(status: RecapSummaryMachine["status"], t: (key: string) => string) {
+  if (status === "running") return t("recap.status.running");
+  if (status === "mold-change") return t("recap.status.moldChange");
+  if (status === "stopped") return t("recap.status.stopped");
+  return t("recap.status.offline");
+}
+
+function toInt(value: number | null | undefined) {
+  if (value == null || Number.isNaN(value)) return 0;
+  return Math.max(0, Math.round(value));
+}
+
+export default function RecapMachineCard({ machine, rangeStart, rangeEnd }: Props) {
+  const { t, locale } = useI18n();
+  const [timeline, setTimeline] = useState<RecapTimelineResponse | null>(null);
+
+  const zeroActivity = machine.goodParts === 0 && machine.scrap === 0 && machine.stopsCount === 0;
+  const primaryMetric = machine.oee == null ? "—" : `${machine.oee.toFixed(1)}%`;
+  const ongoingStopMin = machine.ongoingStopMin ?? 0;
+  const isUrgent = machine.status === "stopped" && ongoingStopMin >= 5;
+  const timelineSegments = timeline?.segments ?? machine.miniTimeline;
+  const timelineStart = timeline?.range.start ?? rangeStart;
+  const timelineEnd = timeline?.range.end ?? rangeEnd;
+  const hasTimelineData = timeline?.hasData ?? timelineSegments.length > 0;
+
+  const lastSeenLabel =
+    machine.lastActivityMin == null
+      ? t("common.never")
+      : t("recap.card.lastActivity", { min: toInt(machine.lastActivityMin) });
+
+  const footerText = machine.activeWorkOrderId
+    ? t("recap.card.activeWorkOrder", { id: machine.activeWorkOrderId })
+    : lastSeenLabel;
+
+  const moldMinutes = machine.moldChange?.active ? machine.moldChange.elapsedMin : null;
+
+  useEffect(() => {
+    let alive = true;
+
+    async function loadTimeline() {
+      try {
+        const res = await fetch(
+          `/api/recap/${machine.machineId}/timeline?range=24h&compact=1&maxSegments=60`,
+          { cache: "no-store" }
+        );
+        const json = await res.json().catch(() => null);
+        if (!alive || !res.ok || !json) return;
+        setTimeline(json as RecapTimelineResponse);
+      } catch {
+      }
+    }
+
+    void loadTimeline();
+    const timer = window.setInterval(() => {
+      void loadTimeline();
+    }, 60000);
+
+    return () => {
+      alive = false;
+      window.clearInterval(timer);
+    };
+  }, [machine.machineId]);
+
+  return (
+    <Link
+      href={`/recap/${machine.machineId}`}
+      className={`rounded-2xl border p-4 transition focus-visible:outline-none focus-visible:ring-2 focus-visible:ring-emerald-300/80 ${
+        isUrgent
+          ? "border-red-500/60 bg-red-500/10 hover:bg-red-500/15 ring-2 ring-red-500/40 animate-pulse"
+          : "border-white/10 bg-white/5 hover:bg-white/10"
+      }`}
+    >
+      <div className="flex items-start justify-between gap-3">
+        <div className="min-w-0">
+          <div className="truncate text-lg font-semibold text-white">{machine.name}</div>
+          <div className="mt-1 truncate text-xs text-zinc-400">{machine.location || t("common.na")}</div>
+        </div>
+        <span className="inline-flex items-center gap-2 rounded-full border border-white/10 px-2 py-1 text-xs text-zinc-200">
+          <span
+            className={`inline-block h-2.5 w-2.5 rounded-full ${STATUS_DOT[machine.status]}`}
+            aria-label={statusLabel(machine.status, t)}
+          />
+          {statusLabel(machine.status, t)}
+        </span>
+      </div>
+
+      <div className="mt-4 flex items-baseline gap-2">
+        <div className={`text-3xl font-semibold ${machine.oee == null ? "text-zinc-400" : "text-white"}`}>{primaryMetric}</div>
+        <div className="text-xs uppercase tracking-wide text-zinc-400">{t("recap.card.oee")}</div>
+      </div>
+      {machine.oee == null ? <div className="mt-1 text-xs text-zinc-500">{t("recap.kpi.noData")}</div> : null}
+
+      {zeroActivity ? <div className="mt-1 text-xs text-zinc-500">{t("recap.card.noProduction")}</div> : null}
+
+      <div className="mt-3 flex flex-wrap items-center gap-x-3 gap-y-1 text-xs text-zinc-300">
+        <span>{t("recap.card.good")}: {machine.goodParts}</span>
+        <span>{t("recap.card.scrap")}: {machine.scrap}</span>
+        <span>{t("recap.card.stops")}: {machine.stopsCount}</span>
+      </div>
+
+      <div className="mt-3">
+        <RecapMiniTimeline
+          rangeStart={timelineStart}
+          rangeEnd={timelineEnd}
+          segments={timelineSegments}
+          locale={locale}
+          hasData={hasTimelineData}
+          muted={zeroActivity}
+        />
+      </div>
+
+      {machine.moldChange?.active ? (
+        <div className="mt-3 rounded-lg border border-amber-400/40 bg-amber-400/10 px-2 py-1.5 text-xs text-amber-200">
+          {t("recap.card.moldChangeActive", { min: toInt(moldMinutes) })}
+        </div>
+      ) : null}
+
+      {machine.offlineForMin != null && machine.offlineForMin > 10 ? (
+        <div className="mt-2 rounded-lg border border-red-500/40 bg-red-500/10 px-2 py-1.5 text-xs text-red-200">
+          {t("recap.banner.offline", { min: toInt(machine.offlineForMin) })}
+        </div>
+      ) : null}
+
+      <div className={`mt-3 text-xs ${isUrgent ? "text-red-200 font-semibold" : "text-zinc-400"}`}>
+        {isUrgent
+          ? t("recap.card.stoppedFor", { min: ongoingStopMin })
+              + (machine.activeWorkOrderId ? ` · WO ${machine.activeWorkOrderId}` : "")
+          : footerText}
+      </div>
+    </Link>
+  );
+}

components/settings/ReasonCatalogConfig.tsx

@@ -0,0 +1,445 @@
+"use client";
+
+import { useCallback, useEffect, useMemo, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+
+type CatalogKind = "downtime" | "scrap";
+
+type ApiItem = {
+  id: string;
+  name: string;
+  codeSuffix: string;
+  reasonCode: string;
+  sortOrder: number;
+  active: boolean;
+};
+
+type ApiCategory = {
+  id: string;
+  kind: string;
+  name: string;
+  codePrefix: string;
+  sortOrder: number;
+  active: boolean;
+  items: ApiItem[];
+};
+
+const PREFIX_RE = /^[A-Za-z][A-Za-z0-9-]*$/;
+
+/** Matches composeReasonCode in reasonCatalogDb (client-safe). */
+function formatPrintedPreview(prefix: string, digits: string): string {
+  const p = String(prefix).trim().toUpperCase();
+  const d = String(digits).trim();
+  if (!d) return p.length >= 3 ? `${p}-…` : `${p}…`;
+  if (/^\d+$/.test(d) && p.length >= 3) return `${p}-${d}`;
+  return `${p}${d}`;
+}
+
+async function readJson(res: Response) {
+  const data = await res.json().catch(() => null);
+  return data as Record<string, unknown> | null;
+}
+
+export function ReasonCatalogConfig({ disabled }: { disabled?: boolean }) {
+  const { t } = useI18n();
+  const [loading, setLoading] = useState(true);
+  const [error, setError] = useState<string | null>(null);
+  const [catalogVersion, setCatalogVersion] = useState(1);
+  const [categories, setCategories] = useState<ApiCategory[]>([]);
+  const [kind, setKind] = useState<CatalogKind>("downtime");
+  const [selectedCategoryId, setSelectedCategoryId] = useState<string | null>(null);
+  const [newCatName, setNewCatName] = useState("");
+  const [newCatPrefix, setNewCatPrefix] = useState("");
+  const [newDigits, setNewDigits] = useState("");
+  const [newItemName, setNewItemName] = useState("");
+  const [busy, setBusy] = useState(false);
+  const [editCatName, setEditCatName] = useState("");
+  const [editCatPrefix, setEditCatPrefix] = useState("");
+
+  const load = useCallback(async () => {
+    setLoading(true);
+    setError(null);
+    try {
+      const res = await fetch("/api/settings/reason-catalog");
+      const data = await readJson(res);
+      if (!res.ok || !data || data.ok !== true) {
+        const msg = typeof data?.error === "string" ? data.error : "Load failed";
+        throw new Error(msg);
+      }
+      setCatalogVersion(Number(data.catalogVersion ?? 1));
+      setCategories(Array.isArray(data.categories) ? (data.categories as ApiCategory[]) : []);
+    } catch (e) {
+      setError(e instanceof Error ? e.message : "Load failed");
+    } finally {
+      setLoading(false);
+    }
+  }, []);
+
+  useEffect(() => {
+    void load();
+  }, [load]);
+
+  const forKind = useMemo(
+    () => categories.filter((c) => String(c.kind).toLowerCase() === kind),
+    [categories, kind]
+  );
+
+  const selected = useMemo(
+    () => forKind.find((c) => c.id === selectedCategoryId) ?? null,
+    [forKind, selectedCategoryId]
+  );
+
+  useEffect(() => {
+    if (!selected) {
+      setEditCatName("");
+      setEditCatPrefix("");
+      return;
+    }
+    setEditCatName(selected.name);
+    setEditCatPrefix(selected.codePrefix);
+  }, [selected?.id, selected?.name, selected?.codePrefix]);
+
+  useEffect(() => {
+    if (!forKind.length) {
+      setSelectedCategoryId(null);
+      return;
+    }
+    if (!selectedCategoryId || !forKind.some((c) => c.id === selectedCategoryId)) {
+      setSelectedCategoryId(forKind[0]?.id ?? null);
+    }
+  }, [forKind, selectedCategoryId]);
+
+  const onDigitsChange = (raw: string) => {
+    setNewDigits(raw.replace(/\D/g, ""));
+  };
+
+  const createCategory = async () => {
+    const name = newCatName.trim();
+    const codePrefix = newCatPrefix.trim().toUpperCase();
+    if (!name || !codePrefix) return;
+    if (!PREFIX_RE.test(codePrefix)) {
+      setError(t("settings.reasonCatalog.prefixInvalid"));
+      return;
+    }
+    setBusy(true);
+    setError(null);
+    try {
+      const res = await fetch("/api/settings/reason-catalog/categories", {
+        method: "POST",
+        headers: { "Content-Type": "application/json" },
+        body: JSON.stringify({ kind, name, codePrefix }),
+      });
+      const data = await readJson(res);
+      if (!res.ok || !data || data.ok !== true) {
+        const msg = typeof data?.error === "string" ? data.error : "Create failed";
+        throw new Error(msg);
+      }
+      setNewCatName("");
+      setNewCatPrefix("");
+      await load();
+      const cat = data.category as { id?: string } | undefined;
+      if (cat?.id) setSelectedCategoryId(cat.id);
+    } catch (e) {
+      setError(e instanceof Error ? e.message : "Create failed");
+    } finally {
+      setBusy(false);
+    }
+  };
+
+  const addItem = async () => {
+    if (!selected) return;
+    const digits = newDigits.trim();
+    const name = newItemName.trim();
+    if (!digits || !name) return;
+    setBusy(true);
+    setError(null);
+    try {
+      const res = await fetch("/api/settings/reason-catalog/items", {
+        method: "POST",
+        headers: { "Content-Type": "application/json" },
+        body: JSON.stringify({ categoryId: selected.id, codeSuffix: digits, name }),
+      });
+      const data = await readJson(res);
+      if (!res.ok || !data || data.ok !== true) {
+        const msg = typeof data?.error === "string" ? data.error : "Create failed";
+        throw new Error(msg);
+      }
+      setNewDigits("");
+      setNewItemName("");
+      await load();
+    } catch (e) {
+      setError(e instanceof Error ? e.message : "Create failed");
+    } finally {
+      setBusy(false);
+    }
+  };
+
+  const patchItem = async (itemId: string, patch: Record<string, unknown>) => {
+    setBusy(true);
+    setError(null);
+    try {
+      const res = await fetch(`/api/settings/reason-catalog/items/${itemId}`, {
+        method: "PATCH",
+        headers: { "Content-Type": "application/json" },
+        body: JSON.stringify(patch),
+      });
+      const data = await readJson(res);
+      if (!res.ok || !data || data.ok !== true) {
+        const msg = typeof data?.error === "string" ? data.error : "Update failed";
+        throw new Error(msg);
+      }
+      await load();
+    } catch (e) {
+      setError(e instanceof Error ? e.message : "Update failed");
+    } finally {
+      setBusy(false);
+    }
+  };
+
+  const patchCategory = async (categoryId: string, patch: Record<string, unknown>) => {
+    setBusy(true);
+    setError(null);
+    try {
+      const res = await fetch(`/api/settings/reason-catalog/categories/${categoryId}`, {
+        method: "PATCH",
+        headers: { "Content-Type": "application/json" },
+        body: JSON.stringify(patch),
+      });
+      const data = await readJson(res);
+      if (!res.ok || !data || data.ok !== true) {
+        const msg = typeof data?.error === "string" ? data.error : "Update failed";
+        throw new Error(msg);
+      }
+      await load();
+    } catch (e) {
+      setError(e instanceof Error ? e.message : "Update failed");
+    } finally {
+      setBusy(false);
+    }
+  };
+
+  const inputCls =
+    "mt-1 w-full rounded-lg border border-white/10 bg-black/30 px-2 py-1.5 text-xs text-white placeholder:text-zinc-600";
+
+  const kindBtn = (k: CatalogKind, label: string) => (
+    <button
+      type="button"
+      disabled={disabled || busy}
+      onClick={() => setKind(k)}
+      className={`rounded-lg px-3 py-1.5 text-xs font-medium transition ${
+        kind === k ? "bg-emerald-500/25 text-emerald-100 ring-1 ring-emerald-400/40" : "bg-black/30 text-zinc-400 hover:bg-white/5"
+      } disabled:opacity-40`}
+    >
+      {label}
+    </button>
+  );
+
+  return (
+    <div className="space-y-6">
+      <div className="rounded-xl border border-white/10 bg-black/20 p-4">
+        <div className="flex flex-wrap items-center justify-between gap-2">
+          <div className="text-[11px] text-zinc-500">
+            {t("settings.reasonCatalog.dbVersionHint", { version: catalogVersion })}
+          </div>
+          <button
+            type="button"
+            disabled={disabled || busy || loading}
+            onClick={() => void load()}
+            className="rounded-lg border border-white/10 bg-white/5 px-2 py-1 text-[11px] text-white hover:bg-white/10 disabled:opacity-40"
+          >
+            {t("settings.reasonCatalog.reload")}
+          </button>
+        </div>
+        {loading ? <p className="mt-2 text-xs text-zinc-500">{t("settings.loading")}</p> : null}
+        {error ? (
+          <p className="mt-2 rounded-lg border border-red-500/30 bg-red-500/10 px-2 py-1.5 text-xs text-red-200">{error}</p>
+        ) : null}
+      </div>
+
+      <div className="rounded-xl border border-white/10 bg-black/20 p-4">
+        <div className="text-xs font-semibold text-zinc-300">{t("settings.reasonCatalog.stepKind")}</div>
+        <div className="mt-2 flex flex-wrap gap-2">
+          {kindBtn("downtime", t("settings.reasonCatalog.downtime"))}
+          {kindBtn("scrap", t("settings.reasonCatalog.scrap"))}
+        </div>
+      </div>
+
+      <div className="rounded-xl border border-white/10 bg-black/20 p-4">
+        <div className="text-xs font-semibold text-zinc-300">{t("settings.reasonCatalog.stepCategory")}</div>
+        <div className="mt-2 flex flex-col gap-2 sm:flex-row sm:items-end">
+          <label className="min-w-[200px] flex-1 text-[11px] text-zinc-400">
+            {t("settings.reasonCatalog.pickCategory")}
+            <select
+              disabled={disabled || busy || !forKind.length}
+              value={selectedCategoryId ?? ""}
+              onChange={(e) => setSelectedCategoryId(e.target.value || null)}
+              className={`${inputCls} cursor-pointer`}
+            >
+              {!forKind.length ? <option value="">{t("settings.reasonCatalog.emptyKind")}</option> : null}
+              {forKind.map((c) => (
+                <option key={c.id} value={c.id}>
+                  {c.name} ({c.codePrefix}){c.active ? "" : ` — ${t("settings.reasonCatalog.inactive")}`}
+                </option>
+              ))}
+            </select>
+          </label>
+        </div>
+
+        {selected ? (
+          <div className="mt-4 grid gap-3 rounded-lg border border-white/5 bg-black/30 p-3 sm:grid-cols-2">
+            <label className="text-[11px] text-zinc-400">
+              {t("settings.reasonCatalog.categoryNameEdit")}
+              <input
+                disabled={disabled || busy}
+                value={editCatName}
+                onChange={(e) => setEditCatName(e.target.value)}
+                onBlur={() => {
+                  const n = editCatName.trim();
+                  if (n && n !== selected.name) void patchCategory(selected.id, { name: n });
+                }}
+                className={inputCls}
+              />
+            </label>
+            <label className="text-[11px] text-zinc-400">
+              {t("settings.reasonCatalog.codePrefixEdit")}
+              <input
+                disabled={disabled || busy}
+                value={editCatPrefix}
+                onChange={(e) => setEditCatPrefix(e.target.value.toUpperCase())}
+                onBlur={() => {
+                  const v = editCatPrefix.trim().toUpperCase();
+                  if (!v || !PREFIX_RE.test(v)) {
+                    setEditCatPrefix(selected.codePrefix);
+                    return;
+                  }
+                  if (v !== selected.codePrefix) void patchCategory(selected.id, { codePrefix: v });
+                }}
+                className={inputCls}
+              />
+            </label>
+            <label className="flex items-center gap-2 text-[11px] text-zinc-400 sm:col-span-2">
+              <input
+                type="checkbox"
+                disabled={disabled || busy}
+                checked={selected.active}
+                onChange={(e) => void patchCategory(selected.id, { active: e.target.checked })}
+                className="h-3.5 w-3.5 rounded border border-white/20 bg-black/20"
+              />
+              {t("settings.reasonCatalog.categoryActive")}
+            </label>
+          </div>
+        ) : null}
+
+        <div className="mt-4 border-t border-white/5 pt-4">
+          <div className="text-[11px] font-semibold text-zinc-400">{t("settings.reasonCatalog.newCategorySection")}</div>
+          <div className="mt-2 grid gap-2 sm:grid-cols-2">
+            <label className="text-[11px] text-zinc-400">
+              {t("settings.reasonCatalog.categoryLabel")}
+              <input
+                disabled={disabled || busy}
+                value={newCatName}
+                onChange={(e) => setNewCatName(e.target.value)}
+                className={inputCls}
+              />
+            </label>
+            <label className="text-[11px] text-zinc-400">
+              {t("settings.reasonCatalog.codePrefixField")}
+              <input
+                disabled={disabled || busy}
+                value={newCatPrefix}
+                onChange={(e) => setNewCatPrefix(e.target.value.toUpperCase())}
+                placeholder="DTPRC"
+                className={inputCls}
+              />
+            </label>
+          </div>
+          <button
+            type="button"
+            disabled={disabled || busy || !newCatName.trim() || !newCatPrefix.trim()}
+            onClick={() => void createCategory()}
+            className="mt-2 rounded-lg border border-emerald-400/30 bg-emerald-500/15 px-3 py-1.5 text-xs text-emerald-100 hover:bg-emerald-500/25 disabled:opacity-40"
+          >
+            {t("settings.reasonCatalog.addCategory")}
+          </button>
+        </div>
+      </div>
+
+      {selected ? (
+        <div className="rounded-xl border border-white/10 bg-black/20 p-4">
+          <div className="text-xs font-semibold text-zinc-300">{t("settings.reasonCatalog.stepReason")}</div>
+          <p className="mt-1 text-[11px] text-zinc-500">{t("settings.reasonCatalog.digitsOnlyHint")}</p>
+          <div className="mt-3 flex flex-wrap items-end gap-3">
+            <div className="text-[11px] text-zinc-400">
+              <span className="block text-zinc-500">{t("settings.reasonCatalog.fullCodePreview")}</span>
+              <span className="mt-1 inline-flex min-h-[2rem] items-center rounded-lg border border-white/10 bg-black/40 px-3 font-mono text-sm text-emerald-200">
+                {formatPrintedPreview(selected.codePrefix, newDigits)}
+              </span>
+            </div>
+            <label className="w-32 text-[11px] text-zinc-400">
+              {t("settings.reasonCatalog.numericSuffix")}
+              <input
+                disabled={disabled || busy}
+                inputMode="numeric"
+                pattern="[0-9]*"
+                value={newDigits}
+                onChange={(e) => onDigitsChange(e.target.value)}
+                placeholder="01"
+                className={inputCls}
+              />
+            </label>
+            <label className="min-w-[180px] flex-1 text-[11px] text-zinc-400">
+              {t("settings.reasonCatalog.detailLabel")}
+              <input
+                disabled={disabled || busy}
+                value={newItemName}
+                onChange={(e) => setNewItemName(e.target.value)}
+                className={inputCls}
+              />
+            </label>
+            <button
+              type="button"
+              disabled={disabled || busy || !newDigits.trim() || !newItemName.trim()}
+              onClick={() => void addItem()}
+              className="rounded-lg border border-emerald-400/30 bg-emerald-500/15 px-3 py-2 text-xs text-emerald-100 hover:bg-emerald-500/25 disabled:opacity-40"
+            >
+              {t("settings.reasonCatalog.addReason")}
+            </button>
+          </div>
+
+          <div className="mt-4">
+            <div className="text-[11px] font-semibold text-zinc-500">{t("settings.reasonCatalog.reasonsInCategory")}</div>
+            <div className="mt-2 space-y-2">
+              {selected.items.length === 0 ? (
+                <div className="text-xs text-zinc-500">{t("settings.reasonCatalog.noItemsYet")}</div>
+              ) : (
+                selected.items.map((it) => (
+                  <div
+                    key={it.id}
+                    className={`flex flex-wrap items-center justify-between gap-2 rounded-lg border border-white/5 px-3 py-2 ${
+                      it.active ? "bg-black/30" : "bg-black/10 opacity-60"
+                    }`}
+                  >
+                    <div className="font-mono text-xs text-emerald-200">{it.reasonCode}</div>
+                    <div className="min-w-0 flex-1 truncate text-xs text-white">{it.name}</div>
+                    <label className="flex items-center gap-1.5 text-[10px] text-zinc-400">
+                      <input
+                        type="checkbox"
+                        disabled={disabled || busy}
+                        checked={it.active}
+                        onChange={(e) => void patchItem(it.id, { active: e.target.checked })}
+                        className="h-3.5 w-3.5 rounded border border-white/20 bg-black/20"
+                      />
+                      {t("settings.reasonCatalog.active")}
+                    </label>
+                  </div>
+                ))
+              )}
+            </div>
+          </div>
+        </div>
+      ) : null}
+
+      <p className="text-[11px] leading-relaxed text-zinc-500">{t("settings.reasonCatalog.hint")}</p>
+    </div>
+  );
+}

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

@@ -111,7 +111,12 @@
   "overview.recap.cta": "Open daily recap",
   "recap.title": "Recap",
   "recap.subtitle": "Last 24h",
+  "recap.card.stoppedFor": "Stopped for {min} min",
+  "machines.status.stopped": "STOPPED",
+  "machines.stoppedFor": "Stopped for {min} min",
   "recap.grid.title": "Machine recap",
+  "recap.status.idle": "Idle",
+  "recap.card.idle": "No active work order",
   "recap.grid.subtitle": "Last 24h · click to open details",
   "recap.grid.updatedAgo": "Updated {sec}s ago",
   "recap.grid.empty": "No machines match the current filters.",
@@ -459,6 +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",
@@ -514,6 +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

@@ -118,6 +118,11 @@
   "overview.recap.cta": "Abrir resumen diario",
   "recap.title": "Resumen",
   "recap.subtitle": "Últimas 24h",
+  "recap.card.stoppedFor": "Detenida hace {min} min",
+  "machines.status.stopped": "DETENIDA",
+  "machines.stoppedFor": "Detenida hace {min} min",
+  "recap.status.idle": "Inactiva",
+  "recap.card.idle": "Sin orden de trabajo activa",
   "recap.grid.title": "Resumen de máquinas",
   "recap.grid.subtitle": "Últimas 24h · click para ver detalle",
   "recap.grid.updatedAgo": "Actualizado hace {sec}s",
@@ -466,6 +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",
@@ -521,6 +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/machines/withLatest.ts

@@ -31,6 +31,15 @@ type LatestKpiRow = {
   cycleTime?: number | null;
 };
 
+export type LatestMacrostopRow = {
+  machineId: string;
+  ts: Date;
+  status: "active" | "resolved" | "unknown";
+  startedAtMs: number;
+};
+
+const MACROSTOP_LOOKBACK_MS = 5 * 60 * 1000;
+
 export async function fetchMachineBase(orgId: string): Promise<MachineBaseRow[]> {
   return prisma.machine.findMany({
     where: { orgId },
@@ -93,20 +102,75 @@ export async function fetchLatestKpis(
   });
 }
 
+export async function fetchLatestMacrostops(
+  orgId: string,
+  machineIds: string[]
+): Promise<LatestMacrostopRow[]> {
+  if (!machineIds.length) return [];
+
+  const rows = await prisma.machineEvent.findMany({
+    where: {
+      orgId,
+      machineId: { in: machineIds },
+      eventType: "macrostop",
+      ts: { gte: new Date(Date.now() - MACROSTOP_LOOKBACK_MS) },
+    },
+    orderBy: [{ machineId: "asc" }, { ts: "desc" }],
+    select: { machineId: true, ts: true, data: true },
+  });
+
+  const byMachine = new Map<string, LatestMacrostopRow>();
+  for (const row of rows) {
+    if (byMachine.has(row.machineId)) continue;
+
+    let parsed: unknown = row.data;
+    if (typeof parsed === "string") {
+      try { parsed = JSON.parse(parsed); } catch { parsed = null; }
+    }
+    const data: Record<string, unknown> =
+      parsed && typeof parsed === "object" && !Array.isArray(parsed)
+        ? (parsed as Record<string, unknown>)
+        : {};
+
+    const isAutoAck =
+      data.is_auto_ack === true || data.isAutoAck === true ||
+      data.is_auto_ack === "true" || data.isAutoAck === "true";
+    if (isAutoAck) continue;
+
+    const rawStatus = String(data.status ?? "").trim().toLowerCase();
+    const status: LatestMacrostopRow["status"] =
+      rawStatus === "active" ? "active" : rawStatus === "resolved" ? "resolved" : "unknown";
+
+    const lastCycleTs = Number(data.last_cycle_timestamp);
+    const startedAtMs = Number.isFinite(lastCycleTs) && lastCycleTs > 0
+      ? lastCycleTs
+      : row.ts.getTime();
+
+    byMachine.set(row.machineId, { machineId: row.machineId, ts: row.ts, status, startedAtMs });
+  }
+
+  return Array.from(byMachine.values());
+}
+
+
 export function mergeMachineOverviewRows(params: {
   machines: MachineBaseRow[];
   heartbeats: LatestHeartbeatRow[];
   kpis?: LatestKpiRow[];
+  macrostops?: LatestMacrostopRow[];
   includeKpi?: boolean;
 }): OverviewMachineRow[] {
-  const { machines, heartbeats, kpis = [], includeKpi = false } = params;
+  const { machines, heartbeats, kpis = [], macrostops = [], includeKpi = false } = params;
   const heartbeatMap = new Map(heartbeats.map((row) => [row.machineId, row]));
   const kpiMap = new Map(kpis.map((row) => [row.machineId, row]));
+  const macrostopMap = new Map(macrostops.map((row) => [row.machineId, row]));
+
 
   return machines.map((machine) => ({
     ...machine,
     latestHeartbeat: (heartbeatMap.get(machine.id) ?? null) as OverviewMachineRow["latestHeartbeat"],
     latestKpi: includeKpi ? (kpiMap.get(machine.id) ?? null) : null,
+    latestMacrostop: macrostopMap.get(machine.id) ?? null,
     heartbeats: undefined,
     kpiSnapshots: undefined,
   }));

lib/machines/withLatest.ts.bak

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

lib/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);
   }
@@ -143,31 +169,37 @@ 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) {
+export function flattenReasonCatalog(
+  catalog: ReasonCatalog,
+  kind: ReasonCatalogKind,
+  options?: FlattenReasonCatalogOptions
+) {
+  const activeOnly = options?.activeOnly === true;
   return (catalog[kind] ?? []).flatMap((category) =>
-    category.details.map((detail) => ({
+    category.details
+      .filter((d) => !activeOnly || isDetailActive(d))
+      .map((detail) => ({
         kind,
         categoryId: category.id,
         categoryLabel: category.label,
         detailId: detail.id,
         detailLabel: detail.label,
-      reasonCode: buildReasonCode(category.id, detail.id),
+        reasonCode: detailEffectiveReasonCode(category, detail),
         reasonLabel: `${category.label} > ${detail.label}`,
+        active: isDetailActive(detail),
       }))
   );
 }
 
+function canonicalText(value: unknown) {
+  return String(value ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+}
+
 export function findCatalogReason(
   catalog: ReasonCatalog | null | undefined,
   kind: ReasonCatalogKind,
@@ -187,11 +219,38 @@ export function findCatalogReason(
     categoryLabel: category.label,
     detailId: detail.id,
     detailLabel: detail.label,
-    reasonCode: buildReasonCode(category.id, detail.id),
+    reasonCode: detailEffectiveReasonCode(category, detail),
     reasonLabel: `${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

@@ -0,0 +1,131 @@
+import type { TimelineEventRow } from "@/lib/recap/timeline";
+
+/**
+ * Shared classifier for machine state across /recap, /machines, /overview.
+ *
+ * State precedence (top wins):
+ *   1. OFFLINE             — heartbeat dead
+ *   2. MOLD_CHANGE         — operator initiated mold swap
+ *   3. STOPPED             — should be producing, isn't
+ *   4. DATA_LOSS           — producing but tracking off (operator forgot START)
+ *   5. IDLE                — nothing loaded, nothing running, nothing expected
+ *   6. RUNNING             — healthy
+ *
+ * Inputs are intentionally raw and computed by the caller, not fetched here,
+ * so this module stays pure (testable, no DB/Prisma dependency).
+ */
+
+export type MachineStateName =
+  | "offline"
+  | "mold-change"
+  | "stopped"
+  | "data-loss"
+  | "idle"
+  | "running";
+
+export type MachineStateResult =
+  | { state: "offline"; lastSeenMs: number | null; offlineForMin: number }
+  | {
+      state: "mold-change";
+      moldChangeStartMs: number | null;
+      moldChangeMin: number;
+    }
+  | {
+      state: "stopped";
+      ongoingStopMin: number;
+      stopStartedAtMs: number | null;
+    }
+  | { state: "idle" }
+  | { state: "running" };
+
+export type MachineStateInputs = {
+  /** Heartbeat freshness — true if the Pi has been seen within the offline threshold */
+  heartbeatAlive: boolean;
+  /** Last heartbeat timestamp in ms (or null if never seen) */
+  lastSeenMs: number | null;
+  /** Computed offline duration in ms — used when heartbeatAlive is false */
+  offlineForMs: number;
+
+  /** Operator pressed START — true if latest KPI snapshot has trackingEnabled=true */
+  trackingEnabled: boolean;
+
+  /** A work order with status RUNNING or PENDING is currently assigned */
+  hasActiveWorkOrder: boolean;
+
+  /** Active mold-change event (from timeline events) */
+  activeMoldChange: { startedAtMs: number } | null;
+
+  /** Active macrostop event (from timeline events) — fires when tracking on + no cycles */
+  activeMacrostop: { startedAtMs: number } | null;
+
+  /**
+   * Untracked cycles arriving while tracking is OFF.
+   * Caller computes by counting MachineCycle rows in the last UNTRACKED_WINDOW_MS
+   * where ts > latestKpi.ts (so they're "after" the tracking-off snapshot).
+   */
+  /**
+   * Most recent cycle timestamp regardless of tracking — used as a sanity check
+   * for IDLE classification.
+   */
+  lastCycleTsMs: number | null;
+};
+
+// Trigger thresholds — tunable
+
+const RECENT_CYCLE_MS = 15 * 60 * 1000; // for IDLE check — "no cycles in 15 min"
+
+export function classifyMachineState(
+  inputs: MachineStateInputs,
+  nowMs: number
+): MachineStateResult {
+  // 1. OFFLINE — wins over everything. If we can't see the Pi, nothing else is reliable.
+  if (!inputs.heartbeatAlive) {
+    return {
+      state: "offline",
+      lastSeenMs: inputs.lastSeenMs,
+      offlineForMin: Math.max(0, Math.floor(inputs.offlineForMs / 60000)),
+    };
+  }
+
+  // 2. MOLD_CHANGE — operator-initiated, suppresses STOPPED/ATTENTION even if cycles missing
+  if (inputs.activeMoldChange) {
+    return {
+      state: "mold-change",
+      moldChangeStartMs: inputs.activeMoldChange.startedAtMs,
+      moldChangeMin: Math.max(
+        0,
+        Math.floor((nowMs - inputs.activeMoldChange.startedAtMs) / 60000)
+      ),
+    };
+  }
+
+  // 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.
+
+  // 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
+// 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",
+      ongoingStopMin: Math.max(0, Math.floor((nowMs - startedAt) / 60000)),
+      stopStartedAtMs: startedAt,
+    };
+  }
+
+  // 5. IDLE — no one expects this machine to be doing anything right now.
+  // No tracking, no WO, no recent cycles. Calm gray.
+  const cycledRecently =
+    inputs.lastCycleTsMs != null && nowMs - inputs.lastCycleTsMs <= RECENT_CYCLE_MS;
+  if (!inputs.trackingEnabled && !inputs.hasActiveWorkOrder && !cycledRecently) {
+    return { state: "idle" };
+  }
+
+  // 6. RUNNING — default. Tracking on, WO loaded, cycles flowing.
+  return { state: "running" };
+}

lib/recap/redesign.ts

@@ -9,6 +9,7 @@ import {
     type TimelineCycleRow,
     type TimelineEventRow,
   } from "@/lib/recap/timeline";
+  import { classifyMachineState, type MachineStateResult } from "@/lib/recap/machineState";
   import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
   import type {
     RecapDetailResponse,
@@ -16,6 +17,7 @@ import type {
     RecapMachineDetail,
     RecapMachineStatus,
     RecapRangeMode,
+    RecapStateContext,
     RecapSummaryMachine,
     RecapSummaryResponse,
   } from "@/lib/recap/types";
@@ -175,24 +177,150 @@ function addDays(input: { year: number; month: number; day: number }, days: numb
     };
   }
 
-function statusFromMachine(machine: RecapMachine, endMs: number) {
+  // Detect active episodes (macrostop, mold-change) from event rows.
+  // Returns the latest non-auto-ack episode whose final status is "active"
+  // and that's been refreshed within ACTIVE_STALE_MS.
+  const ACTIVE_STALE_MS = 2 * 60 * 1000;
+
+  type ActiveEpisode = { startedAtMs: number; lastTsMs: number };
+
+  function detectActiveEpisode(
+    events: TimelineEventRow[] | undefined,
+    eventType: "macrostop" | "mold-change",
+    endMs: number
+  ): ActiveEpisode | null {
+    if (!events || events.length === 0) return null;
+
+    type Episode = { firstTsMs: number; lastTsMs: number; lastStatus: string; lastCycleTs: number | null };
+    const episodes = new Map<string, Episode>();
+
+    for (const event of events) {
+      if (String(event.eventType || "").toLowerCase() !== eventType) continue;
+
+      let parsed: unknown = event.data;
+      if (typeof parsed === "string") {
+        try { parsed = JSON.parse(parsed); } catch { parsed = null; }
+      }
+      const data: Record<string, unknown> =
+        parsed && typeof parsed === "object" && !Array.isArray(parsed)
+          ? (parsed as Record<string, unknown>)
+          : {};
+
+      const isAutoAck =
+        data.is_auto_ack === true ||
+        data.isAutoAck === true ||
+        data.is_auto_ack === "true" ||
+        data.isAutoAck === "true";
+      if (isAutoAck) continue;
+
+      const status = String(data.status ?? "").trim().toLowerCase();
+      const incidentKey = String(data.incidentKey ?? data.incident_key ?? "").trim()
+        || `${eventType}:${event.ts.getTime()}`;
+      const tsMs = event.ts.getTime();
+      const lastCycleTs = Number(data.last_cycle_timestamp);
+
+      const existing = episodes.get(incidentKey);
+      if (!existing) {
+        episodes.set(incidentKey, {
+          firstTsMs: tsMs,
+          lastTsMs: tsMs,
+          lastStatus: status,
+          lastCycleTs: Number.isFinite(lastCycleTs) && lastCycleTs > 0 ? lastCycleTs : null,
+        });
+        continue;
+      }
+      existing.firstTsMs = Math.min(existing.firstTsMs, tsMs);
+      if (tsMs >= existing.lastTsMs) {
+        existing.lastTsMs = tsMs;
+        existing.lastStatus = status;
+      }
+    }
+
+    let best: ActiveEpisode | null = null;
+    for (const ep of episodes.values()) {
+      if (ep.lastStatus !== "active") continue;
+      if (endMs - ep.lastTsMs > ACTIVE_STALE_MS) continue;
+      // Prefer the freshest active episode (highest lastTsMs)
+      if (!best || ep.lastTsMs > best.lastTsMs) {
+        best = {
+          startedAtMs: ep.lastCycleTs ?? ep.firstTsMs,
+          lastTsMs: ep.lastTsMs,
+        };
+      }
+    }
+    return best;
+  }
+
+  function statusFromMachine(
+    machine: RecapMachine,
+    endMs: number,
+    events?: TimelineEventRow[]
+  ): {
+    status: RecapMachineStatus;
+    result: MachineStateResult;
+    stateContext: RecapStateContext;
+    lastSeenMs: number | null;
+    offlineForMin: number | null;
+    ongoingStopMin: number | null;
+  } {
     const lastSeenMs = machine.heartbeat.lastSeenAt ? new Date(machine.heartbeat.lastSeenAt).getTime() : null;
     const offlineForMs = lastSeenMs == null ? Number.POSITIVE_INFINITY : Math.max(0, endMs - lastSeenMs);
-  const offline = !Number.isFinite(lastSeenMs ?? Number.NaN) || offlineForMs > OFFLINE_THRESHOLD_MS;
+    const heartbeatAlive = Number.isFinite(lastSeenMs ?? Number.NaN) && offlineForMs <= OFFLINE_THRESHOLD_MS;
 
-  const ongoingStopMin = machine.downtime.ongoingStopMin ?? 0;
-  const moldActive = machine.workOrders.moldChangeInProgress;
+    const activeMacrostop = detectActiveEpisode(events, "macrostop", endMs);
+    const activeMoldChange = detectActiveEpisode(events, "mold-change", endMs);
+
+    // Round 1 limitation: trackingEnabled and untrackedCycles inputs require KPI/cycle queries
+    // we don't yet plumb here. We approximate from the legacy fields:
+    //   - trackingEnabled: true when there's an active macrostop (Pi only fires those when tracking on)
+    //                      OR when an active WO exists and machine.workOrders.moldChangeInProgress is false.
+    //                      This is a SIMPLIFICATION; Round 3 will replace with real KPI snapshot read.
+    //   - untrackedCycles: 0 (Round 3 will compute from MachineCycle vs latest KPI)
+    //
+    // Effect for Round 1: STOPPED `not_started` reason cannot trigger yet (we always assume tracking
+    // is on when a WO exists). Only `machine_fault` STOPPED fires. DATA_LOSS cannot fire yet.
+    // IDLE fires correctly when there's no WO and no recent activity.
+    const hasActiveWorkOrder = machine.workOrders.active != null;
+    const trackingEnabledApprox = hasActiveWorkOrder; // see comment above
+
+    const lastCycleTsMs = (() => {
+      // Best-effort: use the machine's heartbeat as a "recent activity" proxy.
+      // The Pi only heartbeats every minute regardless of cycles, so this is a weak signal.
+      // Round 3 will pass the actual latest cycle ts.
+      return lastSeenMs;
+    })();
+
+    const result = classifyMachineState(
+      {
+        heartbeatAlive,
+        lastSeenMs,
+        offlineForMs,
+        trackingEnabled: trackingEnabledApprox,
+        hasActiveWorkOrder,
+        activeMoldChange,
+        activeMacrostop,
+        lastCycleTsMs,
+      },
+      endMs
+    );
+
+    // Map the rich classifier result back to the existing RecapMachineStatus union
+    const status: RecapMachineStatus = result.state;
+
+    // Pull common fields out for the caller's convenience
+    let ongoingStopMin: number | null = null;
+    if (result.state === "stopped") ongoingStopMin = result.ongoingStopMin;
+
+    const stateContext: RecapStateContext = {};
 
-  let status: RecapMachineStatus = "running";
-  if (offline) status = "offline";
-  else if (moldActive) status = "mold-change";
-  else if (ongoingStopMin > 0) status = "stopped";
 
     return {
       status,
+      result,
+      stateContext,
       lastSeenMs,
-    offlineForMin: offline ? Math.max(0, Math.floor(offlineForMs / 60000)) : null,
-    ongoingStopMin: machine.downtime.ongoingStopMin,
+      offlineForMin: result.state === "offline" ? result.offlineForMin : null,
+      ongoingStopMin,
     };
   }
 
@@ -225,6 +353,7 @@ async function loadTimelineRowsForMachines(params: {
           ts: true,
           cycleCount: true,
           actualCycleTime: true,
+          theoreticalCycleTime: true,
           workOrderId: true,
           sku: true,
         },
@@ -258,6 +387,7 @@ async function loadTimelineRowsForMachines(params: {
         ts: row.ts,
         cycleCount: row.cycleCount,
         actualCycleTime: row.actualCycleTime,
+        theoreticalCycleTime: row.theoreticalCycleTime ?? null,
         workOrderId: row.workOrderId,
         sku: row.sku,
       });
@@ -281,9 +411,10 @@ function toSummaryMachine(params: {
     machine: RecapMachine;
     miniTimeline: ReturnType<typeof compressTimelineSegments>;
     rangeEndMs: number;
+    events?: TimelineEventRow[];
   }): RecapSummaryMachine {
-  const { machine, miniTimeline, rangeEndMs } = params;
-  const status = statusFromMachine(machine, rangeEndMs);
+    const { machine, miniTimeline, rangeEndMs, events } = params;
+    const status = statusFromMachine(machine, rangeEndMs, events);
 
     return {
       machineId: machine.machineId,
@@ -299,6 +430,7 @@ function toSummaryMachine(params: {
         status.lastSeenMs == null ? null : Math.max(0, Math.floor((rangeEndMs - status.lastSeenMs) / 60000)),
       offlineForMin: status.offlineForMin,
       ongoingStopMin: status.ongoingStopMin,
+      stateContext: status.stateContext,
       activeWorkOrderId: machine.workOrders.active?.id ?? null,
       moldChange: {
         active: machine.workOrders.moldChangeInProgress,
@@ -349,6 +481,7 @@ async function computeRecapSummary(params: { orgId: string; hours: number }) {
         machine,
         miniTimeline,
         rangeEndMs: end.getTime(),
+        events: timelineRows.eventsByMachine.get(machine.machineId),
       });
     });
 
@@ -608,7 +741,11 @@ async function computeRecapMachineDetail(params: {
       rangeEnd: range.end,
     });
 
-  const status = statusFromMachine(machine, range.end.getTime());
+    const status = statusFromMachine(
+      machine,
+      range.end.getTime(),
+      timelineRows.eventsByMachine.get(params.machineId)
+    );
 
     const downtimeTotalMin = Math.max(0, machine.downtime.totalMin);
     const downtimeTop = machine.downtime.topReasons.slice(0, 3).map((row) => ({
@@ -632,6 +769,8 @@ async function computeRecapMachineDetail(params: {
       lastSeenMs: status.lastSeenMs,
       offlineForMin: status.offlineForMin,
       ongoingStopMin: status.ongoingStopMin,
+      stateContext: status.stateContext,
+
       moldChange: {
         active: machine.workOrders.moldChangeInProgress,
         startMs: machine.workOrders.moldChangeStartMs,

lib/recap/redesign.ts.bak

@@ -0,0 +1,776 @@
+import { unstable_cache } from "next/cache";
+import { prisma } from "@/lib/prisma";
+import { normalizeShiftOverrides, type ShiftOverrideDay } from "@/lib/settings";
+import { getRecapDataCached } from "@/lib/recap/getRecapData";
+import {
+  buildTimelineSegments,
+  compressTimelineSegments,
+  TIMELINE_EVENT_TYPES,
+  type TimelineCycleRow,
+  type TimelineEventRow,
+} from "@/lib/recap/timeline";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
+import type {
+  RecapDetailResponse,
+  RecapMachine,
+  RecapMachineDetail,
+  RecapMachineStatus,
+  RecapRangeMode,
+  RecapSummaryMachine,
+  RecapSummaryResponse,
+} from "@/lib/recap/types";
+
+type DetailRangeInput = {
+  mode?: string | null;
+  start?: string | null;
+  end?: string | null;
+};
+
+const OFFLINE_THRESHOLD_MS = RECAP_HEARTBEAT_STALE_MS;
+const TIMELINE_EVENT_LOOKBACK_MS = 24 * 60 * 60 * 1000;
+const TIMELINE_CYCLE_LOOKBACK_MS = 15 * 60 * 1000;
+const RECAP_CACHE_TTL_SEC = 60;
+const WEEKDAY_KEYS: ShiftOverrideDay[] = ["sun", "mon", "tue", "wed", "thu", "fri", "sat"];
+const WEEKDAY_KEY_MAP: Record<string, ShiftOverrideDay> = {
+  Mon: "mon",
+  Tue: "tue",
+  Wed: "wed",
+  Thu: "thu",
+  Fri: "fri",
+  Sat: "sat",
+  Sun: "sun",
+};
+
+function round2(value: number) {
+  return Math.round(value * 100) / 100;
+}
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (Number.isFinite(n)) {
+    const d = new Date(n);
+    return Number.isFinite(d.getTime()) ? d : null;
+  }
+  const d = new Date(input);
+  return Number.isFinite(d.getTime()) ? d : null;
+}
+
+function parseHours(input: string | null) {
+  const parsed = Math.trunc(Number(input ?? "24"));
+  if (!Number.isFinite(parsed)) return 24;
+  return Math.max(1, Math.min(72, parsed));
+}
+
+function parseTimeMinutes(input?: string | null) {
+  if (!input) return null;
+  const match = /^(\d{2}):(\d{2})$/.exec(input.trim());
+  if (!match) return null;
+  const hours = Number(match[1]);
+  const minutes = Number(match[2]);
+  if (!Number.isInteger(hours) || !Number.isInteger(minutes) || hours < 0 || hours > 23 || minutes < 0 || minutes > 59) {
+    return null;
+  }
+  return hours * 60 + minutes;
+}
+
+function getLocalParts(ts: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      year: "numeric",
+      month: "2-digit",
+      day: "2-digit",
+      hour: "2-digit",
+      minute: "2-digit",
+      weekday: "short",
+      hour12: false,
+    }).formatToParts(ts);
+
+    const value = (type: string) => parts.find((part) => part.type === type)?.value ?? "";
+    const year = Number(value("year"));
+    const month = Number(value("month"));
+    const day = Number(value("day"));
+    const hour = Number(value("hour"));
+    const minute = Number(value("minute"));
+    const weekday = value("weekday");
+
+    return {
+      year,
+      month,
+      day,
+      hour,
+      minute,
+      weekday: WEEKDAY_KEY_MAP[weekday] ?? WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: hour * 60 + minute,
+    };
+  } catch {
+    return {
+      year: ts.getUTCFullYear(),
+      month: ts.getUTCMonth() + 1,
+      day: ts.getUTCDate(),
+      hour: ts.getUTCHours(),
+      minute: ts.getUTCMinutes(),
+      weekday: WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: ts.getUTCHours() * 60 + ts.getUTCMinutes(),
+    };
+  }
+}
+
+function parseOffsetMinutes(offsetLabel: string | null) {
+  if (!offsetLabel) return null;
+  const normalized = offsetLabel.replace("UTC", "GMT");
+  const match = /^GMT([+-])(\d{1,2})(?::?(\d{2}))?$/.exec(normalized);
+  if (!match) return null;
+  const sign = match[1] === "-" ? -1 : 1;
+  const hour = Number(match[2]);
+  const minute = Number(match[3] ?? "0");
+  if (!Number.isFinite(hour) || !Number.isFinite(minute)) return null;
+  return sign * (hour * 60 + minute);
+}
+
+function getTzOffsetMinutes(utcDate: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      timeZoneName: "shortOffset",
+      hour: "2-digit",
+    }).formatToParts(utcDate);
+    const offsetPart = parts.find((part) => part.type === "timeZoneName")?.value ?? null;
+    return parseOffsetMinutes(offsetPart);
+  } catch {
+    return null;
+  }
+}
+
+function zonedToUtcDate(input: {
+  year: number;
+  month: number;
+  day: number;
+  hours: number;
+  minutes: number;
+  timeZone: string;
+}) {
+  const baseUtc = Date.UTC(input.year, input.month - 1, input.day, input.hours, input.minutes, 0, 0);
+  const guessDate = new Date(baseUtc);
+  const offsetA = getTzOffsetMinutes(guessDate, input.timeZone);
+  if (offsetA == null) return guessDate;
+
+  let corrected = new Date(baseUtc - offsetA * 60000);
+  const offsetB = getTzOffsetMinutes(corrected, input.timeZone);
+  if (offsetB != null && offsetB !== offsetA) {
+    corrected = new Date(baseUtc - offsetB * 60000);
+  }
+
+  return corrected;
+}
+
+function addDays(input: { year: number; month: number; day: number }, days: number) {
+  const base = new Date(Date.UTC(input.year, input.month - 1, input.day));
+  base.setUTCDate(base.getUTCDate() + days);
+  return {
+    year: base.getUTCFullYear(),
+    month: base.getUTCMonth() + 1,
+    day: base.getUTCDate(),
+  };
+}
+
+function statusFromMachine(machine: RecapMachine, endMs: number) {
+  const lastSeenMs = machine.heartbeat.lastSeenAt ? new Date(machine.heartbeat.lastSeenAt).getTime() : null;
+  const offlineForMs = lastSeenMs == null ? Number.POSITIVE_INFINITY : Math.max(0, endMs - lastSeenMs);
+  const offline = !Number.isFinite(lastSeenMs ?? Number.NaN) || offlineForMs > OFFLINE_THRESHOLD_MS;
+
+  const ongoingStopMin = machine.downtime.ongoingStopMin ?? 0;
+  const moldActive = machine.workOrders.moldChangeInProgress;
+
+  let status: RecapMachineStatus = "running";
+  if (offline) status = "offline";
+  else if (moldActive) status = "mold-change";
+  else if (ongoingStopMin > 0) status = "stopped";
+
+  return {
+    status,
+    lastSeenMs,
+    offlineForMin: offline ? Math.max(0, Math.floor(offlineForMs / 60000)) : null,
+    ongoingStopMin: machine.downtime.ongoingStopMin,
+  };
+}
+
+async function loadTimelineRowsForMachines(params: {
+  orgId: string;
+  machineIds: string[];
+  start: Date;
+  end: Date;
+}) {
+  if (!params.machineIds.length) {
+    return {
+      cyclesByMachine: new Map<string, TimelineCycleRow[]>(),
+      eventsByMachine: new Map<string, TimelineEventRow[]>(),
+    };
+  }
+
+  const [cycles, events] = await Promise.all([
+    prisma.machineCycle.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_CYCLE_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        cycleCount: true,
+        actualCycleTime: true,
+        workOrderId: true,
+        sku: true,
+      },
+    }),
+    prisma.machineEvent.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        eventType: { in: TIMELINE_EVENT_TYPES as unknown as string[] },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_EVENT_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        eventType: true,
+        data: true,
+      },
+    }),
+  ]);
+
+  const cyclesByMachine = new Map<string, TimelineCycleRow[]>();
+  const eventsByMachine = new Map<string, TimelineEventRow[]>();
+
+  for (const row of cycles) {
+    const list = cyclesByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      cycleCount: row.cycleCount,
+      actualCycleTime: row.actualCycleTime,
+      workOrderId: row.workOrderId,
+      sku: row.sku,
+    });
+    cyclesByMachine.set(row.machineId, list);
+  }
+
+  for (const row of events) {
+    const list = eventsByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      eventType: row.eventType,
+      data: row.data,
+    });
+    eventsByMachine.set(row.machineId, list);
+  }
+
+  return { cyclesByMachine, eventsByMachine };
+}
+
+function toSummaryMachine(params: {
+  machine: RecapMachine;
+  miniTimeline: ReturnType<typeof compressTimelineSegments>;
+  rangeEndMs: number;
+}): RecapSummaryMachine {
+  const { machine, miniTimeline, rangeEndMs } = params;
+  const status = statusFromMachine(machine, rangeEndMs);
+
+  return {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    lastSeenMs: status.lastSeenMs,
+    lastActivityMin:
+      status.lastSeenMs == null ? null : Math.max(0, Math.floor((rangeEndMs - status.lastSeenMs) / 60000)),
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+      elapsedMin:
+        machine.workOrders.moldChangeStartMs == null
+          ? null
+          : Math.max(0, Math.floor((rangeEndMs - machine.workOrders.moldChangeStartMs) / 60000)),
+    },
+    miniTimeline,
+  };
+}
+
+async function computeRecapSummary(params: { orgId: string; hours: number }) {
+  const now = new Date();
+  const end = new Date(Math.floor(now.getTime() / 60000) * 60000);
+  const start = new Date(end.getTime() - params.hours * 60 * 60 * 1000);
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    start,
+    end,
+  });
+
+  const machineIds = recap.machines.map((machine) => machine.machineId);
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds,
+    start,
+    end,
+  });
+
+  const machines = recap.machines.map((machine) => {
+    const segments = buildTimelineSegments({
+      cycles: timelineRows.cyclesByMachine.get(machine.machineId) ?? [],
+      events: timelineRows.eventsByMachine.get(machine.machineId) ?? [],
+      rangeStart: start,
+      rangeEnd: end,
+    });
+    const miniTimeline = compressTimelineSegments({
+      segments,
+      rangeStart: start,
+      rangeEnd: end,
+      maxSegments: 60,
+    });
+
+    return toSummaryMachine({
+      machine,
+      miniTimeline,
+      rangeEndMs: end.getTime(),
+    });
+  });
+
+  const response: RecapSummaryResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      start: start.toISOString(),
+      end: end.toISOString(),
+      hours: params.hours,
+    },
+    machines,
+  };
+
+  return response;
+}
+
+function normalizedRangeMode(mode?: string | null): RecapRangeMode {
+  const raw = String(mode ?? "").trim().toLowerCase();
+  if (raw === "shift") return "shift";
+  if (raw === "yesterday") return "yesterday";
+  if (raw === "custom") return "custom";
+  return "24h";
+}
+
+async function resolveCurrentShiftRange(params: { orgId: string; now: Date }) {
+  const settings = await prisma.orgSettings.findUnique({
+    where: { orgId: params.orgId },
+    select: {
+      timezone: true,
+      shiftScheduleOverridesJson: true,
+    },
+  });
+  const shifts = await prisma.orgShift.findMany({
+    where: { orgId: params.orgId },
+    orderBy: { sortOrder: "asc" },
+    select: {
+      name: true,
+      startTime: true,
+      endTime: true,
+      enabled: true,
+      sortOrder: true,
+    },
+  });
+
+  const enabledShifts = shifts.filter((shift) => shift.enabled !== false);
+  if (!enabledShifts.length) {
+    return {
+      hasEnabledShifts: false,
+      range: null,
+    } as const;
+  }
+
+  const timeZone = settings?.timezone || "UTC";
+  const local = getLocalParts(params.now, timeZone);
+  const overrides = normalizeShiftOverrides(settings?.shiftScheduleOverridesJson);
+  const dayOverrides = overrides?.[local.weekday];
+  const activeShifts = (dayOverrides?.length
+    ? dayOverrides.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.start,
+        end: shift.end,
+      }))
+    : enabledShifts.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.startTime,
+        end: shift.endTime,
+      }))
+  ).filter((shift) => shift.enabled);
+
+  for (const shift of activeShifts) {
+    const startMin = parseTimeMinutes(shift.start ?? null);
+    const endMin = parseTimeMinutes(shift.end ?? null);
+    if (startMin == null || endMin == null) continue;
+
+    const minutesNow = local.minutesOfDay;
+    let inRange = false;
+    let startDate = { year: local.year, month: local.month, day: local.day };
+    let endDate = { year: local.year, month: local.month, day: local.day };
+
+    if (startMin <= endMin) {
+      inRange = minutesNow >= startMin && minutesNow < endMin;
+    } else {
+      inRange = minutesNow >= startMin || minutesNow < endMin;
+      if (minutesNow >= startMin) {
+        endDate = addDays(endDate, 1);
+      } else {
+        startDate = addDays(startDate, -1);
+      }
+    }
+
+    if (!inRange) continue;
+
+    const start = zonedToUtcDate({
+      ...startDate,
+      hours: Math.floor(startMin / 60),
+      minutes: startMin % 60,
+      timeZone,
+    });
+     const shiftEndUtc = zonedToUtcDate({
+      ...endDate,
+      hours: Math.floor(endMin / 60),
+      minutes: endMin % 60,
+      timeZone,
+    });
+
+    if (shiftEndUtc <= start) continue;
+
+    // Cap end at "now" so we render shift-so-far, not shift-as-planned.
+    // Without cap:
+    //   - timeline fills future minutes with idle (visual lie)
+    //   - offline calc = (shift_end_future - last_seen) = looks 5h offline
+    //     even on a machine producing right now
+    const end = params.now < shiftEndUtc ? params.now : shiftEndUtc;
+
+    return {
+      hasEnabledShifts: true,
+      range: { start, end },
+    };
+  }
+
+  return {
+    hasEnabledShifts: true,
+    range: null,
+  } as const;
+}
+
+async function resolveDetailRange(params: { orgId: string; input: DetailRangeInput }) {
+  const now = new Date(Math.floor(Date.now() / 60000) * 60000);
+  const requestedMode = normalizedRangeMode(params.input.mode);
+  const shiftEnabledCount = await prisma.orgShift.count({
+    where: {
+      orgId: params.orgId,
+      enabled: { not: false },
+    },
+  });
+  const shiftAvailable = shiftEnabledCount > 0;
+
+  if (requestedMode === "custom") {
+    const start = parseDate(params.input.start);
+    const end = parseDate(params.input.end);
+    if (start && end && end > start) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start,
+        end,
+        shiftAvailable,
+      } as const;
+    }
+  }
+
+  if (requestedMode === "yesterday") {
+    const settings = await prisma.orgSettings.findUnique({
+      where: { orgId: params.orgId },
+      select: { timezone: true },
+    });
+    const timeZone = settings?.timezone || "America/Mexico_City";
+    const localNow = getLocalParts(now, timeZone);
+    const today = { year: localNow.year, month: localNow.month, day: localNow.day };
+    const yesterday = addDays(today, -1);
+    const start = zonedToUtcDate({
+      ...yesterday,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    const end = zonedToUtcDate({
+      ...today,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    return {
+      requestedMode,
+      mode: requestedMode,
+      start,
+      end,
+      shiftAvailable,
+    } as const;
+  }
+
+  if (requestedMode === "shift") {
+    const shiftRange = await resolveCurrentShiftRange({ orgId: params.orgId, now });
+    if (shiftRange.range) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start: shiftRange.range.start,
+        end: shiftRange.range.end,
+        shiftAvailable,
+      } as const;
+    }
+    if (!shiftRange.hasEnabledShifts) {
+      return {
+        requestedMode,
+        mode: "24h" as const,
+        start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+        end: now,
+        shiftAvailable,
+        fallbackReason: "shift-unavailable" as const,
+      } as const;
+    }
+    return {
+      requestedMode,
+      mode: "24h" as const,
+      start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+      end: now,
+      shiftAvailable,
+      fallbackReason: "shift-inactive" as const,
+    } as const;
+  }
+
+  return {
+    requestedMode,
+    mode: "24h" as const,
+    start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+    end: now,
+    shiftAvailable,
+  } as const;
+}
+
+async function computeRecapMachineDetail(params: {
+  orgId: string;
+  machineId: string;
+  range: {
+    requestedMode: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: Date;
+    end: Date;
+    shiftAvailable: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+}) {
+  const { range } = params;
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    machineId: params.machineId,
+    start: range.start,
+    end: range.end,
+  });
+
+  const machine = recap.machines.find((row) => row.machineId === params.machineId) ?? null;
+  if (!machine) return null;
+
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds: [params.machineId],
+    start: range.start,
+    end: range.end,
+  });
+
+  const timeline = buildTimelineSegments({
+    cycles: timelineRows.cyclesByMachine.get(params.machineId) ?? [],
+    events: timelineRows.eventsByMachine.get(params.machineId) ?? [],
+    rangeStart: range.start,
+    rangeEnd: range.end,
+  });
+
+  const status = statusFromMachine(machine, range.end.getTime());
+
+  const downtimeTotalMin = Math.max(0, machine.downtime.totalMin);
+  const downtimeTop = machine.downtime.topReasons.slice(0, 3).map((row) => ({
+    reasonLabel: row.reasonLabel,
+    minutes: row.minutes,
+    count: row.count,
+    percent: downtimeTotalMin > 0 ? round2((row.minutes / downtimeTotalMin) * 100) : 0,
+  }));
+
+  const machineDetail: RecapMachineDetail = {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    stopMinutes: downtimeTotalMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    lastSeenMs: status.lastSeenMs,
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+    },
+    timeline,
+    productionBySku: machine.production.bySku,
+    downtimeTop,
+    workOrders: {
+      completed: machine.workOrders.completed,
+      active: machine.workOrders.active,
+    },
+    heartbeat: {
+      lastSeenAt: machine.heartbeat.lastSeenAt,
+      uptimePct: machine.heartbeat.uptimePct,
+      connectionStatus: status.status === "offline" ? "offline" : "online",
+    },
+  };
+
+  const response: RecapDetailResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      requestedMode: range.requestedMode,
+      mode: range.mode,
+      start: range.start.toISOString(),
+      end: range.end.toISOString(),
+      shiftAvailable: range.shiftAvailable,
+      fallbackReason: range.fallbackReason,
+    },
+    machine: machineDetail,
+  };
+
+  return response;
+}
+
+function summaryCacheKey(params: { orgId: string; hours: number }) {
+  return ["recap-summary-v1", params.orgId, String(params.hours)];
+}
+
+function detailCacheKey(params: {
+  orgId: string;
+  machineId: string;
+  requestedMode: RecapRangeMode;
+  mode: RecapRangeMode;
+  shiftAvailable: boolean;
+  fallbackReason?: "shift-unavailable" | "shift-inactive";
+  startMs: number;
+  endMs: number;
+}) {
+  return [
+    "recap-detail-v1",
+    params.orgId,
+    params.machineId,
+    params.requestedMode,
+    params.mode,
+    params.shiftAvailable ? "shift-on" : "shift-off",
+    params.fallbackReason ?? "",
+    String(Math.trunc(params.startMs / 60000)),
+    String(Math.trunc(params.endMs / 60000)),
+  ];
+}
+
+export function parseRecapSummaryHours(raw: string | null) {
+  return parseHours(raw);
+}
+
+export function parseRecapDetailRangeInput(searchParams: URLSearchParams | Record<string, string | string[] | undefined>) {
+  if (searchParams instanceof URLSearchParams) {
+    return {
+      mode: searchParams.get("range") ?? undefined,
+      start: searchParams.get("start") ?? undefined,
+      end: searchParams.get("end") ?? undefined,
+    };
+  }
+
+  const pick = (key: string) => {
+    const value = searchParams[key];
+    if (Array.isArray(value)) return value[0] ?? undefined;
+    return value ?? undefined;
+  };
+
+  return {
+    mode: pick("range"),
+    start: pick("start"),
+    end: pick("end"),
+  };
+}
+
+export async function getRecapSummaryCached(params: { orgId: string; hours: number }) {
+  const cache = unstable_cache(
+    () => computeRecapSummary(params),
+    summaryCacheKey(params),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`],
+    }
+  );
+
+  return cache();
+}
+
+export async function getRecapMachineDetailCached(params: {
+  orgId: string;
+  machineId: string;
+  input: DetailRangeInput;
+}) {
+  const resolved = await resolveDetailRange({
+    orgId: params.orgId,
+    input: params.input,
+  });
+
+  const cache = unstable_cache(
+    () =>
+      computeRecapMachineDetail({
+        orgId: params.orgId,
+        machineId: params.machineId,
+        range: {
+          requestedMode: resolved.requestedMode,
+          mode: resolved.mode,
+          start: resolved.start,
+          end: resolved.end,
+          shiftAvailable: resolved.shiftAvailable,
+          fallbackReason: resolved.fallbackReason,
+        },
+      }),
+    detailCacheKey({
+      orgId: params.orgId,
+      machineId: params.machineId,
+      requestedMode: resolved.requestedMode,
+      mode: resolved.mode,
+      shiftAvailable: resolved.shiftAvailable,
+      fallbackReason: resolved.fallbackReason,
+      startMs: resolved.start.getTime(),
+      endMs: resolved.end.getTime(),
+    }),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`, `recap:${params.orgId}:${params.machineId}`],
+    }
+  );
+
+  return cache();
+}

lib/recap/redesign.ts.bak.step3

@@ -0,0 +1,848 @@
+import { unstable_cache } from "next/cache";
+import { prisma } from "@/lib/prisma";
+import { normalizeShiftOverrides, type ShiftOverrideDay } from "@/lib/settings";
+import { getRecapDataCached } from "@/lib/recap/getRecapData";
+import {
+  buildTimelineSegments,
+  compressTimelineSegments,
+  TIMELINE_EVENT_TYPES,
+  type TimelineCycleRow,
+  type TimelineEventRow,
+} from "@/lib/recap/timeline";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
+import type {
+  RecapDetailResponse,
+  RecapMachine,
+  RecapMachineDetail,
+  RecapMachineStatus,
+  RecapRangeMode,
+  RecapSummaryMachine,
+  RecapSummaryResponse,
+} from "@/lib/recap/types";
+
+type DetailRangeInput = {
+  mode?: string | null;
+  start?: string | null;
+  end?: string | null;
+};
+
+const OFFLINE_THRESHOLD_MS = RECAP_HEARTBEAT_STALE_MS;
+const TIMELINE_EVENT_LOOKBACK_MS = 24 * 60 * 60 * 1000;
+const TIMELINE_CYCLE_LOOKBACK_MS = 15 * 60 * 1000;
+const RECAP_CACHE_TTL_SEC = 60;
+const WEEKDAY_KEYS: ShiftOverrideDay[] = ["sun", "mon", "tue", "wed", "thu", "fri", "sat"];
+const WEEKDAY_KEY_MAP: Record<string, ShiftOverrideDay> = {
+  Mon: "mon",
+  Tue: "tue",
+  Wed: "wed",
+  Thu: "thu",
+  Fri: "fri",
+  Sat: "sat",
+  Sun: "sun",
+};
+
+function round2(value: number) {
+  return Math.round(value * 100) / 100;
+}
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (Number.isFinite(n)) {
+    const d = new Date(n);
+    return Number.isFinite(d.getTime()) ? d : null;
+  }
+  const d = new Date(input);
+  return Number.isFinite(d.getTime()) ? d : null;
+}
+
+function parseHours(input: string | null) {
+  const parsed = Math.trunc(Number(input ?? "24"));
+  if (!Number.isFinite(parsed)) return 24;
+  return Math.max(1, Math.min(72, parsed));
+}
+
+function parseTimeMinutes(input?: string | null) {
+  if (!input) return null;
+  const match = /^(\d{2}):(\d{2})$/.exec(input.trim());
+  if (!match) return null;
+  const hours = Number(match[1]);
+  const minutes = Number(match[2]);
+  if (!Number.isInteger(hours) || !Number.isInteger(minutes) || hours < 0 || hours > 23 || minutes < 0 || minutes > 59) {
+    return null;
+  }
+  return hours * 60 + minutes;
+}
+
+function getLocalParts(ts: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      year: "numeric",
+      month: "2-digit",
+      day: "2-digit",
+      hour: "2-digit",
+      minute: "2-digit",
+      weekday: "short",
+      hour12: false,
+    }).formatToParts(ts);
+
+    const value = (type: string) => parts.find((part) => part.type === type)?.value ?? "";
+    const year = Number(value("year"));
+    const month = Number(value("month"));
+    const day = Number(value("day"));
+    const hour = Number(value("hour"));
+    const minute = Number(value("minute"));
+    const weekday = value("weekday");
+
+    return {
+      year,
+      month,
+      day,
+      hour,
+      minute,
+      weekday: WEEKDAY_KEY_MAP[weekday] ?? WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: hour * 60 + minute,
+    };
+  } catch {
+    return {
+      year: ts.getUTCFullYear(),
+      month: ts.getUTCMonth() + 1,
+      day: ts.getUTCDate(),
+      hour: ts.getUTCHours(),
+      minute: ts.getUTCMinutes(),
+      weekday: WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: ts.getUTCHours() * 60 + ts.getUTCMinutes(),
+    };
+  }
+}
+
+function parseOffsetMinutes(offsetLabel: string | null) {
+  if (!offsetLabel) return null;
+  const normalized = offsetLabel.replace("UTC", "GMT");
+  const match = /^GMT([+-])(\d{1,2})(?::?(\d{2}))?$/.exec(normalized);
+  if (!match) return null;
+  const sign = match[1] === "-" ? -1 : 1;
+  const hour = Number(match[2]);
+  const minute = Number(match[3] ?? "0");
+  if (!Number.isFinite(hour) || !Number.isFinite(minute)) return null;
+  return sign * (hour * 60 + minute);
+}
+
+function getTzOffsetMinutes(utcDate: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      timeZoneName: "shortOffset",
+      hour: "2-digit",
+    }).formatToParts(utcDate);
+    const offsetPart = parts.find((part) => part.type === "timeZoneName")?.value ?? null;
+    return parseOffsetMinutes(offsetPart);
+  } catch {
+    return null;
+  }
+}
+
+function zonedToUtcDate(input: {
+  year: number;
+  month: number;
+  day: number;
+  hours: number;
+  minutes: number;
+  timeZone: string;
+}) {
+  const baseUtc = Date.UTC(input.year, input.month - 1, input.day, input.hours, input.minutes, 0, 0);
+  const guessDate = new Date(baseUtc);
+  const offsetA = getTzOffsetMinutes(guessDate, input.timeZone);
+  if (offsetA == null) return guessDate;
+
+  let corrected = new Date(baseUtc - offsetA * 60000);
+  const offsetB = getTzOffsetMinutes(corrected, input.timeZone);
+  if (offsetB != null && offsetB !== offsetA) {
+    corrected = new Date(baseUtc - offsetB * 60000);
+  }
+
+  return corrected;
+}
+
+function addDays(input: { year: number; month: number; day: number }, days: number) {
+  const base = new Date(Date.UTC(input.year, input.month - 1, input.day));
+  base.setUTCDate(base.getUTCDate() + days);
+  return {
+    year: base.getUTCFullYear(),
+    month: base.getUTCMonth() + 1,
+    day: base.getUTCDate(),
+  };
+}
+
+// Active stoppage = freshest macrostop episode whose latest event is "active"
+// and whose latest event timestamp is within ACTIVE_STALE_MS of rangeEnd.
+// Mirrors the same rules used by lib/recap/timeline.ts so the card status
+// agrees with the timeline rendering.
+const STOPPAGE_ACTIVE_STALE_MS = 2 * 60 * 1000;
+
+function detectActiveMacrostop(events: TimelineEventRow[] | undefined, endMs: number) {
+  if (!events || events.length === 0) return null;
+
+  type Episode = { firstTsMs: number; lastTsMs: number; lastStatus: string };
+  const episodes = new Map<string, Episode>();
+
+  for (const event of events) {
+    if (String(event.eventType || "").toLowerCase() !== "macrostop") continue;
+
+    // Defensive: parse data the same way timeline.ts does.
+    let parsed: unknown = event.data;
+    if (typeof parsed === "string") {
+      try { parsed = JSON.parse(parsed); } catch { parsed = null; }
+    }
+    const data: Record<string, unknown> =
+      parsed && typeof parsed === "object" && !Array.isArray(parsed)
+        ? (parsed as Record<string, unknown>)
+        : {};
+
+    // Drop only the auto-ack pings (same rule as timeline.ts Fix B).
+    const isAutoAck =
+      data.is_auto_ack === true ||
+      data.isAutoAck === true ||
+      data.is_auto_ack === "true" ||
+      data.isAutoAck === "true";
+    if (isAutoAck) continue;
+
+    const status = String(data.status ?? "").trim().toLowerCase();
+    const incidentKey = String(data.incidentKey ?? data.incident_key ?? "").trim()
+      || `macrostop:${event.ts.getTime()}`;
+    const tsMs = event.ts.getTime();
+
+    const existing = episodes.get(incidentKey);
+    if (!existing) {
+      episodes.set(incidentKey, { firstTsMs: tsMs, lastTsMs: tsMs, lastStatus: status });
+      continue;
+    }
+    existing.firstTsMs = Math.min(existing.firstTsMs, tsMs);
+    if (tsMs >= existing.lastTsMs) {
+      existing.lastTsMs = tsMs;
+      existing.lastStatus = status;
+    }
+  }
+
+  let activeOngoingMin = 0;
+  for (const ep of episodes.values()) {
+    if (ep.lastStatus !== "active") continue;
+    if (endMs - ep.lastTsMs > STOPPAGE_ACTIVE_STALE_MS) continue;
+    const ongoingMin = Math.max(0, Math.floor((endMs - ep.firstTsMs) / 60000));
+    if (ongoingMin > activeOngoingMin) activeOngoingMin = ongoingMin;
+  }
+
+  return activeOngoingMin > 0 ? activeOngoingMin : null;
+}
+
+function statusFromMachine(machine: RecapMachine, endMs: number, events?: TimelineEventRow[]) {
+  const lastSeenMs = machine.heartbeat.lastSeenAt ? new Date(machine.heartbeat.lastSeenAt).getTime() : null;
+  const offlineForMs = lastSeenMs == null ? Number.POSITIVE_INFINITY : Math.max(0, endMs - lastSeenMs);
+  const offline = !Number.isFinite(lastSeenMs ?? Number.NaN) || offlineForMs > OFFLINE_THRESHOLD_MS;
+
+  // ongoingStopMin from the legacy heartbeat-based path (typically null) OR
+  // from the macrostop event detection (preferred — accurate)
+  const macrostopOngoingMin = detectActiveMacrostop(events, endMs);
+  const legacyOngoingStopMin = machine.downtime.ongoingStopMin ?? 0;
+  const ongoingStopMin = macrostopOngoingMin ?? (legacyOngoingStopMin > 0 ? legacyOngoingStopMin : null);
+
+  const moldActive = machine.workOrders.moldChangeInProgress;
+
+  let status: RecapMachineStatus = "running";
+  if (offline) status = "offline";
+  else if (moldActive) status = "mold-change";
+  else if (ongoingStopMin != null && ongoingStopMin > 0) status = "stopped";
+
+  return {
+    status,
+    lastSeenMs,
+    offlineForMin: offline ? Math.max(0, Math.floor(offlineForMs / 60000)) : null,
+    ongoingStopMin,
+  };
+}
+
+async function loadTimelineRowsForMachines(params: {
+  orgId: string;
+  machineIds: string[];
+  start: Date;
+  end: Date;
+}) {
+  if (!params.machineIds.length) {
+    return {
+      cyclesByMachine: new Map<string, TimelineCycleRow[]>(),
+      eventsByMachine: new Map<string, TimelineEventRow[]>(),
+    };
+  }
+
+  const [cycles, events] = await Promise.all([
+    prisma.machineCycle.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_CYCLE_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        cycleCount: true,
+        actualCycleTime: true,
+        workOrderId: true,
+        sku: true,
+      },
+    }),
+    prisma.machineEvent.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        eventType: { in: TIMELINE_EVENT_TYPES as unknown as string[] },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_EVENT_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        eventType: true,
+        data: true,
+      },
+    }),
+  ]);
+
+  const cyclesByMachine = new Map<string, TimelineCycleRow[]>();
+  const eventsByMachine = new Map<string, TimelineEventRow[]>();
+
+  for (const row of cycles) {
+    const list = cyclesByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      cycleCount: row.cycleCount,
+      actualCycleTime: row.actualCycleTime,
+      workOrderId: row.workOrderId,
+      sku: row.sku,
+    });
+    cyclesByMachine.set(row.machineId, list);
+  }
+
+  for (const row of events) {
+    const list = eventsByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      eventType: row.eventType,
+      data: row.data,
+    });
+    eventsByMachine.set(row.machineId, list);
+  }
+
+  return { cyclesByMachine, eventsByMachine };
+}
+
+function toSummaryMachine(params: {
+  machine: RecapMachine;
+  miniTimeline: ReturnType<typeof compressTimelineSegments>;
+  rangeEndMs: number;
+  events?: TimelineEventRow[];
+}): RecapSummaryMachine {
+  const { machine, miniTimeline, rangeEndMs, events } = params;
+  const status = statusFromMachine(machine, rangeEndMs, events);
+
+  return {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    lastSeenMs: status.lastSeenMs,
+    lastActivityMin:
+      status.lastSeenMs == null ? null : Math.max(0, Math.floor((rangeEndMs - status.lastSeenMs) / 60000)),
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+      elapsedMin:
+        machine.workOrders.moldChangeStartMs == null
+          ? null
+          : Math.max(0, Math.floor((rangeEndMs - machine.workOrders.moldChangeStartMs) / 60000)),
+    },
+    miniTimeline,
+  };
+}
+
+async function computeRecapSummary(params: { orgId: string; hours: number }) {
+  const now = new Date();
+  const end = new Date(Math.floor(now.getTime() / 60000) * 60000);
+  const start = new Date(end.getTime() - params.hours * 60 * 60 * 1000);
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    start,
+    end,
+  });
+
+  const machineIds = recap.machines.map((machine) => machine.machineId);
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds,
+    start,
+    end,
+  });
+
+  const machines = recap.machines.map((machine) => {
+    const segments = buildTimelineSegments({
+      cycles: timelineRows.cyclesByMachine.get(machine.machineId) ?? [],
+      events: timelineRows.eventsByMachine.get(machine.machineId) ?? [],
+      rangeStart: start,
+      rangeEnd: end,
+    });
+    const miniTimeline = compressTimelineSegments({
+      segments,
+      rangeStart: start,
+      rangeEnd: end,
+      maxSegments: 60,
+    });
+
+    return toSummaryMachine({
+      machine,
+      miniTimeline,
+      rangeEndMs: end.getTime(),
+      events: timelineRows.eventsByMachine.get(machine.machineId),
+    });
+  });
+
+  const response: RecapSummaryResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      start: start.toISOString(),
+      end: end.toISOString(),
+      hours: params.hours,
+    },
+    machines,
+  };
+
+  return response;
+}
+
+function normalizedRangeMode(mode?: string | null): RecapRangeMode {
+  const raw = String(mode ?? "").trim().toLowerCase();
+  if (raw === "shift") return "shift";
+  if (raw === "yesterday") return "yesterday";
+  if (raw === "custom") return "custom";
+  return "24h";
+}
+
+async function resolveCurrentShiftRange(params: { orgId: string; now: Date }) {
+  const settings = await prisma.orgSettings.findUnique({
+    where: { orgId: params.orgId },
+    select: {
+      timezone: true,
+      shiftScheduleOverridesJson: true,
+    },
+  });
+  const shifts = await prisma.orgShift.findMany({
+    where: { orgId: params.orgId },
+    orderBy: { sortOrder: "asc" },
+    select: {
+      name: true,
+      startTime: true,
+      endTime: true,
+      enabled: true,
+      sortOrder: true,
+    },
+  });
+
+  const enabledShifts = shifts.filter((shift) => shift.enabled !== false);
+  if (!enabledShifts.length) {
+    return {
+      hasEnabledShifts: false,
+      range: null,
+    } as const;
+  }
+
+  const timeZone = settings?.timezone || "UTC";
+  const local = getLocalParts(params.now, timeZone);
+  const overrides = normalizeShiftOverrides(settings?.shiftScheduleOverridesJson);
+  const dayOverrides = overrides?.[local.weekday];
+  const activeShifts = (dayOverrides?.length
+    ? dayOverrides.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.start,
+        end: shift.end,
+      }))
+    : enabledShifts.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.startTime,
+        end: shift.endTime,
+      }))
+  ).filter((shift) => shift.enabled);
+
+  for (const shift of activeShifts) {
+    const startMin = parseTimeMinutes(shift.start ?? null);
+    const endMin = parseTimeMinutes(shift.end ?? null);
+    if (startMin == null || endMin == null) continue;
+
+    const minutesNow = local.minutesOfDay;
+    let inRange = false;
+    let startDate = { year: local.year, month: local.month, day: local.day };
+    let endDate = { year: local.year, month: local.month, day: local.day };
+
+    if (startMin <= endMin) {
+      inRange = minutesNow >= startMin && minutesNow < endMin;
+    } else {
+      inRange = minutesNow >= startMin || minutesNow < endMin;
+      if (minutesNow >= startMin) {
+        endDate = addDays(endDate, 1);
+      } else {
+        startDate = addDays(startDate, -1);
+      }
+    }
+
+    if (!inRange) continue;
+
+    const start = zonedToUtcDate({
+      ...startDate,
+      hours: Math.floor(startMin / 60),
+      minutes: startMin % 60,
+      timeZone,
+    });
+     const shiftEndUtc = zonedToUtcDate({
+      ...endDate,
+      hours: Math.floor(endMin / 60),
+      minutes: endMin % 60,
+      timeZone,
+    });
+
+    if (shiftEndUtc <= start) continue;
+
+    // Cap end at "now" so we render shift-so-far, not shift-as-planned.
+    // Without cap:
+    //   - timeline fills future minutes with idle (visual lie)
+    //   - offline calc = (shift_end_future - last_seen) = looks 5h offline
+    //     even on a machine producing right now
+    const end = params.now < shiftEndUtc ? params.now : shiftEndUtc;
+
+    return {
+      hasEnabledShifts: true,
+      range: { start, end },
+    };
+  }
+
+  return {
+    hasEnabledShifts: true,
+    range: null,
+  } as const;
+}
+
+async function resolveDetailRange(params: { orgId: string; input: DetailRangeInput }) {
+  const now = new Date(Math.floor(Date.now() / 60000) * 60000);
+  const requestedMode = normalizedRangeMode(params.input.mode);
+  const shiftEnabledCount = await prisma.orgShift.count({
+    where: {
+      orgId: params.orgId,
+      enabled: { not: false },
+    },
+  });
+  const shiftAvailable = shiftEnabledCount > 0;
+
+  if (requestedMode === "custom") {
+    const start = parseDate(params.input.start);
+    const end = parseDate(params.input.end);
+    if (start && end && end > start) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start,
+        end,
+        shiftAvailable,
+      } as const;
+    }
+  }
+
+  if (requestedMode === "yesterday") {
+    const settings = await prisma.orgSettings.findUnique({
+      where: { orgId: params.orgId },
+      select: { timezone: true },
+    });
+    const timeZone = settings?.timezone || "America/Mexico_City";
+    const localNow = getLocalParts(now, timeZone);
+    const today = { year: localNow.year, month: localNow.month, day: localNow.day };
+    const yesterday = addDays(today, -1);
+    const start = zonedToUtcDate({
+      ...yesterday,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    const end = zonedToUtcDate({
+      ...today,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    return {
+      requestedMode,
+      mode: requestedMode,
+      start,
+      end,
+      shiftAvailable,
+    } as const;
+  }
+
+  if (requestedMode === "shift") {
+    const shiftRange = await resolveCurrentShiftRange({ orgId: params.orgId, now });
+    if (shiftRange.range) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start: shiftRange.range.start,
+        end: shiftRange.range.end,
+        shiftAvailable,
+      } as const;
+    }
+    if (!shiftRange.hasEnabledShifts) {
+      return {
+        requestedMode,
+        mode: "24h" as const,
+        start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+        end: now,
+        shiftAvailable,
+        fallbackReason: "shift-unavailable" as const,
+      } as const;
+    }
+    return {
+      requestedMode,
+      mode: "24h" as const,
+      start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+      end: now,
+      shiftAvailable,
+      fallbackReason: "shift-inactive" as const,
+    } as const;
+  }
+
+  return {
+    requestedMode,
+    mode: "24h" as const,
+    start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+    end: now,
+    shiftAvailable,
+  } as const;
+}
+
+async function computeRecapMachineDetail(params: {
+  orgId: string;
+  machineId: string;
+  range: {
+    requestedMode: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: Date;
+    end: Date;
+    shiftAvailable: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+}) {
+  const { range } = params;
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    machineId: params.machineId,
+    start: range.start,
+    end: range.end,
+  });
+
+  const machine = recap.machines.find((row) => row.machineId === params.machineId) ?? null;
+  if (!machine) return null;
+
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds: [params.machineId],
+    start: range.start,
+    end: range.end,
+  });
+
+  const timeline = buildTimelineSegments({
+    cycles: timelineRows.cyclesByMachine.get(params.machineId) ?? [],
+    events: timelineRows.eventsByMachine.get(params.machineId) ?? [],
+    rangeStart: range.start,
+    rangeEnd: range.end,
+  });
+
+  const status = statusFromMachine(
+    machine,
+    range.end.getTime(),
+    timelineRows.eventsByMachine.get(params.machineId)
+  );
+
+  const downtimeTotalMin = Math.max(0, machine.downtime.totalMin);
+  const downtimeTop = machine.downtime.topReasons.slice(0, 3).map((row) => ({
+    reasonLabel: row.reasonLabel,
+    minutes: row.minutes,
+    count: row.count,
+    percent: downtimeTotalMin > 0 ? round2((row.minutes / downtimeTotalMin) * 100) : 0,
+  }));
+
+  const machineDetail: RecapMachineDetail = {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    stopMinutes: downtimeTotalMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    lastSeenMs: status.lastSeenMs,
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+    },
+    timeline,
+    productionBySku: machine.production.bySku,
+    downtimeTop,
+    workOrders: {
+      completed: machine.workOrders.completed,
+      active: machine.workOrders.active,
+    },
+    heartbeat: {
+      lastSeenAt: machine.heartbeat.lastSeenAt,
+      uptimePct: machine.heartbeat.uptimePct,
+      connectionStatus: status.status === "offline" ? "offline" : "online",
+    },
+  };
+
+  const response: RecapDetailResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      requestedMode: range.requestedMode,
+      mode: range.mode,
+      start: range.start.toISOString(),
+      end: range.end.toISOString(),
+      shiftAvailable: range.shiftAvailable,
+      fallbackReason: range.fallbackReason,
+    },
+    machine: machineDetail,
+  };
+
+  return response;
+}
+
+function summaryCacheKey(params: { orgId: string; hours: number }) {
+  return ["recap-summary-v1", params.orgId, String(params.hours)];
+}
+
+function detailCacheKey(params: {
+  orgId: string;
+  machineId: string;
+  requestedMode: RecapRangeMode;
+  mode: RecapRangeMode;
+  shiftAvailable: boolean;
+  fallbackReason?: "shift-unavailable" | "shift-inactive";
+  startMs: number;
+  endMs: number;
+}) {
+  return [
+    "recap-detail-v1",
+    params.orgId,
+    params.machineId,
+    params.requestedMode,
+    params.mode,
+    params.shiftAvailable ? "shift-on" : "shift-off",
+    params.fallbackReason ?? "",
+    String(Math.trunc(params.startMs / 60000)),
+    String(Math.trunc(params.endMs / 60000)),
+  ];
+}
+
+export function parseRecapSummaryHours(raw: string | null) {
+  return parseHours(raw);
+}
+
+export function parseRecapDetailRangeInput(searchParams: URLSearchParams | Record<string, string | string[] | undefined>) {
+  if (searchParams instanceof URLSearchParams) {
+    return {
+      mode: searchParams.get("range") ?? undefined,
+      start: searchParams.get("start") ?? undefined,
+      end: searchParams.get("end") ?? undefined,
+    };
+  }
+
+  const pick = (key: string) => {
+    const value = searchParams[key];
+    if (Array.isArray(value)) return value[0] ?? undefined;
+    return value ?? undefined;
+  };
+
+  return {
+    mode: pick("range"),
+    start: pick("start"),
+    end: pick("end"),
+  };
+}
+
+export async function getRecapSummaryCached(params: { orgId: string; hours: number }) {
+  const cache = unstable_cache(
+    () => computeRecapSummary(params),
+    summaryCacheKey(params),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`],
+    }
+  );
+
+  return cache();
+}
+
+export async function getRecapMachineDetailCached(params: {
+  orgId: string;
+  machineId: string;
+  input: DetailRangeInput;
+}) {
+  const resolved = await resolveDetailRange({
+    orgId: params.orgId,
+    input: params.input,
+  });
+
+  const cache = unstable_cache(
+    () =>
+      computeRecapMachineDetail({
+        orgId: params.orgId,
+        machineId: params.machineId,
+        range: {
+          requestedMode: resolved.requestedMode,
+          mode: resolved.mode,
+          start: resolved.start,
+          end: resolved.end,
+          shiftAvailable: resolved.shiftAvailable,
+          fallbackReason: resolved.fallbackReason,
+        },
+      }),
+    detailCacheKey({
+      orgId: params.orgId,
+      machineId: params.machineId,
+      requestedMode: resolved.requestedMode,
+      mode: resolved.mode,
+      shiftAvailable: resolved.shiftAvailable,
+      fallbackReason: resolved.fallbackReason,
+      startMs: resolved.start.getTime(),
+      endMs: resolved.end.getTime(),
+    }),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`, `recap:${params.orgId}:${params.machineId}`],
+    }
+  );
+
+  return cache();
+}

lib/recap/redesign.ts.bak.step4

@@ -0,0 +1,905 @@
+import { unstable_cache } from "next/cache";
+import { prisma } from "@/lib/prisma";
+import { normalizeShiftOverrides, type ShiftOverrideDay } from "@/lib/settings";
+import { getRecapDataCached } from "@/lib/recap/getRecapData";
+import {
+  buildTimelineSegments,
+  compressTimelineSegments,
+  TIMELINE_EVENT_TYPES,
+  type TimelineCycleRow,
+  type TimelineEventRow,
+} from "@/lib/recap/timeline";
+import { classifyMachineState, type MachineStateResult } from "@/lib/recap/machineState";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
+import type {
+  RecapDetailResponse,
+  RecapMachine,
+  RecapMachineDetail,
+  RecapMachineStatus,
+  RecapRangeMode,
+  RecapSummaryMachine,
+  RecapSummaryResponse,
+} from "@/lib/recap/types";
+
+type DetailRangeInput = {
+  mode?: string | null;
+  start?: string | null;
+  end?: string | null;
+};
+
+const OFFLINE_THRESHOLD_MS = RECAP_HEARTBEAT_STALE_MS;
+const TIMELINE_EVENT_LOOKBACK_MS = 24 * 60 * 60 * 1000;
+const TIMELINE_CYCLE_LOOKBACK_MS = 15 * 60 * 1000;
+const RECAP_CACHE_TTL_SEC = 60;
+const WEEKDAY_KEYS: ShiftOverrideDay[] = ["sun", "mon", "tue", "wed", "thu", "fri", "sat"];
+const WEEKDAY_KEY_MAP: Record<string, ShiftOverrideDay> = {
+  Mon: "mon",
+  Tue: "tue",
+  Wed: "wed",
+  Thu: "thu",
+  Fri: "fri",
+  Sat: "sat",
+  Sun: "sun",
+};
+
+function round2(value: number) {
+  return Math.round(value * 100) / 100;
+}
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (Number.isFinite(n)) {
+    const d = new Date(n);
+    return Number.isFinite(d.getTime()) ? d : null;
+  }
+  const d = new Date(input);
+  return Number.isFinite(d.getTime()) ? d : null;
+}
+
+function parseHours(input: string | null) {
+  const parsed = Math.trunc(Number(input ?? "24"));
+  if (!Number.isFinite(parsed)) return 24;
+  return Math.max(1, Math.min(72, parsed));
+}
+
+function parseTimeMinutes(input?: string | null) {
+  if (!input) return null;
+  const match = /^(\d{2}):(\d{2})$/.exec(input.trim());
+  if (!match) return null;
+  const hours = Number(match[1]);
+  const minutes = Number(match[2]);
+  if (!Number.isInteger(hours) || !Number.isInteger(minutes) || hours < 0 || hours > 23 || minutes < 0 || minutes > 59) {
+    return null;
+  }
+  return hours * 60 + minutes;
+}
+
+function getLocalParts(ts: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      year: "numeric",
+      month: "2-digit",
+      day: "2-digit",
+      hour: "2-digit",
+      minute: "2-digit",
+      weekday: "short",
+      hour12: false,
+    }).formatToParts(ts);
+
+    const value = (type: string) => parts.find((part) => part.type === type)?.value ?? "";
+    const year = Number(value("year"));
+    const month = Number(value("month"));
+    const day = Number(value("day"));
+    const hour = Number(value("hour"));
+    const minute = Number(value("minute"));
+    const weekday = value("weekday");
+
+    return {
+      year,
+      month,
+      day,
+      hour,
+      minute,
+      weekday: WEEKDAY_KEY_MAP[weekday] ?? WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: hour * 60 + minute,
+    };
+  } catch {
+    return {
+      year: ts.getUTCFullYear(),
+      month: ts.getUTCMonth() + 1,
+      day: ts.getUTCDate(),
+      hour: ts.getUTCHours(),
+      minute: ts.getUTCMinutes(),
+      weekday: WEEKDAY_KEYS[ts.getUTCDay()],
+      minutesOfDay: ts.getUTCHours() * 60 + ts.getUTCMinutes(),
+    };
+  }
+}
+
+function parseOffsetMinutes(offsetLabel: string | null) {
+  if (!offsetLabel) return null;
+  const normalized = offsetLabel.replace("UTC", "GMT");
+  const match = /^GMT([+-])(\d{1,2})(?::?(\d{2}))?$/.exec(normalized);
+  if (!match) return null;
+  const sign = match[1] === "-" ? -1 : 1;
+  const hour = Number(match[2]);
+  const minute = Number(match[3] ?? "0");
+  if (!Number.isFinite(hour) || !Number.isFinite(minute)) return null;
+  return sign * (hour * 60 + minute);
+}
+
+function getTzOffsetMinutes(utcDate: Date, timeZone: string) {
+  try {
+    const parts = new Intl.DateTimeFormat("en-US", {
+      timeZone,
+      timeZoneName: "shortOffset",
+      hour: "2-digit",
+    }).formatToParts(utcDate);
+    const offsetPart = parts.find((part) => part.type === "timeZoneName")?.value ?? null;
+    return parseOffsetMinutes(offsetPart);
+  } catch {
+    return null;
+  }
+}
+
+function zonedToUtcDate(input: {
+  year: number;
+  month: number;
+  day: number;
+  hours: number;
+  minutes: number;
+  timeZone: string;
+}) {
+  const baseUtc = Date.UTC(input.year, input.month - 1, input.day, input.hours, input.minutes, 0, 0);
+  const guessDate = new Date(baseUtc);
+  const offsetA = getTzOffsetMinutes(guessDate, input.timeZone);
+  if (offsetA == null) return guessDate;
+
+  let corrected = new Date(baseUtc - offsetA * 60000);
+  const offsetB = getTzOffsetMinutes(corrected, input.timeZone);
+  if (offsetB != null && offsetB !== offsetA) {
+    corrected = new Date(baseUtc - offsetB * 60000);
+  }
+
+  return corrected;
+}
+
+function addDays(input: { year: number; month: number; day: number }, days: number) {
+  const base = new Date(Date.UTC(input.year, input.month - 1, input.day));
+  base.setUTCDate(base.getUTCDate() + days);
+  return {
+    year: base.getUTCFullYear(),
+    month: base.getUTCMonth() + 1,
+    day: base.getUTCDate(),
+  };
+}
+
+// Detect active episodes (macrostop, mold-change) from event rows.
+// Returns the latest non-auto-ack episode whose final status is "active"
+// and that's been refreshed within ACTIVE_STALE_MS.
+const ACTIVE_STALE_MS = 2 * 60 * 1000;
+
+type ActiveEpisode = { startedAtMs: number; lastTsMs: number };
+
+function detectActiveEpisode(
+  events: TimelineEventRow[] | undefined,
+  eventType: "macrostop" | "mold-change",
+  endMs: number
+): ActiveEpisode | null {
+  if (!events || events.length === 0) return null;
+
+  type Episode = { firstTsMs: number; lastTsMs: number; lastStatus: string; lastCycleTs: number | null };
+  const episodes = new Map<string, Episode>();
+
+  for (const event of events) {
+    if (String(event.eventType || "").toLowerCase() !== eventType) continue;
+
+    let parsed: unknown = event.data;
+    if (typeof parsed === "string") {
+      try { parsed = JSON.parse(parsed); } catch { parsed = null; }
+    }
+    const data: Record<string, unknown> =
+      parsed && typeof parsed === "object" && !Array.isArray(parsed)
+        ? (parsed as Record<string, unknown>)
+        : {};
+
+    const isAutoAck =
+      data.is_auto_ack === true ||
+      data.isAutoAck === true ||
+      data.is_auto_ack === "true" ||
+      data.isAutoAck === "true";
+    if (isAutoAck) continue;
+
+    const status = String(data.status ?? "").trim().toLowerCase();
+    const incidentKey = String(data.incidentKey ?? data.incident_key ?? "").trim()
+      || `${eventType}:${event.ts.getTime()}`;
+    const tsMs = event.ts.getTime();
+    const lastCycleTs = Number(data.last_cycle_timestamp);
+
+    const existing = episodes.get(incidentKey);
+    if (!existing) {
+      episodes.set(incidentKey, {
+        firstTsMs: tsMs,
+        lastTsMs: tsMs,
+        lastStatus: status,
+        lastCycleTs: Number.isFinite(lastCycleTs) && lastCycleTs > 0 ? lastCycleTs : null,
+      });
+      continue;
+    }
+    existing.firstTsMs = Math.min(existing.firstTsMs, tsMs);
+    if (tsMs >= existing.lastTsMs) {
+      existing.lastTsMs = tsMs;
+      existing.lastStatus = status;
+    }
+  }
+
+  let best: ActiveEpisode | null = null;
+  for (const ep of episodes.values()) {
+    if (ep.lastStatus !== "active") continue;
+    if (endMs - ep.lastTsMs > ACTIVE_STALE_MS) continue;
+    // Prefer the freshest active episode (highest lastTsMs)
+    if (!best || ep.lastTsMs > best.lastTsMs) {
+      best = {
+        startedAtMs: ep.lastCycleTs ?? ep.firstTsMs,
+        lastTsMs: ep.lastTsMs,
+      };
+    }
+  }
+  return best;
+}
+
+function statusFromMachine(
+  machine: RecapMachine,
+  endMs: number,
+  events?: TimelineEventRow[]
+): {
+  status: RecapMachineStatus;
+  result: MachineStateResult;
+  lastSeenMs: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+} {
+  const lastSeenMs = machine.heartbeat.lastSeenAt ? new Date(machine.heartbeat.lastSeenAt).getTime() : null;
+  const offlineForMs = lastSeenMs == null ? Number.POSITIVE_INFINITY : Math.max(0, endMs - lastSeenMs);
+  const heartbeatAlive = Number.isFinite(lastSeenMs ?? Number.NaN) && offlineForMs <= OFFLINE_THRESHOLD_MS;
+
+  const activeMacrostop = detectActiveEpisode(events, "macrostop", endMs);
+  const activeMoldChange = detectActiveEpisode(events, "mold-change", endMs);
+
+  // Round 1 limitation: trackingEnabled and untrackedCycles inputs require KPI/cycle queries
+  // we don't yet plumb here. We approximate from the legacy fields:
+  //   - trackingEnabled: true when there's an active macrostop (Pi only fires those when tracking on)
+  //                      OR when an active WO exists and machine.workOrders.moldChangeInProgress is false.
+  //                      This is a SIMPLIFICATION; Round 3 will replace with real KPI snapshot read.
+  //   - untrackedCycles: 0 (Round 3 will compute from MachineCycle vs latest KPI)
+  //
+  // Effect for Round 1: STOPPED `not_started` reason cannot trigger yet (we always assume tracking
+  // is on when a WO exists). Only `machine_fault` STOPPED fires. DATA_LOSS cannot fire yet.
+  // IDLE fires correctly when there's no WO and no recent activity.
+  const hasActiveWorkOrder = machine.workOrders.active != null;
+  const trackingEnabledApprox = hasActiveWorkOrder; // see comment above
+
+  const lastCycleTsMs = (() => {
+    // Best-effort: use the machine's heartbeat as a "recent activity" proxy.
+    // The Pi only heartbeats every minute regardless of cycles, so this is a weak signal.
+    // Round 3 will pass the actual latest cycle ts.
+    return lastSeenMs;
+  })();
+
+  const result = classifyMachineState(
+    {
+      heartbeatAlive,
+      lastSeenMs,
+      offlineForMs,
+      trackingEnabled: trackingEnabledApprox,
+      hasActiveWorkOrder,
+      activeMoldChange,
+      activeMacrostop,
+      untrackedCycles: { count: 0, oldestTsMs: null },
+      lastCycleTsMs,
+    },
+    endMs
+  );
+
+  // Map the rich classifier result back to the existing RecapMachineStatus union
+  const status: RecapMachineStatus = result.state;
+
+  // Pull common fields out for the caller's convenience
+  let ongoingStopMin: number | null = null;
+  if (result.state === "stopped") ongoingStopMin = result.ongoingStopMin;
+
+  return {
+    status,
+    result,
+    lastSeenMs,
+    offlineForMin: result.state === "offline" ? result.offlineForMin : null,
+    ongoingStopMin,
+  };
+}
+
+async function loadTimelineRowsForMachines(params: {
+  orgId: string;
+  machineIds: string[];
+  start: Date;
+  end: Date;
+}) {
+  if (!params.machineIds.length) {
+    return {
+      cyclesByMachine: new Map<string, TimelineCycleRow[]>(),
+      eventsByMachine: new Map<string, TimelineEventRow[]>(),
+    };
+  }
+
+  const [cycles, events] = await Promise.all([
+    prisma.machineCycle.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_CYCLE_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        cycleCount: true,
+        actualCycleTime: true,
+        workOrderId: true,
+        sku: true,
+      },
+    }),
+    prisma.machineEvent.findMany({
+      where: {
+        orgId: params.orgId,
+        machineId: { in: params.machineIds },
+        eventType: { in: TIMELINE_EVENT_TYPES as unknown as string[] },
+        ts: {
+          gte: new Date(params.start.getTime() - TIMELINE_EVENT_LOOKBACK_MS),
+          lte: params.end,
+        },
+      },
+      orderBy: [{ machineId: "asc" }, { ts: "asc" }],
+      select: {
+        machineId: true,
+        ts: true,
+        eventType: true,
+        data: true,
+      },
+    }),
+  ]);
+
+  const cyclesByMachine = new Map<string, TimelineCycleRow[]>();
+  const eventsByMachine = new Map<string, TimelineEventRow[]>();
+
+  for (const row of cycles) {
+    const list = cyclesByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      cycleCount: row.cycleCount,
+      actualCycleTime: row.actualCycleTime,
+      workOrderId: row.workOrderId,
+      sku: row.sku,
+    });
+    cyclesByMachine.set(row.machineId, list);
+  }
+
+  for (const row of events) {
+    const list = eventsByMachine.get(row.machineId) ?? [];
+    list.push({
+      ts: row.ts,
+      eventType: row.eventType,
+      data: row.data,
+    });
+    eventsByMachine.set(row.machineId, list);
+  }
+
+  return { cyclesByMachine, eventsByMachine };
+}
+
+function toSummaryMachine(params: {
+  machine: RecapMachine;
+  miniTimeline: ReturnType<typeof compressTimelineSegments>;
+  rangeEndMs: number;
+  events?: TimelineEventRow[];
+}): RecapSummaryMachine {
+  const { machine, miniTimeline, rangeEndMs, events } = params;
+  const status = statusFromMachine(machine, rangeEndMs, events);
+
+  return {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    lastSeenMs: status.lastSeenMs,
+    lastActivityMin:
+      status.lastSeenMs == null ? null : Math.max(0, Math.floor((rangeEndMs - status.lastSeenMs) / 60000)),
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+      elapsedMin:
+        machine.workOrders.moldChangeStartMs == null
+          ? null
+          : Math.max(0, Math.floor((rangeEndMs - machine.workOrders.moldChangeStartMs) / 60000)),
+    },
+    miniTimeline,
+  };
+}
+
+async function computeRecapSummary(params: { orgId: string; hours: number }) {
+  const now = new Date();
+  const end = new Date(Math.floor(now.getTime() / 60000) * 60000);
+  const start = new Date(end.getTime() - params.hours * 60 * 60 * 1000);
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    start,
+    end,
+  });
+
+  const machineIds = recap.machines.map((machine) => machine.machineId);
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds,
+    start,
+    end,
+  });
+
+  const machines = recap.machines.map((machine) => {
+    const segments = buildTimelineSegments({
+      cycles: timelineRows.cyclesByMachine.get(machine.machineId) ?? [],
+      events: timelineRows.eventsByMachine.get(machine.machineId) ?? [],
+      rangeStart: start,
+      rangeEnd: end,
+    });
+    const miniTimeline = compressTimelineSegments({
+      segments,
+      rangeStart: start,
+      rangeEnd: end,
+      maxSegments: 60,
+    });
+
+    return toSummaryMachine({
+      machine,
+      miniTimeline,
+      rangeEndMs: end.getTime(),
+      events: timelineRows.eventsByMachine.get(machine.machineId),
+    });
+  });
+
+  const response: RecapSummaryResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      start: start.toISOString(),
+      end: end.toISOString(),
+      hours: params.hours,
+    },
+    machines,
+  };
+
+  return response;
+}
+
+function normalizedRangeMode(mode?: string | null): RecapRangeMode {
+  const raw = String(mode ?? "").trim().toLowerCase();
+  if (raw === "shift") return "shift";
+  if (raw === "yesterday") return "yesterday";
+  if (raw === "custom") return "custom";
+  return "24h";
+}
+
+async function resolveCurrentShiftRange(params: { orgId: string; now: Date }) {
+  const settings = await prisma.orgSettings.findUnique({
+    where: { orgId: params.orgId },
+    select: {
+      timezone: true,
+      shiftScheduleOverridesJson: true,
+    },
+  });
+  const shifts = await prisma.orgShift.findMany({
+    where: { orgId: params.orgId },
+    orderBy: { sortOrder: "asc" },
+    select: {
+      name: true,
+      startTime: true,
+      endTime: true,
+      enabled: true,
+      sortOrder: true,
+    },
+  });
+
+  const enabledShifts = shifts.filter((shift) => shift.enabled !== false);
+  if (!enabledShifts.length) {
+    return {
+      hasEnabledShifts: false,
+      range: null,
+    } as const;
+  }
+
+  const timeZone = settings?.timezone || "UTC";
+  const local = getLocalParts(params.now, timeZone);
+  const overrides = normalizeShiftOverrides(settings?.shiftScheduleOverridesJson);
+  const dayOverrides = overrides?.[local.weekday];
+  const activeShifts = (dayOverrides?.length
+    ? dayOverrides.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.start,
+        end: shift.end,
+      }))
+    : enabledShifts.map((shift) => ({
+        enabled: shift.enabled !== false,
+        start: shift.startTime,
+        end: shift.endTime,
+      }))
+  ).filter((shift) => shift.enabled);
+
+  for (const shift of activeShifts) {
+    const startMin = parseTimeMinutes(shift.start ?? null);
+    const endMin = parseTimeMinutes(shift.end ?? null);
+    if (startMin == null || endMin == null) continue;
+
+    const minutesNow = local.minutesOfDay;
+    let inRange = false;
+    let startDate = { year: local.year, month: local.month, day: local.day };
+    let endDate = { year: local.year, month: local.month, day: local.day };
+
+    if (startMin <= endMin) {
+      inRange = minutesNow >= startMin && minutesNow < endMin;
+    } else {
+      inRange = minutesNow >= startMin || minutesNow < endMin;
+      if (minutesNow >= startMin) {
+        endDate = addDays(endDate, 1);
+      } else {
+        startDate = addDays(startDate, -1);
+      }
+    }
+
+    if (!inRange) continue;
+
+    const start = zonedToUtcDate({
+      ...startDate,
+      hours: Math.floor(startMin / 60),
+      minutes: startMin % 60,
+      timeZone,
+    });
+     const shiftEndUtc = zonedToUtcDate({
+      ...endDate,
+      hours: Math.floor(endMin / 60),
+      minutes: endMin % 60,
+      timeZone,
+    });
+
+    if (shiftEndUtc <= start) continue;
+
+    // Cap end at "now" so we render shift-so-far, not shift-as-planned.
+    // Without cap:
+    //   - timeline fills future minutes with idle (visual lie)
+    //   - offline calc = (shift_end_future - last_seen) = looks 5h offline
+    //     even on a machine producing right now
+    const end = params.now < shiftEndUtc ? params.now : shiftEndUtc;
+
+    return {
+      hasEnabledShifts: true,
+      range: { start, end },
+    };
+  }
+
+  return {
+    hasEnabledShifts: true,
+    range: null,
+  } as const;
+}
+
+async function resolveDetailRange(params: { orgId: string; input: DetailRangeInput }) {
+  const now = new Date(Math.floor(Date.now() / 60000) * 60000);
+  const requestedMode = normalizedRangeMode(params.input.mode);
+  const shiftEnabledCount = await prisma.orgShift.count({
+    where: {
+      orgId: params.orgId,
+      enabled: { not: false },
+    },
+  });
+  const shiftAvailable = shiftEnabledCount > 0;
+
+  if (requestedMode === "custom") {
+    const start = parseDate(params.input.start);
+    const end = parseDate(params.input.end);
+    if (start && end && end > start) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start,
+        end,
+        shiftAvailable,
+      } as const;
+    }
+  }
+
+  if (requestedMode === "yesterday") {
+    const settings = await prisma.orgSettings.findUnique({
+      where: { orgId: params.orgId },
+      select: { timezone: true },
+    });
+    const timeZone = settings?.timezone || "America/Mexico_City";
+    const localNow = getLocalParts(now, timeZone);
+    const today = { year: localNow.year, month: localNow.month, day: localNow.day };
+    const yesterday = addDays(today, -1);
+    const start = zonedToUtcDate({
+      ...yesterday,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    const end = zonedToUtcDate({
+      ...today,
+      hours: 0,
+      minutes: 0,
+      timeZone,
+    });
+    return {
+      requestedMode,
+      mode: requestedMode,
+      start,
+      end,
+      shiftAvailable,
+    } as const;
+  }
+
+  if (requestedMode === "shift") {
+    const shiftRange = await resolveCurrentShiftRange({ orgId: params.orgId, now });
+    if (shiftRange.range) {
+      return {
+        requestedMode,
+        mode: requestedMode,
+        start: shiftRange.range.start,
+        end: shiftRange.range.end,
+        shiftAvailable,
+      } as const;
+    }
+    if (!shiftRange.hasEnabledShifts) {
+      return {
+        requestedMode,
+        mode: "24h" as const,
+        start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+        end: now,
+        shiftAvailable,
+        fallbackReason: "shift-unavailable" as const,
+      } as const;
+    }
+    return {
+      requestedMode,
+      mode: "24h" as const,
+      start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+      end: now,
+      shiftAvailable,
+      fallbackReason: "shift-inactive" as const,
+    } as const;
+  }
+
+  return {
+    requestedMode,
+    mode: "24h" as const,
+    start: new Date(now.getTime() - 24 * 60 * 60 * 1000),
+    end: now,
+    shiftAvailable,
+  } as const;
+}
+
+async function computeRecapMachineDetail(params: {
+  orgId: string;
+  machineId: string;
+  range: {
+    requestedMode: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: Date;
+    end: Date;
+    shiftAvailable: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+}) {
+  const { range } = params;
+
+  const recap = await getRecapDataCached({
+    orgId: params.orgId,
+    machineId: params.machineId,
+    start: range.start,
+    end: range.end,
+  });
+
+  const machine = recap.machines.find((row) => row.machineId === params.machineId) ?? null;
+  if (!machine) return null;
+
+  const timelineRows = await loadTimelineRowsForMachines({
+    orgId: params.orgId,
+    machineIds: [params.machineId],
+    start: range.start,
+    end: range.end,
+  });
+
+  const timeline = buildTimelineSegments({
+    cycles: timelineRows.cyclesByMachine.get(params.machineId) ?? [],
+    events: timelineRows.eventsByMachine.get(params.machineId) ?? [],
+    rangeStart: range.start,
+    rangeEnd: range.end,
+  });
+
+  const status = statusFromMachine(
+    machine,
+    range.end.getTime(),
+    timelineRows.eventsByMachine.get(params.machineId)
+  );
+
+  const downtimeTotalMin = Math.max(0, machine.downtime.totalMin);
+  const downtimeTop = machine.downtime.topReasons.slice(0, 3).map((row) => ({
+    reasonLabel: row.reasonLabel,
+    minutes: row.minutes,
+    count: row.count,
+    percent: downtimeTotalMin > 0 ? round2((row.minutes / downtimeTotalMin) * 100) : 0,
+  }));
+
+  const machineDetail: RecapMachineDetail = {
+    machineId: machine.machineId,
+    name: machine.machineName,
+    location: machine.location,
+    status: status.status,
+    oee: machine.oee.avg,
+    goodParts: machine.production.goodParts,
+    scrap: machine.production.scrapParts,
+    stopsCount: machine.downtime.stopsCount,
+    stopMinutes: downtimeTotalMin,
+    activeWorkOrderId: machine.workOrders.active?.id ?? null,
+    lastSeenMs: status.lastSeenMs,
+    offlineForMin: status.offlineForMin,
+    ongoingStopMin: status.ongoingStopMin,
+    moldChange: {
+      active: machine.workOrders.moldChangeInProgress,
+      startMs: machine.workOrders.moldChangeStartMs,
+    },
+    timeline,
+    productionBySku: machine.production.bySku,
+    downtimeTop,
+    workOrders: {
+      completed: machine.workOrders.completed,
+      active: machine.workOrders.active,
+    },
+    heartbeat: {
+      lastSeenAt: machine.heartbeat.lastSeenAt,
+      uptimePct: machine.heartbeat.uptimePct,
+      connectionStatus: status.status === "offline" ? "offline" : "online",
+    },
+  };
+
+  const response: RecapDetailResponse = {
+    generatedAt: new Date().toISOString(),
+    range: {
+      requestedMode: range.requestedMode,
+      mode: range.mode,
+      start: range.start.toISOString(),
+      end: range.end.toISOString(),
+      shiftAvailable: range.shiftAvailable,
+      fallbackReason: range.fallbackReason,
+    },
+    machine: machineDetail,
+  };
+
+  return response;
+}
+
+function summaryCacheKey(params: { orgId: string; hours: number }) {
+  return ["recap-summary-v1", params.orgId, String(params.hours)];
+}
+
+function detailCacheKey(params: {
+  orgId: string;
+  machineId: string;
+  requestedMode: RecapRangeMode;
+  mode: RecapRangeMode;
+  shiftAvailable: boolean;
+  fallbackReason?: "shift-unavailable" | "shift-inactive";
+  startMs: number;
+  endMs: number;
+}) {
+  return [
+    "recap-detail-v1",
+    params.orgId,
+    params.machineId,
+    params.requestedMode,
+    params.mode,
+    params.shiftAvailable ? "shift-on" : "shift-off",
+    params.fallbackReason ?? "",
+    String(Math.trunc(params.startMs / 60000)),
+    String(Math.trunc(params.endMs / 60000)),
+  ];
+}
+
+export function parseRecapSummaryHours(raw: string | null) {
+  return parseHours(raw);
+}
+
+export function parseRecapDetailRangeInput(searchParams: URLSearchParams | Record<string, string | string[] | undefined>) {
+  if (searchParams instanceof URLSearchParams) {
+    return {
+      mode: searchParams.get("range") ?? undefined,
+      start: searchParams.get("start") ?? undefined,
+      end: searchParams.get("end") ?? undefined,
+    };
+  }
+
+  const pick = (key: string) => {
+    const value = searchParams[key];
+    if (Array.isArray(value)) return value[0] ?? undefined;
+    return value ?? undefined;
+  };
+
+  return {
+    mode: pick("range"),
+    start: pick("start"),
+    end: pick("end"),
+  };
+}
+
+export async function getRecapSummaryCached(params: { orgId: string; hours: number }) {
+  const cache = unstable_cache(
+    () => computeRecapSummary(params),
+    summaryCacheKey(params),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`],
+    }
+  );
+
+  return cache();
+}
+
+export async function getRecapMachineDetailCached(params: {
+  orgId: string;
+  machineId: string;
+  input: DetailRangeInput;
+}) {
+  const resolved = await resolveDetailRange({
+    orgId: params.orgId,
+    input: params.input,
+  });
+
+  const cache = unstable_cache(
+    () =>
+      computeRecapMachineDetail({
+        orgId: params.orgId,
+        machineId: params.machineId,
+        range: {
+          requestedMode: resolved.requestedMode,
+          mode: resolved.mode,
+          start: resolved.start,
+          end: resolved.end,
+          shiftAvailable: resolved.shiftAvailable,
+          fallbackReason: resolved.fallbackReason,
+        },
+      }),
+    detailCacheKey({
+      orgId: params.orgId,
+      machineId: params.machineId,
+      requestedMode: resolved.requestedMode,
+      mode: resolved.mode,
+      shiftAvailable: resolved.shiftAvailable,
+      fallbackReason: resolved.fallbackReason,
+      startMs: resolved.start.getTime(),
+      endMs: resolved.end.getTime(),
+    }),
+    {
+      revalidate: RECAP_CACHE_TTL_SEC,
+      tags: [`recap:${params.orgId}`, `recap:${params.orgId}:${params.machineId}`],
+    }
+  );
+
+  return cache();
+}

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;
@@ -622,15 +625,16 @@ export function buildTimelineSegments(input: {
     if (!TIMELINE_EVENT_TYPES.includes(eventType)) continue;
 
     const data = extractData(event.data);
-    const isUpdate = safeBool(data.is_update ?? data.isUpdate);
     const isAutoAck = safeBool(data.is_auto_ack ?? data.isAutoAck);
-    if (isUpdate || isAutoAck) continue;
+    if (isAutoAck) continue;
 
     const tsMs = event.ts.getTime();
     const key = eventIncidentKey(eventType, data, tsMs);
     const status = String(data.status ?? "").trim().toLowerCase();
 
-    const episode = eventEpisodes.get(key) ?? {
+    let episode = eventEpisodes.get(key);
+    if (!episode) {
+      episode = {
         type: eventType,
         firstTsMs: tsMs,
         lastTsMs: tsMs,
@@ -643,10 +647,19 @@ export function buildTimelineSegments(input: {
         fromMoldId: null,
         toMoldId: null,
       };
+    } else if ((PRIORITY[eventType] ?? 0) > (PRIORITY[episode.type] ?? 0)) {
+      // Upgrade type when escalation is detected within the same incidentKey
+      // (e.g. microstop → macrostop preserves the same key by design)
+      episode.type = eventType;
+    }
     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) ??
@@ -673,7 +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) {
@@ -688,8 +701,14 @@ export function buildTimelineSegments(input: {
         }
       }
     } else if (endMs <= startMs && episode.durationSec != null && episode.durationSec > 0) {
+      // 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;
 
@@ -726,6 +745,34 @@ export function buildTimelineSegments(input: {
   const absorbed = absorbShortSegments(normalized, ABSORB_SHORT_SEGMENT_MS);
  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

@@ -121,7 +121,15 @@ export type RecapQuery = {
   shift?: string;
 };
 
-export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "offline";
+export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "offline" | "idle";
+
+/**
+ * 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 = Record<string, never>;
+
 
 export type RecapSummaryMachine = {
   machineId: string;
@@ -136,6 +144,7 @@ export type RecapSummaryMachine = {
   lastActivityMin: number | null;
   offlineForMin: number | null;
   ongoingStopMin: number | null;
+  stateContext: RecapStateContext;
   activeWorkOrderId: string | null;
   moldChange: {
     active: boolean;
@@ -193,6 +202,7 @@ export type RecapMachineDetail = {
   lastSeenMs: number | null;
   offlineForMin: number | null;
   ongoingStopMin: number | null;
+  stateContext: RecapStateContext;
   moldChange: {
     active: boolean;
     startMs: number | null;

lib/recap/types.ts.bak

@@ -0,0 +1,222 @@
+export type RecapSkuRow = {
+  machineName: string;
+  sku: string;
+  good: number;
+  scrap: number;
+  target: number | null;
+  progressPct: number | null;
+};
+
+export type RecapMachine = {
+  machineId: string;
+  machineName: string;
+  location: string | null;
+  production: {
+    goodParts: number;
+    scrapParts: number;
+    totalCycles: number;
+    bySku: RecapSkuRow[];
+  };
+  oee: {
+    avg: number | null;
+    availability: number | null;
+    performance: number | null;
+    quality: number | null;
+  };
+  downtime: {
+    totalMin: number;
+    stopsCount: number;
+    topReasons: Array<{
+      reasonLabel: string;
+      minutes: number;
+      count: number;
+    }>;
+    ongoingStopMin: number | null;
+  };
+  workOrders: {
+    completed: Array<{
+      id: string;
+      sku: string | null;
+      goodParts: number;
+      durationHrs: number;
+    }>;
+    active: {
+      id: string;
+      sku: string | null;
+      progressPct: number | null;
+      startedAt: string | null;
+    } | null;
+    moldChangeInProgress: boolean;
+    moldChangeStartMs: number | null;
+  };
+  heartbeat: {
+    lastSeenAt: string | null;
+    uptimePct: number | null;
+  };
+};
+
+export type RecapTimelineSegment =
+  | {
+      type: "production";
+      startMs: number;
+      endMs: number;
+      durationSec: number;
+      workOrderId: string | null;
+      sku: string | null;
+      label: string;
+    }
+  | {
+      type: "mold-change";
+      startMs: number;
+      endMs: number;
+      fromMoldId: string | null;
+      toMoldId: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "macrostop" | "microstop" | "slow-cycle";
+      startMs: number;
+      endMs: number;
+      reason: string | null;
+      reasonLabel?: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "idle";
+      startMs: number;
+      endMs: number;
+      durationSec: number;
+      label: string;
+    };
+
+export type RecapTimelineResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  segments: RecapTimelineSegment[];
+  hasData: boolean;
+  generatedAt: string;
+};
+
+export type RecapResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  availableShifts: Array<{
+    id: string;
+    name: string;
+  }>;
+  machines: RecapMachine[];
+};
+
+export type RecapQuery = {
+  orgId: string;
+  machineId?: string;
+  start?: Date;
+  end?: Date;
+  shift?: string;
+};
+
+export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "offline";
+
+export type RecapSummaryMachine = {
+  machineId: string;
+  name: string;
+  location: string | null;
+  status: RecapMachineStatus;
+  oee: number | null;
+  goodParts: number;
+  scrap: number;
+  stopsCount: number;
+  lastSeenMs: number | null;
+  lastActivityMin: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+  activeWorkOrderId: string | null;
+  moldChange: {
+    active: boolean;
+    startMs: number | null;
+    elapsedMin: number | null;
+  } | null;
+  miniTimeline: RecapTimelineSegment[];
+};
+
+export type RecapSummaryResponse = {
+  generatedAt: string;
+  range: {
+    start: string;
+    end: string;
+    hours: number;
+  };
+  machines: RecapSummaryMachine[];
+};
+
+export type RecapRangeMode = "24h" | "shift" | "yesterday" | "custom";
+
+export type RecapDowntimeTopRow = {
+  reasonLabel: string;
+  minutes: number;
+  count: number;
+  percent: number;
+};
+
+export type RecapWorkOrders = {
+  completed: Array<{
+    id: string;
+    sku: string | null;
+    goodParts: number;
+    durationHrs: number;
+  }>;
+  active: {
+    id: string;
+    sku: string | null;
+    progressPct: number | null;
+    startedAt: string | null;
+  } | null;
+};
+
+export type RecapMachineDetail = {
+  machineId: string;
+  name: string;
+  location: string | null;
+  status: RecapMachineStatus;
+  oee: number | null;
+  goodParts: number;
+  scrap: number;
+  stopsCount: number;
+  stopMinutes: number;
+  activeWorkOrderId: string | null;
+  lastSeenMs: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+  moldChange: {
+    active: boolean;
+    startMs: number | null;
+  } | null;
+  timeline: RecapTimelineSegment[];
+  productionBySku: RecapSkuRow[];
+  downtimeTop: RecapDowntimeTopRow[];
+  workOrders: RecapWorkOrders;
+  heartbeat: {
+    lastSeenAt: string | null;
+    uptimePct: number | null;
+    connectionStatus: "online" | "offline";
+  };
+};
+
+export type RecapDetailResponse = {
+  generatedAt: string;
+  range: {
+    requestedMode?: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: string;
+    end: string;
+    shiftAvailable?: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+  machine: RecapMachineDetail;
+};

lib/recap/types.ts.bak.step4

@@ -0,0 +1,222 @@
+export type RecapSkuRow = {
+  machineName: string;
+  sku: string;
+  good: number;
+  scrap: number;
+  target: number | null;
+  progressPct: number | null;
+};
+
+export type RecapMachine = {
+  machineId: string;
+  machineName: string;
+  location: string | null;
+  production: {
+    goodParts: number;
+    scrapParts: number;
+    totalCycles: number;
+    bySku: RecapSkuRow[];
+  };
+  oee: {
+    avg: number | null;
+    availability: number | null;
+    performance: number | null;
+    quality: number | null;
+  };
+  downtime: {
+    totalMin: number;
+    stopsCount: number;
+    topReasons: Array<{
+      reasonLabel: string;
+      minutes: number;
+      count: number;
+    }>;
+    ongoingStopMin: number | null;
+  };
+  workOrders: {
+    completed: Array<{
+      id: string;
+      sku: string | null;
+      goodParts: number;
+      durationHrs: number;
+    }>;
+    active: {
+      id: string;
+      sku: string | null;
+      progressPct: number | null;
+      startedAt: string | null;
+    } | null;
+    moldChangeInProgress: boolean;
+    moldChangeStartMs: number | null;
+  };
+  heartbeat: {
+    lastSeenAt: string | null;
+    uptimePct: number | null;
+  };
+};
+
+export type RecapTimelineSegment =
+  | {
+      type: "production";
+      startMs: number;
+      endMs: number;
+      durationSec: number;
+      workOrderId: string | null;
+      sku: string | null;
+      label: string;
+    }
+  | {
+      type: "mold-change";
+      startMs: number;
+      endMs: number;
+      fromMoldId: string | null;
+      toMoldId: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "macrostop" | "microstop" | "slow-cycle";
+      startMs: number;
+      endMs: number;
+      reason: string | null;
+      reasonLabel?: string | null;
+      durationSec: number;
+      label: string;
+    }
+  | {
+      type: "idle";
+      startMs: number;
+      endMs: number;
+      durationSec: number;
+      label: string;
+    };
+
+export type RecapTimelineResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  segments: RecapTimelineSegment[];
+  hasData: boolean;
+  generatedAt: string;
+};
+
+export type RecapResponse = {
+  range: {
+    start: string;
+    end: string;
+  };
+  availableShifts: Array<{
+    id: string;
+    name: string;
+  }>;
+  machines: RecapMachine[];
+};
+
+export type RecapQuery = {
+  orgId: string;
+  machineId?: string;
+  start?: Date;
+  end?: Date;
+  shift?: string;
+};
+
+export type RecapMachineStatus = "running" | "mold-change" | "stopped" | "data-loss" | "offline" | "idle";
+
+export type RecapSummaryMachine = {
+  machineId: string;
+  name: string;
+  location: string | null;
+  status: RecapMachineStatus;
+  oee: number | null;
+  goodParts: number;
+  scrap: number;
+  stopsCount: number;
+  lastSeenMs: number | null;
+  lastActivityMin: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+  activeWorkOrderId: string | null;
+  moldChange: {
+    active: boolean;
+    startMs: number | null;
+    elapsedMin: number | null;
+  } | null;
+  miniTimeline: RecapTimelineSegment[];
+};
+
+export type RecapSummaryResponse = {
+  generatedAt: string;
+  range: {
+    start: string;
+    end: string;
+    hours: number;
+  };
+  machines: RecapSummaryMachine[];
+};
+
+export type RecapRangeMode = "24h" | "shift" | "yesterday" | "custom";
+
+export type RecapDowntimeTopRow = {
+  reasonLabel: string;
+  minutes: number;
+  count: number;
+  percent: number;
+};
+
+export type RecapWorkOrders = {
+  completed: Array<{
+    id: string;
+    sku: string | null;
+    goodParts: number;
+    durationHrs: number;
+  }>;
+  active: {
+    id: string;
+    sku: string | null;
+    progressPct: number | null;
+    startedAt: string | null;
+  } | null;
+};
+
+export type RecapMachineDetail = {
+  machineId: string;
+  name: string;
+  location: string | null;
+  status: RecapMachineStatus;
+  oee: number | null;
+  goodParts: number;
+  scrap: number;
+  stopsCount: number;
+  stopMinutes: number;
+  activeWorkOrderId: string | null;
+  lastSeenMs: number | null;
+  offlineForMin: number | null;
+  ongoingStopMin: number | null;
+  moldChange: {
+    active: boolean;
+    startMs: number | null;
+  } | null;
+  timeline: RecapTimelineSegment[];
+  productionBySku: RecapSkuRow[];
+  downtimeTop: RecapDowntimeTopRow[];
+  workOrders: RecapWorkOrders;
+  heartbeat: {
+    lastSeenAt: string | null;
+    uptimePct: number | null;
+    connectionStatus: "online" | "offline";
+  };
+};
+
+export type RecapDetailResponse = {
+  generatedAt: string;
+  range: {
+    requestedMode?: RecapRangeMode;
+    mode: RecapRangeMode;
+    start: string;
+    end: string;
+    shiftAvailable?: boolean;
+    fallbackReason?: "shift-unavailable" | "shift-inactive";
+  };
+  machine: RecapMachineDetail;
+};

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,
   };

package.json

@@ -10,7 +10,8 @@
     "test:downtime-reason-guard": "node scripts/test-downtime-reason-guard.mjs",
     "backfill:downtime-reasons": "node scripts/backfill-downtime-reasons.mjs",
     "prisma:generate": "prisma generate",
-    "prisma:migrate:deploy": "prisma migrate deploy"
+    "prisma:migrate:deploy": "prisma migrate deploy",
+    "seed:reason-catalog": "node scripts/seed-reason-catalog-from-xlsx.mjs"
   },
   "dependencies": {
     "@prisma/client": "^6.19.1",

prisma/migrations/20260505120000_reason_catalog_tables/migration.sql

@@ -0,0 +1,42 @@
+-- Reason catalog: relational storage (replaces JSON in org_settings for new data).
+
+CREATE TABLE "reason_catalog_category" (
+    "id" TEXT NOT NULL,
+    "org_id" TEXT NOT NULL,
+    "kind" TEXT NOT NULL,
+    "name" TEXT NOT NULL,
+    "code_prefix" TEXT NOT NULL,
+    "sort_order" INTEGER NOT NULL DEFAULT 0,
+    "active" BOOLEAN NOT NULL DEFAULT true,
+    "created_at" TIMESTAMP(3) NOT NULL DEFAULT CURRENT_TIMESTAMP,
+    "updated_at" TIMESTAMP(3) NOT NULL,
+
+    CONSTRAINT "reason_catalog_category_pkey" PRIMARY KEY ("id")
+);
+
+CREATE TABLE "reason_catalog_item" (
+    "id" TEXT NOT NULL,
+    "org_id" TEXT NOT NULL,
+    "category_id" TEXT NOT NULL,
+    "name" TEXT NOT NULL,
+    "code_suffix" TEXT NOT NULL,
+    "reason_code" TEXT NOT NULL,
+    "sort_order" INTEGER NOT NULL DEFAULT 0,
+    "active" BOOLEAN NOT NULL DEFAULT true,
+    "created_at" TIMESTAMP(3) NOT NULL DEFAULT CURRENT_TIMESTAMP,
+    "updated_at" TIMESTAMP(3) NOT NULL,
+
+    CONSTRAINT "reason_catalog_item_pkey" PRIMARY KEY ("id")
+);
+
+CREATE INDEX "reason_catalog_category_org_id_kind_active_idx" ON "reason_catalog_category"("org_id", "kind", "active");
+
+CREATE UNIQUE INDEX "reason_catalog_item_org_id_reason_code_key" ON "reason_catalog_item"("org_id", "reason_code");
+
+CREATE INDEX "reason_catalog_item_org_id_category_id_idx" ON "reason_catalog_item"("org_id", "category_id");
+
+ALTER TABLE "reason_catalog_category" ADD CONSTRAINT "reason_catalog_category_org_id_fkey" FOREIGN KEY ("org_id") REFERENCES "Org"("id") ON DELETE CASCADE ON UPDATE CASCADE;
+
+ALTER TABLE "reason_catalog_item" ADD CONSTRAINT "reason_catalog_item_org_id_fkey" FOREIGN KEY ("org_id") REFERENCES "Org"("id") ON DELETE CASCADE ON UPDATE CASCADE;
+
+ALTER TABLE "reason_catalog_item" ADD CONSTRAINT "reason_catalog_item_category_id_fkey" FOREIGN KEY ("category_id") REFERENCES "reason_catalog_category"("id") ON DELETE CASCADE ON UPDATE CASCADE;

prisma/schema.prisma

@@ -33,6 +33,8 @@ model Org {
   shifts                     OrgShift[]
   productCostOverrides       ProductCostOverride[]
   settingsAudits             SettingsAudit[]
+  reasonCatalogCategories     ReasonCatalogCategory[]
+  reasonCatalogItems          ReasonCatalogItem[]
 }
 
 model User {
@@ -135,6 +137,8 @@ model Machine {
   settings             MachineSettings?
   workOrders           MachineWorkOrder[]
   settingsAudits       SettingsAudit[]
+  productionEnabled    Boolean  @default(true) @map("production_enabled")
+
 
   @@unique([orgId, name])
   @@index([orgId])
@@ -288,6 +292,42 @@ model IngestLog {
   @@index([machineId, seq])
 }
 
+model ReasonCatalogCategory {
+  id         String              @id @default(uuid())
+  orgId      String              @map("org_id")
+  kind       String
+  name       String
+  codePrefix String              @map("code_prefix")
+  sortOrder  Int                 @default(0) @map("sort_order")
+  active     Boolean             @default(true)
+  createdAt  DateTime            @default(now()) @map("created_at")
+  updatedAt  DateTime            @updatedAt @map("updated_at")
+  org        Org                 @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  items      ReasonCatalogItem[]
+
+  @@index([orgId, kind, active])
+  @@map("reason_catalog_category")
+}
+
+model ReasonCatalogItem {
+  id         String                @id @default(uuid())
+  orgId      String                @map("org_id")
+  categoryId String                @map("category_id")
+  name       String
+  codeSuffix String                @map("code_suffix")
+  reasonCode String                @map("reason_code")
+  sortOrder  Int                   @default(0) @map("sort_order")
+  active     Boolean               @default(true)
+  createdAt  DateTime              @default(now()) @map("created_at")
+  updatedAt  DateTime              @updatedAt @map("updated_at")
+  org        Org                   @relation(fields: [orgId], references: [id], onDelete: Cascade)
+  category   ReasonCatalogCategory @relation(fields: [categoryId], references: [id], onDelete: Cascade)
+
+  @@unique([orgId, reasonCode])
+  @@index([orgId, categoryId])
+  @@map("reason_catalog_item")
+}
+
 model OrgSettings {
   orgId                      String   @id @map("org_id")
   timezone                   String   @default("UTC")

scripts/REASON_CATALOG_SYNC.md

@@ -0,0 +1,22 @@
+# Reason catalog: Control Tower → settings → MySQL (Pi)
+
+## Authority
+
+- The canonical catalog lives in Control Tower: `org_settings.defaults_json.reasonCatalog` (and `reasonCatalogData` alias), merged in API responses with fallback from `downtime_menu.md`.
+- Each **detail** may include:
+  - `reasonCode`: official printed code (e.g. `DTPRC-01`, `MX001`). If omitted, a slug `CATEGORY__DETAIL` is derived for backward compatibility.
+  - `active`: `false` to hide from operator pickers while keeping history/report labels. **Never remove** a code from JSON once used; only set `active: false`.
+
+## Raspberry Pi
+
+1. Apply [`scripts/mysql/reason_catalog_mirror.sql`](mysql/reason_catalog_mirror.sql) on the same MySQL database used by Node-RED (`node-red-node-mysql`).
+2. Deploy [`flows_may_4_26.json`](../flows_may_4_26.json). After each successful **Apply settings + update UI**, the flow emits a message on output 3 to **Build reason catalog mirror SQL**, which reads `global.settings.reasonCatalog` and runs `INSERT ... ON DUPLICATE KEY UPDATE` into `reason_catalog_row` (no deletes).
+
+## Operator payloads (printed codes)
+
+- On downtime acknowledge and scrap entry, send `reason.reasonCode` (and labels) matching the printed sheet. Ingest already normalizes and stores uppercase codes.
+- Generate printable lists from the same JSON as CT: [`scripts/export-reason-catalog-csv.mjs`](export-reason-catalog-csv.mjs).
+
+```bash
+node scripts/export-reason-catalog-csv.mjs path/to/reasonCatalog.json > claves.csv
+```

scripts/export-reason-catalog-csv.mjs

@@ -0,0 +1,76 @@
+#!/usr/bin/env node
+/**
+ * Export reasonCatalog JSON (downtime + scrap) to CSV for printed operator sheets.
+ * Usage: node scripts/export-reason-catalog-csv.mjs <path-to-catalog.json>
+ *        cat reasonCatalog.json | node scripts/export-reason-catalog-csv.mjs
+ *
+ * CSV columns: kind, reasonCode, categoryLabel, reasonLabel, active
+ */
+import { readFileSync, existsSync } from "fs";
+
+function escCsv(s) {
+  const t = String(s ?? "");
+  if (/[",\n\r]/.test(t)) return `"${t.replace(/"/g, '""')}"`;
+  return t;
+}
+
+function effectiveReasonCode(categoryId, detail) {
+  const c = String(detail.reasonCode ?? detail.code ?? "").trim();
+  if (c) return c.toUpperCase();
+  const cat = String(categoryId ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+  const det = String(detail.id ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+  return `${cat}__${det}`.toUpperCase();
+}
+
+function walk(kind, categories, rows) {
+  if (!Array.isArray(categories)) return;
+  for (const cat of categories) {
+    const cid = String(cat.id ?? "").trim();
+    const clab = String(cat.label ?? "").trim();
+    const details = Array.isArray(cat.details)
+      ? cat.details
+      : Array.isArray(cat.children)
+        ? cat.children
+        : [];
+    for (const d of details) {
+      const active = d.active === false ? "0" : "1";
+      const dlab = String(d.label ?? "").trim();
+      rows.push({
+        kind,
+        reasonCode: effectiveReasonCode(cid || clab, d),
+        categoryLabel: clab,
+        reasonLabel: dlab,
+        active,
+      });
+    }
+  }
+}
+
+let raw = "";
+const arg = process.argv[2];
+if (arg && existsSync(arg)) {
+  raw = readFileSync(arg, "utf8");
+} else {
+  raw = readFileSync(0, "utf8");
+}
+
+const catalog = JSON.parse(raw || "{}");
+const rows = [];
+walk("downtime", catalog.downtime, rows);
+walk("scrap", catalog.scrap, rows);
+
+const header = ["kind", "reasonCode", "categoryLabel", "reasonLabel", "active"];
+console.log(header.map(escCsv).join(","));
+for (const r of rows) {
+  console.log([r.kind, r.reasonCode, r.categoryLabel, r.reasonLabel, r.active].map(escCsv).join(","));
+}

scripts/mysql/reason_catalog_mirror.sql

@@ -0,0 +1,18 @@
+-- Mirror of Control Tower reasonCatalog on the Raspberry Pi (MySQL / MariaDB).
+-- Policy: never DELETE rows by reason_code; only INSERT ... ON DUPLICATE KEY UPDATE
+-- and set active=0 when CT marks a code inactive.
+
+CREATE TABLE IF NOT EXISTS reason_catalog_row (
+  kind VARCHAR(16) NOT NULL COMMENT 'downtime | scrap',
+  category_id VARCHAR(128) NOT NULL,
+  category_label VARCHAR(255) NOT NULL,
+  reason_code VARCHAR(64) NOT NULL,
+  reason_label VARCHAR(512) NOT NULL,
+  sort_order INT NOT NULL DEFAULT 0,
+  active TINYINT(1) NOT NULL DEFAULT 1,
+  catalog_version INT NOT NULL DEFAULT 1,
+  updated_at TIMESTAMP(3) NOT NULL DEFAULT CURRENT_TIMESTAMP(3) ON UPDATE CURRENT_TIMESTAMP(3),
+  PRIMARY KEY (kind, reason_code),
+  KEY idx_reason_catalog_kind_active (kind, active),
+  KEY idx_reason_catalog_version (catalog_version)
+) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COLLATE=utf8mb4_unicode_ci;

scripts/patch-flows-reason-mirror.mjs

@@ -0,0 +1,213 @@
+#!/usr/bin/env node
+/**
+ * Patches flows_may_4_26.json:
+ * - Apply settings: pass reasonCode/active in catalog; 3 outputs; trigger MySQL mirror sync
+ * - New nodes: Build reason catalog mirror SQL → mysql
+ */
+import { readFileSync, writeFileSync } from "fs";
+
+const path = new URL("../flows_may_4_26.json", import.meta.url).pathname;
+const j = JSON.parse(readFileSync(path, "utf8"));
+
+const applyId = "abbec199700a5e29";
+const gateId = "f8e0d1c2b3a40911";
+const mysqlPersistId = "f8e0d1c2b3a40912";
+
+const apply = j.find((n) => n.id === applyId);
+if (!apply || apply.type !== "function") {
+  console.error("Apply settings node not found");
+  process.exit(1);
+}
+
+const oldDetails =
+  "const details = detailsRaw.map((d, jdx) => ({\n        id: String(d.id || d.detailId || (categoryId + \"_d\" + jdx)),\n        label: String(d.label || d.detailLabel || (\"Detalle \" + (jdx + 1)))\n      }));";
+
+const newDetails = `const details = detailsRaw.map((d, jdx) => {
+        const row = {
+          id: String(d.id || d.detailId || (categoryId + "_d" + jdx)),
+          label: String(d.label || d.detailLabel || ("Detalle " + (jdx + 1)))
+        };
+        if (d.reasonCode != null && String(d.reasonCode).trim()) {
+          row.reasonCode = String(d.reasonCode).trim();
+        } else if (d.code != null && String(d.code).trim()) {
+          row.reasonCode = String(d.code).trim();
+        }
+        if (d.active === false) {
+          row.active = false;
+        }
+        return row;
+      });`;
+
+if (!apply.func.includes(oldDetails)) {
+  console.error("Expected normalizeCatalog details snippet not found; abort.");
+  process.exit(1);
+}
+apply.func = apply.func.replace(oldDetails, newDetails);
+
+apply.func = apply.func.replaceAll("node.send([uiConfigMsg, null]);", "node.send([uiConfigMsg, null, null]);");
+apply.func = apply.func.replaceAll("node.send([uiMoldMsg, null]);", "node.send([uiMoldMsg, null, null]);");
+apply.func = apply.func.replaceAll("node.send([uiReadOnlyMsg, null]);", "node.send([uiReadOnlyMsg, null, null]);");
+apply.func = apply.func.replaceAll("node.send([uiReasonCatalogMsg, null]);", "node.send([uiReasonCatalogMsg, null, null]);");
+
+const oldReturnAck = `const ackMsg = {
+  topic: ackTopic,
+  payload: JSON.stringify({
+    type: "settings_ack",
+    orgId,
+    machineId,
+    version,
+    source: "node-red",
+    ts: new Date().toISOString()
+  })
+};
+
+return [null, ackMsg];
+`;
+
+const newReturnAck = `const ackMsg = {
+  topic: ackTopic,
+  payload: JSON.stringify({
+    type: "settings_ack",
+    orgId,
+    machineId,
+    version,
+    source: "node-red",
+    ts: new Date().toISOString()
+  })
+};
+
+const mirrorTrigger = { payload: { _syncReasonCatalog: true } };
+return [null, ackMsg, mirrorTrigger];
+`;
+
+if (!apply.func.includes(oldReturnAck.trim())) {
+  console.error("Expected ack return block not found");
+  process.exit(1);
+}
+apply.func = apply.func.replace(oldReturnAck.trim(), newReturnAck.trim());
+
+apply.func = apply.func.replace(
+  `if (!orgId || !machineId) {
+  return [null, null];
+}`,
+  `if (!orgId || !machineId) {
+  return [null, null, null];
+}`
+);
+
+apply.outputs = 3;
+apply.wires = [
+  ["2c8562b2471078ab", "dbfd127c516efa87", "9748899355370bae"],
+  [],
+  [gateId],
+];
+
+const gateFunc = `const p = msg.payload || {};
+if (!p._syncReasonCatalog) {
+  return null;
+}
+const settings = global.get("settings") || {};
+const cat = settings.reasonCatalog || {};
+const ver = Number(cat.version || 1);
+function esc(v) {
+  return String(v ?? "").replace(/\\\\/g, "\\\\\\\\").replace(/'/g, "''");
+}
+const parts = [];
+function walk(kind, list) {
+  if (!Array.isArray(list)) {
+    return;
+  }
+  let sort = 0;
+  list.forEach((c) => {
+    const categoryId = esc(String(c.id || ""));
+    const categoryLabel = esc(String(c.label || ""));
+    const ch = c.children || c.details || [];
+    if (!Array.isArray(ch)) {
+      return;
+    }
+    ch.forEach((d) => {
+      const id = String(d.id || "").trim();
+      const label = String(d.label || "").trim();
+      const rc = String(d.reasonCode || d.code || id || "").trim();
+      if (!rc) {
+        return;
+      }
+      const active = d.active === false ? 0 : 1;
+      parts.push(
+        "('" +
+          kind +
+          "','" +
+          categoryId +
+          "','" +
+          categoryLabel +
+          "','" +
+          esc(rc) +
+          "','" +
+          esc(label) +
+          "'," +
+          sort +
+          "," +
+          active +
+          "," +
+          ver +
+          ")"
+      );
+      sort += 1;
+    });
+  });
+}
+walk("downtime", cat.downtime || []);
+walk("scrap", cat.scrap || []);
+if (!parts.length) {
+  node.status({ fill: "yellow", shape: "ring", text: "No reason rows to mirror" });
+  return null;
+}
+const sql =
+  "INSERT INTO reason_catalog_row (kind,category_id,category_label,reason_code,reason_label,sort_order,active,catalog_version) VALUES " +
+  parts.join(",") +
+  " ON DUPLICATE KEY UPDATE category_id=VALUES(category_id),category_label=VALUES(category_label),reason_label=VALUES(reason_label),sort_order=VALUES(sort_order),active=VALUES(active),catalog_version=VALUES(catalog_version),updated_at=CURRENT_TIMESTAMP(3)";
+node.status({ fill: "green", shape: "dot", text: "Reason mirror SQL built" });
+msg.topic = sql;
+msg.payload = [];
+return msg;
+`;
+
+const gateNode = {
+  id: gateId,
+  type: "function",
+  z: "05d4cb231221b842",
+  g: "a1b43a9e095c10db",
+  name: "Build reason catalog mirror SQL",
+  func: gateFunc,
+  outputs: 1,
+  timeout: 0,
+  noerr: 0,
+  initialize: "",
+  finalize: "",
+  libs: [],
+  x: 1500,
+  y: 1020,
+  wires: [[mysqlPersistId]],
+};
+
+const mysqlNode = {
+  id: mysqlPersistId,
+  type: "mysql",
+  z: "05d4cb231221b842",
+  g: "a1b43a9e095c10db",
+  mydb: "fc9634aabefee16b",
+  name: "Persist reason catalog mirror",
+  x: 1820,
+  y: 1020,
+  wires: [[]],
+};
+
+if (j.some((n) => n.id === gateId)) {
+  console.log("Patch already applied (gate node exists). Skipping insert.");
+} else {
+  const idx = j.findIndex((n) => n.id === applyId);
+  j.splice(idx + 1, 0, gateNode, mysqlNode);
+}
+
+writeFileSync(path, JSON.stringify(j, null, 4) + "\n");
+console.log("Patched", path);

scripts/seed-reason-catalog-from-xlsx.mjs

@@ -0,0 +1,280 @@
+#!/usr/bin/env node
+/**
+ * Load downtime + scrap catalogs from Excel under ./reasons/ into Postgres.
+ *
+ *   npx dotenv -e .env -- node scripts/seed-reason-catalog-from-xlsx.mjs --org-id <uuid>
+ *   npx dotenv -e .env -- node scripts/seed-reason-catalog-from-xlsx.mjs --org-slug my-org --replace
+ *
+ * --dry-run   parse and print counts only
+ * --replace   delete existing reason_catalog_* rows for the org before insert
+ */
+
+import { readFileSync, existsSync } from "fs";
+import path from "path";
+import { fileURLToPath } from "url";
+import * as XLSX from "xlsx";
+import { PrismaClient } from "@prisma/client";
+
+const __dirname = path.dirname(fileURLToPath(import.meta.url));
+const ROOT = path.join(__dirname, "..");
+
+const prisma = new PrismaClient();
+
+function composeReasonCode(prefix, suffix) {
+  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();
+}
+
+function parseArgs(argv) {
+  const out = {
+    dryRun: false,
+    replace: false,
+    orgId: null,
+    orgSlug: null,
+    downtimePath: path.join(ROOT, "reasons", "Claves Tiempo Muerto.xlsx"),
+    scrapPath: path.join(ROOT, "reasons", "Claves de Scrap.xlsx"),
+  };
+
+  for (let i = 0; i < argv.length; i += 1) {
+    const t = argv[i];
+    if (t === "--dry-run") out.dryRun = true;
+    else if (t === "--replace") out.replace = true;
+    else if (t === "--org-id") {
+      out.orgId = argv[i + 1] || null;
+      i += 1;
+    } else if (t === "--org-slug") {
+      out.orgSlug = argv[i + 1] || null;
+      i += 1;
+    } else if (t === "--downtime") {
+      out.downtimePath = argv[i + 1] || out.downtimePath;
+      i += 1;
+    } else if (t === "--scrap") {
+      out.scrapPath = argv[i + 1] || out.scrapPath;
+      i += 1;
+    } else {
+      throw new Error(`Unknown arg: ${t}`);
+    }
+  }
+  return out;
+}
+
+function readWorkbook(filePath) {
+  if (!existsSync(filePath)) {
+    throw new Error(`File not found: ${filePath}`);
+  }
+  const buf = readFileSync(filePath);
+  return XLSX.read(buf, { type: "buffer" });
+}
+
+/** @returns {{ kind:'downtime', name:string, codePrefix:string, items: { suffix:string, name:string }[] }[]} */
+function parseDowntimeXlsx(filePath) {
+  const wb = readWorkbook(filePath);
+  const data = XLSX.utils.sheet_to_json(wb.Sheets["Sheet1"], { header: 1, defval: "" });
+  const headerRowIdx = 3;
+  const header = data[headerRowIdx] || [];
+  const cols = [];
+  for (let c = 0; c < header.length; c += 1) {
+    if (String(header[c] || "").trim()) cols.push(c);
+  }
+
+  const categoryByCol = {};
+  cols.forEach((c) => {
+    categoryByCol[c] = String(header[c]).trim();
+  });
+
+  const CODE = /^([A-Z0-9][A-Za-z0-9-]*)-(\d+)\s+(.*)$/;
+  const rawItems = [];
+
+  for (let r = headerRowIdx + 1; r < data.length; r += 1) {
+    const row = data[r] || [];
+    for (const c of cols) {
+      const cell = String(row[c] ?? "").trim();
+      if (!cell) continue;
+
+      const m = cell.match(CODE);
+      if (m) {
+        rawItems.push({
+          col: c,
+          categoryLabel: categoryByCol[c],
+          prefix: m[1].toUpperCase(),
+          suffix: m[2],
+          name: m[3].trim(),
+          row: r,
+        });
+      } else if (cell.length > 2 && cell === cell.toUpperCase() && !/\d/.test(cell)) {
+        categoryByCol[c] = cell;
+      }
+    }
+  }
+
+  /** @type {Map<string, { kind:'downtime', name:string, codePrefix:string, items: { suffix:string, name:string }[]}>} */
+  const catMap = new Map();
+
+  function catKey(categoryName, prefix) {
+    return `${categoryName}\0${prefix}`;
+  }
+
+  for (const it of rawItems) {
+    const key = catKey(it.categoryLabel, it.prefix);
+    let bucket = catMap.get(key);
+    if (!bucket) {
+      bucket = { kind: "downtime", name: it.categoryLabel, codePrefix: it.prefix, items: [] };
+      catMap.set(key, bucket);
+    }
+    bucket.items.push({ suffix: it.suffix, name: it.name });
+  }
+
+  /** Dedupe suffix per category (keep first description). */
+  for (const b of catMap.values()) {
+    const seen = new Map();
+    const next = [];
+    for (const row of b.items) {
+      if (seen.has(row.suffix)) continue;
+      seen.set(row.suffix, true);
+      next.push(row);
+    }
+    b.items = next.sort((a, b) => Number(a.suffix) - Number(b.suffix));
+  }
+
+  return [...catMap.values()];
+}
+
+function parseScrapXlsx(filePath) {
+  const wb = readWorkbook(filePath);
+  const data = XLSX.utils.sheet_to_json(wb.Sheets["Sheet1"], { header: 1, defval: "" });
+  /** @type { { suffix:string, name:string, full:string }[] } */
+  const rows = [];
+  for (let r = 0; r < data.length; r += 1) {
+    const clave = String(data[r][0] ?? "").trim();
+    const desc = String(data[r][1] ?? "").trim().replace(/\s+/g, " ");
+    if (!clave || /^clave/i.test(clave)) continue;
+    if (!desc || /Rev\.?\s*[A-Z]/i.test(desc)) continue;
+    const m = clave.toUpperCase().match(/^([A-Z]+)(\d+)$/);
+    if (!m) {
+      console.warn(`[scrap] skip row ${r}:`, clave);
+      continue;
+    }
+    rows.push({
+      full: `${m[1]}${m[2]}`,
+      suffix: m[2],
+      name: desc,
+    });
+  }
+
+  /** Single category when all MX… */
+  const prefixes = new Set(rows.map((x) => x.full.replace(/\d+$/, "")));
+  if (prefixes.size !== 1) {
+    console.warn("[scrap] multiple prefixes:", [...prefixes]);
+  }
+  const codePrefix = [...prefixes][0] || "MX";
+  const items = rows.map(({ suffix, name }) => ({ suffix, name }));
+  return [{ kind: "scrap", name: "Scrap", codePrefix, items }];
+}
+
+async function main() {
+  const args = parseArgs(process.argv.slice(2));
+
+  let orgId = args.orgId;
+  if (!orgId && args.orgSlug) {
+    const org = await prisma.org.findUnique({ where: { slug: args.orgSlug }, select: { id: true } });
+    if (!org) throw new Error(`Org slug not found: ${args.orgSlug}`);
+    orgId = org.id;
+  }
+  if (!orgId) {
+    console.error("Provide --org-id <uuid> or --org-slug <slug>");
+    process.exit(1);
+  }
+
+  const downtimeCats = parseDowntimeXlsx(args.downtimePath);
+  const scrapCats = parseScrapXlsx(args.scrapPath);
+
+  const totalItems =
+    downtimeCats.reduce((n, c) => n + c.items.length, 0) + scrapCats.reduce((n, c) => n + c.items.length, 0);
+
+  console.log("[seed] downtime categories:", downtimeCats.length, "scrap categories:", scrapCats.length);
+  console.log("[seed] total items:", totalItems);
+
+  if (args.dryRun) {
+    console.log(JSON.stringify({ downtimeCats: downtimeCats.slice(0, 2), scrapCats }, null, 2));
+    return;
+  }
+
+  const existing = await prisma.reasonCatalogCategory.count({ where: { orgId } });
+  if (existing && !args.replace) {
+    console.error(
+      `Org already has ${existing} catalog categor(ies). Re-run with --replace to wipe and reload, or use Control Tower UI.`
+    );
+    process.exit(1);
+  }
+
+  const bundled = [...downtimeCats, ...scrapCats];
+  /** @type {string[]} */
+  const dupCheck = [];
+
+  await prisma.$transaction(async (tx) => {
+    if (args.replace) {
+      await tx.reasonCatalogItem.deleteMany({ where: { orgId } });
+      await tx.reasonCatalogCategory.deleteMany({ where: { orgId } });
+    }
+
+    let catOrder = 0;
+    for (const block of bundled) {
+      const category = await tx.reasonCatalogCategory.create({
+        data: {
+          orgId,
+          kind: block.kind,
+          name: block.name,
+          codePrefix: block.codePrefix,
+          sortOrder: catOrder++,
+          active: true,
+        },
+      });
+
+      let itOrder = 0;
+      for (const row of block.items) {
+        const reasonCode = composeReasonCode(block.codePrefix, row.suffix);
+        dupCheck.push(reasonCode);
+
+        await tx.reasonCatalogItem.create({
+          data: {
+            orgId,
+            categoryId: category.id,
+            name: row.name,
+            codeSuffix: row.suffix,
+            reasonCode,
+            sortOrder: itOrder++,
+            active: true,
+          },
+        });
+      }
+    }
+
+    await tx.orgSettings.update({
+      where: { orgId },
+      data: { version: { increment: 1 } },
+    });
+  });
+
+  const seen = new Set();
+  let dup = 0;
+  for (const rc of dupCheck) {
+    if (seen.has(rc)) dup++;
+    seen.add(rc);
+  }
+  if (dup) console.warn("[seed] duplicate reason_code skipped by DB unique?", dup);
+
+  console.log("[seed] done. Bump org_settings.version (+1).");
+}
+
+main()
+  .catch((e) => {
+    console.error(e);
+    process.exit(1);
+  })
+  .finally(async () => {
+    await prisma.$disconnect();
+  });