Downtime catalog

LOGGING.md

@@ -0,0 +1,84 @@
+# Logging & debugging errors
+
+## Where errors are logged
+
+### 1. **Log file** (JSON lines)
+
+- **Path:** `LOG_FILE` env var, or **`/tmp/mis-control-tower.log`** if unset.
+- **Contents:** JSON lines for `requireSession.error`, `getOverviewData.error`, `OverviewPage.getOverviewData.error`, plus any `logLine(...)` usage (e.g. health, signup).
+
+**View recent entries:**
+```bash
+tail -f /tmp/mis-control-tower.log
+```
+
+**Or with a custom path:**
+```bashls -la
+export LOG_FILE=/var/log/mis-control-tower.log
+# then start the app; tail that path
+tail -f /var/log/mis-control-tower.log
+```
+
+### 2. **Process stdout / stderr**
+
+- **`console.error`** and **`console.log`** go to the process that runs Next.js.
+- **Dev:** terminal where you run `npm run dev`.
+- **Production:** PM2 logs (`pm2 logs`), Docker (`docker logs ...`), systemd (`journalctl -u your-service -f`), etc.
+
+### 3. **Debug logs API** (optional)
+
+- **URL:** `GET /api/debug/logs?key=YOUR_DEBUG_LOGS_KEY`
+- **Purpose:** Returns the last 100 lines of the log file as JSON.
+- **Setup:** Add to `.env`:
+  ```
+  DEBUG_LOGS_KEY=your-secret-string
+  ```
+- **Usage:**  
+  `curl "https://mis.maliountech.com.mx/api/debug/logs?key=your-secret-string"`
+- If `DEBUG_LOGS_KEY` is unset or the `key` param is wrong, the route returns 401.
+
+## Error events we log
+
+| Event | When |
+|-------|------|
+| `requireSession.error` | Session lookup (cookies / DB) fails |
+| `getOverviewData.error` | Overview data fetch (DB) fails |
+| `OverviewPage.getOverviewData.error` | Overview page catch-around fetch fails |
+
+Each includes `message` and `stack` when available.
+
+## Quick checks when you see "Internal Server Error"
+
+1. **Tail the log file:**  
+   `tail -f /tmp/mis-control-tower.log`  
+   (or `$LOG_FILE` if you set it.)
+
+2. **Check process logs:**  
+   Wherever `next start` or `npm run dev` runs (PM2, Docker, systemd). Look for `[requireSession]`, `[getOverviewData]`, `[OverviewPage]`, or `[middleware]`.
+
+3. **Call the debug API** (if configured):  
+   `curl "https://your-domain/api/debug/logs?key=YOUR_DEBUG_LOGS_KEY"`  
+   and inspect the `entries` array for recent errors.
+
+## KPI quality trace (Node-RED vs processing)
+
+Use this when `Quality` is shown as `0` and you need to see exactly what was received and saved.
+
+1. Enable trace logging:
+   `TRACE_KPI_INGEST=1`
+
+2. Send KPI payloads as usual from Node-RED.
+
+3. Inspect logs:
+   `tail -f /tmp/mis-control-tower.log`
+   or:
+   `curl "https://your-domain/api/debug/logs?key=YOUR_DEBUG_LOGS_KEY"`
+
+4. Look for event `ingest.kpi.trace`, which includes:
+   `trace.rawQualityCandidates` (raw payload values found at multiple paths),
+   `trace.normalizedQuality` (post-normalization),
+   `trace.persistedQuality` (value written to DB).
+
+Optional one-shot trace without env var:
+- Send header `x-debug-ingest: 1` on a KPI request.
+- The response will include a `trace` object with the same quality details.

MACHINE_STATE_PROGRESS.md

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+# 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

README.md

@@ -20,7 +20,109 @@ You can start editing the page by modifying `app/page.tsx`. The page auto-update
 
 This project uses [`next/font`](https://nextjs.org/docs/app/building-your-application/optimizing/fonts) to automatically optimize and load [Geist](https://vercel.com/font), a new font family for Vercel.
 
-## Learn More
+## Downtime Action Reminders
+
+Reminders are sent by calling `POST /api/downtime/actions/reminders`. This endpoint does not run automatically, so you need to schedule it with cron or systemd. It sends at most one reminder per threshold (1w/1d/1h/overdue) and resets if the due date changes.
+The secret can be any random string; it just needs to match what your scheduler sends in the Authorization header.
+
+1) Set a secret in your env file (example: `/etc/mis-control-tower.env`):
+
+```
+DOWNTIME_ACTION_REMINDER_SECRET=your-secret-here
+APP_BASE_URL=https://your-domain
+```
+
+2) Cron example (runs hourly for 1w/1d/1h/overdue thresholds):
+
+```
+0 * * * * . /etc/mis-control-tower.env && curl -s -X POST "$APP_BASE_URL/api/downtime/actions/reminders?dueInDays=7" -H "Authorization: Bearer $DOWNTIME_ACTION_REMINDER_SECRET"
+```
+
+If you prefer systemd instead of cron, you can create a small service + timer that runs the same curl command.
+
+Example systemd units:
+
+`/etc/systemd/system/mis-control-tower-reminders.service`
+
+```
+[Unit]
+Description=MIS Control Tower downtime action reminders
+
+[Service]
+Type=oneshot
+EnvironmentFile=/etc/mis-control-tower.env
+ExecStart=/usr/bin/curl -s -X POST "$APP_BASE_URL/api/downtime/actions/reminders?dueInDays=7" -H "Authorization: Bearer $DOWNTIME_ACTION_REMINDER_SECRET"
+```
+
+`/etc/systemd/system/mis-control-tower-reminders.timer`
+
+```
+[Unit]
+Description=Run MIS Control Tower reminders hourly
+
+[Timer]
+OnCalendar=hourly
+Persistent=true
+
+[Install]
+WantedBy=timers.target
+```
+
+Enable with:
+
+```
+sudo systemctl daemon-reload
+sudo systemctl enable --now mis-control-tower-reminders.timer
+```
+
+## Downtime Reason Backfill
+
+Control-Tower now preserves manual downtime reasons from `downtime-acknowledged` events when later default stop events (`PENDIENTE` / `UNCLASSIFIED`) arrive for the same incident.
+
+If historical rows were already overwritten, run the one-time backfill:
+
+1) Dry run (default lookback: 30 days):
+
+```bash
+npm run backfill:downtime-reasons -- --dry-run --since 30d
+```
+
+2) Apply updates:
+
+```bash
+npm run backfill:downtime-reasons -- --since 30d
+```
+
+Optional filters:
+
+```bash
+npm run backfill:downtime-reasons -- --dry-run --since 14d --org-id <orgId> --machine-id <machineId>
+```
+
+Quick verification query (shows recent incidents with reason + source):
+
+```bash
+node -e 'const {PrismaClient}=require("@prisma/client");const p=new PrismaClient();(async()=>{const rows=await p.reasonEntry.findMany({where:{kind:"downtime"},orderBy:{capturedAt:"desc"},take:30,select:{id:true,orgId:true,machineId:true,episodeId:true,reasonCode:true,reasonLabel:true,capturedAt:true,meta:true}});console.log(JSON.stringify(rows,(_,v)=>typeof v==="bigint"?v.toString():v,2));})().finally(()=>p.$disconnect());'
+```
+
+## Production build and deploy
+
+**Dev uses Turbopack, production build uses Webpack.** Next.js 16 defaults to Turbopack for both, but Turbopack production builds have known issues. This project uses:
+
+- `npm run dev` → `next dev --turbopack` (fast dev)
+- `npm run build` → `next build --webpack` (stable production build)
+
+**When deploying** (e.g. for `https://mis.maliountech.com.mx`):
+
+1. **Build:** Run `npm run build` (Webpack).
+2. **Start:** Run `npm run start` (or your process manager) to serve the built app.
+3. If you previously built with Turbopack, run `rm -rf .next` then `npm run build` for a clean Webpack build.
+4. Hard-refresh the browser (or clear site data) after redeploying so clients don’t load old Turbopack chunks.
+
+## Logging and debugging
+
+See **[LOGGING.md](./LOGGING.md)** for where errors are logged (log file, process stdout, optional `/api/debug/logs`), how to tail them, and how to debug "Internal Server Error".
+
 
 To learn more about Next.js, take a look at the following resources:
 

Reliability.md

@@ -0,0 +1,161 @@
+Data Reliability — Handoff Prompt
+Problem
+Same machine shows different numbers in 3 places:
+
+Home UI (Node-RED): goodParts=353, OEE=77.9%
+Recap: goodParts=185, OEE=56%
+Machine detail: OEE=4.3%, "Sin datos" in 1h timeline
+Root cause: each view queries a different table with different logic. No single source of truth.
+
+Rule: pick one source per metric, reuse across views
+Metric	Authoritative source	Why
+goodParts, scrapParts (per WO)	MachineWorkOrder.good_parts / scrap_parts	Node-RED writes this via UPDATE work_orders SET .... It's what Home UI shows.
+cycleCount	MachineWorkOrder.cycle_count	Same reason.
+oee / availability / performance / quality	time-weighted avg of MachineKpiSnapshot rows in window	Snapshots are minute-by-minute; Node-RED already sends them. Don't recompute.
+Stops (count, duration)	MachineEvent filtered by eventType IN (microstop, macrostop, mold-change) + data->>'status' != 'active' + !is_update && !is_auto_ack	Deduped at source.
+Timeline segments	UNION of: MachineWorkOrder status spans, MachineEvent (mold-change/micro/macro), filled with idle	Only way to get continuous coverage.
+Backend changes
+/api/recap/[machineId]/route.ts and /api/recap/summary/route.ts
+goodParts aggregation — stop summing MachineCycle.good_delta. Instead:
+
+// For window [start, end], sum good_parts from WOs that had activity in window
+const wos = await prisma.machineWorkOrder.findMany({
+  where: { machineId, orgId, updatedAt: { gte: start } },
+  select: { workOrderId: true, sku: true, good_parts: true, scrap_parts: true, target_qty: true, status: true, updatedAt: true }
+});
+const goodParts = wos.reduce((s, w) => s + (w.good_parts ?? 0), 0);
+const scrapParts = wos.reduce((s, w) => s + (w.scrap_parts ?? 0), 0);
+Optionally scope to WOs that were RUNNING during the window; but for 24h window this rarely matters.
+
+OEE aggregation — time-weighted average:
+
+const snaps = await prisma.machineKpiSnapshot.findMany({
+  where: { machineId, orgId, ts: { gte: start, lte: end } },
+  orderBy: { ts: 'asc' },
+  select: { ts: true, oee: true, availability: true, performance: true, quality: true }
+});
+
+function weightedAvg(field: 'oee' | 'availability' | 'performance' | 'quality') {
+  if (snaps.length === 0) return null;
+  let totalMs = 0, sum = 0;
+  for (let i = 0; i < snaps.length; i++) {
+    const nextTs = (snaps[i+1]?.ts ?? end).getTime();
+    const dt = Math.max(0, nextTs - snaps[i].ts.getTime());
+    sum += (snaps[i][field] ?? 0) * dt;
+    totalMs += dt;
+  }
+  return totalMs > 0 ? sum / totalMs : null;
+}
+Return null (not 0, not 100) when no snapshots. Frontend renders — for null.
+
+Stops aggregation — filter properly:
+
+const stops = await prisma.machineEvent.findMany({
+  where: {
+    machineId, orgId,
+    ts: { gte: start, lte: end },
+    eventType: { in: ['microstop','macrostop'] },
+  }
+});
+const real = stops.filter(e => {
+  const d = e.data as any;
+  return d?.status !== 'active' && !d?.is_auto_ack && !d?.is_update;
+});
+const stopsCount = real.length;
+const stopsMin = real.reduce((s, e) => s + (((e.data as any)?.stoppage_duration_seconds ?? 0) / 60), 0);
+/api/recap/[machineId]/timeline — MUST include mold-change
+Segment builder in priority order (higher priority wins when overlapping):
+
+mold-change segments (pair active→resolved by incidentKey, duration from data.duration_sec)
+macrostop segments (same pairing)
+microstop segments (merge runs <60s apart into cluster)
+production segments — derived from WO status history, use MachineWorkOrder.status transitions + MachineCycle density (no cycles for >threshold → not production)
+idle gap-fill
+Never return empty array if any event exists in window. "Sin datos" only if literally zero rows in both MachineEvent and MachineCycle for the window.
+
+Merge rules:
+
+Same-type consecutive segments separated by <30s → merge
+Any segment <30s duration, absorb into neighbor
+Return format:
+
+{
+  range: { start, end },
+  segments: Array<{
+    type: 'production' | 'mold-change' | 'macrostop' | 'microstop' | 'idle',
+    startMs, endMs, durationSec,
+    label?: string,        // WO id, mold ids, reason
+    workOrderId?: string,
+    sku?: string,
+    reasonLabel?: string,
+  }>,
+  hasData: boolean  // false only if literally empty
+}
+Frontend changes
+RecapMachineCard.tsx / Machine detail page / OverviewTimeline.tsx
+All three MUST consume the same endpoint and render from the same shape. Timeline in Machine detail page (app/(app)/machines/[machineId]/MachineDetailClient.tsx) currently queries its own source — refactor to call /api/recap/[machineId]/timeline with range=1h for the small timeline, range=24h for the recap.
+
+"Sin datos" fallback: render only when hasData === false. If timeline has any mold-change or stop segment, render the bar.
+
+Null handling for OEE
+If backend returns oee: null:
+
+<div className="text-2xl font-semibold text-zinc-400">—</div>
+<div className="text-xs text-zinc-500">Sin datos de KPI</div>
+Not 0.0%. Not 100%. Dash. User knows "no data" vs. "bad performance".
+
+Reconciling with Home UI live numbers
+Home UI reads live state.activeWorkOrder.goodParts from Node-RED. Recap reads MachineWorkOrder.good_parts from CT DB.
+
+These WILL briefly differ because of outbox lag (cycle POST → DB insert → next recap query). Mitigate:
+
+Cache recap endpoints 30-60s max (shorter than current 2-5 min).
+On recap header, show "Actualizado hace Xs" timestamp so user sees freshness.
+Pi cycle outbox should already be fast (<5s normally). If backlog is persistent, flag it in the UI with a "CT desincronizado" warning (compare MachineHeartbeat.ts to now; if >5min, show amber status).
+Sanity check queries for debugging
+Run on CT to audit one machine:
+
+-- Authoritative WO state (matches Home UI)
+SELECT work_order_id, sku, good_parts, scrap_parts, cycle_count, status, "updatedAt"
+FROM "MachineWorkOrder"
+WHERE "machineId" = '<uuid>'
+ORDER BY "updatedAt" DESC LIMIT 5;
+
+-- What KPI snapshots exist in last 24h
+SELECT ts, oee, availability, performance, quality
+FROM "MachineKpiSnapshot"
+WHERE "machineId" = '<uuid>' AND ts > NOW() - INTERVAL '24 hours'
+ORDER BY ts DESC LIMIT 20;
+
+-- Events breakdown
+SELECT "eventType",
+       COUNT(*) AS total,
+       COUNT(*) FILTER (WHERE data->>'status' = 'active') AS active,
+       COUNT(*) FILTER (WHERE (data->>'is_update')::bool) AS updates,
+       COUNT(*) FILTER (WHERE (data->>'is_auto_ack')::bool) AS auto_acks
+FROM "MachineEvent"
+WHERE "machineId" = '<uuid>' AND ts > NOW() - INTERVAL '24 hours'
+GROUP BY "eventType";
+If MachineWorkOrder.good_parts says 353 and Home UI says 353 but recap says 185 → recap is still using old aggregation.
+If MachineKpiSnapshot count is 0 for last hour → Node-RED isn't sending snapshots (check outbox).
+
+Checklist
+not done
+Recap endpoints use MachineWorkOrder.good_parts not cycle sum
+not done
+OEE uses time-weighted MachineKpiSnapshot avg, returns null when empty
+not done
+Timeline includes mold-change events
+not done
+Machine detail timeline uses same endpoint as recap
+not done
+"Sin datos" fallback only when hasData: false
+not done
+Null OEE renders as —, not 0 or 100
+not done
+Same endpoint feeds recap grid mini timeline + detail full timeline
+not done
+Cache TTL reduced to 30-60s
+not done
+Staleness indicator visible in UI header
+Non-goals: no schema changes, no Node-RED changes, no new ingest endpoints

app/(app)/alerts/AlertsClient.tsx

@@ -0,0 +1,499 @@
+"use client";
+
+import { useEffect, useMemo, useRef, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+
+type MachineRow = {
+  id: string;
+  name: string;
+  location?: string | null;
+};
+
+type ShiftRow = {
+  name: string;
+  enabled: boolean;
+};
+
+type AlertEvent = {
+  id: string;
+  ts: string;
+  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;
+};
+
+const RANGE_OPTIONS = [
+  { value: "24h", labelKey: "alerts.inbox.range.24h" },
+  { value: "7d", labelKey: "alerts.inbox.range.7d" },
+  { value: "30d", labelKey: "alerts.inbox.range.30d" },
+  { value: "custom", labelKey: "alerts.inbox.range.custom" },
+] as const;
+
+function formatDuration(seconds: number | null | undefined, t: (key: string) => string) {
+  if (seconds == null || !Number.isFinite(seconds)) return t("alerts.inbox.duration.na");
+  if (seconds < 60) return `${Math.round(seconds)}${t("alerts.inbox.duration.sec")}`;
+  if (seconds < 3600) return `${Math.round(seconds / 60)}${t("alerts.inbox.duration.min")}`;
+  return `${(seconds / 3600).toFixed(1)}${t("alerts.inbox.duration.hr")}`;
+}
+
+function normalizeLabel(value?: string | null) {
+  if (!value) return "";
+  return String(value).trim();
+}
+
+export default function AlertsClient({
+  initialMachines = [],
+  initialShifts = [],
+  initialEvents = [],
+}: {
+  initialMachines?: MachineRow[];
+  initialShifts?: ShiftRow[];
+  initialEvents?: AlertEvent[];
+}) {
+  const { t, locale } = useI18n();
+  const [events, setEvents] = useState<AlertEvent[]>(() => initialEvents);
+  const [machines, setMachines] = useState<MachineRow[]>(() => initialMachines);
+  const [shifts, setShifts] = useState<ShiftRow[]>(() => initialShifts);
+  const [loading, setLoading] = useState(() => initialMachines.length === 0 || initialShifts.length === 0);
+  const [loadingEvents, setLoadingEvents] = useState(false);
+  const [error, setError] = useState<string | null>(null);
+  const [range, setRange] = useState<string>("24h");
+  const [start, setStart] = useState<string>("");
+  const [end, setEnd] = useState<string>("");
+  const [machineId, setMachineId] = useState<string>("");
+  const [location, setLocation] = useState<string>("");
+  const [shift, setShift] = useState<string>("");
+  const [eventType, setEventType] = useState<string>("");
+  const [severity, setSeverity] = useState<string>("");
+  const [status, setStatus] = useState<string>("");
+  const [includeUpdates, setIncludeUpdates] = useState(false);
+  const [search, setSearch] = useState("");
+  const skipInitialEventsRef = useRef(true);
+
+  const locations = useMemo(() => {
+    const seen = new Set<string>();
+    for (const machine of machines) {
+      if (!machine.location) continue;
+      seen.add(machine.location);
+    }
+    return Array.from(seen).sort();
+  }, [machines]);
+
+  useEffect(() => {
+    if (initialMachines.length && initialShifts.length) {
+      setLoading(false);
+      return;
+    }
+    let alive = true;
+
+    async function loadFilters() {
+      setLoading(true);
+      try {
+        const [machinesRes, settingsRes] = await Promise.all([
+          fetch("/api/machines", { cache: "no-store" }),
+          fetch("/api/settings", { cache: "no-store" }),
+        ]);
+        const machinesJson = await machinesRes.json().catch(() => ({}));
+        const settingsJson = await settingsRes.json().catch(() => ({}));
+        if (!alive) return;
+        setMachines(machinesJson.machines ?? []);
+        const shiftRows = settingsJson?.settings?.shiftSchedule?.shifts ?? [];
+        setShifts(
+          Array.isArray(shiftRows)
+            ? shiftRows
+                .map((row: unknown) => {
+                  const data = row && typeof row === "object" ? (row as Record<string, unknown>) : {};
+                  const name = typeof data.name === "string" ? data.name : "";
+                  const enabled = data.enabled !== false;
+                  return { name, enabled };
+                })
+                .filter((row) => row.name)
+            : []
+        );
+      } catch {
+        if (!alive) return;
+      } finally {
+        if (alive) setLoading(false);
+      }
+    }
+
+    loadFilters();
+    return () => {
+      alive = false;
+    };
+  }, [initialMachines, initialShifts]);
+
+  useEffect(() => {
+    let alive = true;
+    const controller = new AbortController();
+
+    async function loadEvents() {
+      const isDefault =
+        range === "24h" &&
+        !start &&
+        !end &&
+        !machineId &&
+        !location &&
+        !shift &&
+        !eventType &&
+        !severity &&
+        !status &&
+        !includeUpdates;
+      if (skipInitialEventsRef.current) {
+        skipInitialEventsRef.current = false;
+        if (initialEvents.length && isDefault) return;
+      }
+
+      setLoadingEvents(true);
+      setError(null);
+      const params = new URLSearchParams();
+      params.set("range", range);
+      if (range === "custom") {
+        if (start) params.set("start", start);
+        if (end) params.set("end", end);
+      }
+      if (machineId) params.set("machineId", machineId);
+      if (location) params.set("location", location);
+      if (shift) params.set("shift", shift);
+      if (eventType) params.set("eventType", eventType);
+      if (severity) params.set("severity", severity);
+      if (status) params.set("status", status);
+      if (includeUpdates) params.set("includeUpdates", "1");
+      params.set("limit", "250");
+
+      try {
+        const res = await fetch(`/api/alerts/inbox?${params.toString()}`, {
+          cache: "no-store",
+          signal: controller.signal,
+        });
+        const json = await res.json().catch(() => ({}));
+        if (!alive) return;
+        if (!res.ok || !json?.ok) {
+          setError(json?.error || t("alerts.inbox.error"));
+          setEvents([]);
+        } else {
+          setEvents(json.events ?? []);
+        }
+      } catch {
+        if (alive) {
+          setError(t("alerts.inbox.error"));
+          setEvents([]);
+        }
+      } finally {
+        if (alive) setLoadingEvents(false);
+      }
+    }
+
+    loadEvents();
+    return () => {
+      alive = false;
+      controller.abort();
+    };
+  }, [
+    range,
+    start,
+    end,
+    machineId,
+    location,
+    shift,
+    eventType,
+    severity,
+    status,
+    includeUpdates,
+    t,
+    initialEvents.length,
+  ]);
+
+  const eventTypes = useMemo(() => {
+    const seen = new Set<string>();
+    for (const ev of events) {
+      if (ev.eventType) seen.add(ev.eventType);
+    }
+    return Array.from(seen).sort();
+  }, [events]);
+
+  const severities = useMemo(() => {
+    const seen = new Set<string>();
+    for (const ev of events) {
+      if (ev.severity) seen.add(ev.severity);
+    }
+    return Array.from(seen).sort();
+  }, [events]);
+
+  const statuses = useMemo(() => {
+    const seen = new Set<string>();
+    for (const ev of events) {
+      if (ev.status) seen.add(ev.status);
+    }
+    return Array.from(seen).sort();
+  }, [events]);
+
+  const filteredEvents = useMemo(() => {
+    if (!search.trim()) return events;
+    const needle = search.trim().toLowerCase();
+    return events.filter((ev) => {
+      return (
+        normalizeLabel(ev.title).toLowerCase().includes(needle) ||
+        normalizeLabel(ev.description).toLowerCase().includes(needle) ||
+        normalizeLabel(ev.machineName).toLowerCase().includes(needle) ||
+        normalizeLabel(ev.location).toLowerCase().includes(needle) ||
+        normalizeLabel(ev.eventType).toLowerCase().includes(needle)
+      );
+    });
+  }, [events, search]);
+
+  function formatEventTypeLabel(value: string) {
+    const key = `alerts.event.${value}`;
+    const label = t(key);
+    return label === key ? value : label;
+  }
+
+  function formatStatusLabel(value?: string | null) {
+    if (!value) return t("alerts.inbox.table.unknown");
+    const key = `alerts.inbox.status.${value}`;
+    const label = t(key);
+    return label === key ? value : label;
+  }
+
+  return (
+    <div className="mx-auto flex w-full max-w-7xl flex-col gap-6 px-4 py-6 sm:px-6 sm:py-8">
+      <div>
+        <h1 className="text-2xl font-semibold text-white">{t("alerts.title")}</h1>
+        <p className="mt-2 text-sm text-zinc-400">{t("alerts.subtitle")}</p>
+      </div>
+
+      <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+        <div className="mb-4 flex flex-col gap-2 sm:flex-row sm:items-center sm:justify-between">
+          <div className="text-sm font-semibold text-white">{t("alerts.inbox.filters.title")}</div>
+          {loading && <div className="text-xs text-zinc-500">{t("alerts.inbox.loadingFilters")}</div>}
+        </div>
+        <div className="grid grid-cols-1 gap-3 md:grid-cols-2 xl:grid-cols-4">
+          <label className="text-xs text-zinc-400">
+            {t("alerts.inbox.filters.range")}
+            <select
+              className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              value={range}
+              onChange={(event) => setRange(event.target.value)}
+            >
+              {RANGE_OPTIONS.map((option) => (
+                <option key={option.value} value={option.value}>
+                  {t(option.labelKey)}
+                </option>
+              ))}
+            </select>
+          </label>
+          {range === "custom" && (
+            <>
+              <label className="text-xs text-zinc-400">
+                {t("alerts.inbox.filters.start")}
+                <input
+                  type="date"
+                  className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+                  value={start}
+                  onChange={(event) => setStart(event.target.value)}
+                />
+              </label>
+              <label className="text-xs text-zinc-400">
+                {t("alerts.inbox.filters.end")}
+                <input
+                  type="date"
+                  className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+                  value={end}
+                  onChange={(event) => setEnd(event.target.value)}
+                />
+              </label>
+            </>
+          )}
+          <label className="text-xs text-zinc-400">
+            {t("alerts.inbox.filters.machine")}
+            <select
+              className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              value={machineId}
+              onChange={(event) => setMachineId(event.target.value)}
+            >
+              <option value="">{t("alerts.inbox.filters.allMachines")}</option>
+              {machines.map((machine) => (
+                <option key={machine.id} value={machine.id}>
+                  {machine.name}
+                </option>
+              ))}
+            </select>
+          </label>
+          <label className="text-xs text-zinc-400">
+            {t("alerts.inbox.filters.site")}
+            <select
+              className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              value={location}
+              onChange={(event) => setLocation(event.target.value)}
+            >
+              <option value="">{t("alerts.inbox.filters.allSites")}</option>
+              {locations.map((loc) => (
+                <option key={loc} value={loc}>
+                  {loc}
+                </option>
+              ))}
+            </select>
+          </label>
+          <label className="text-xs text-zinc-400">
+            {t("alerts.inbox.filters.shift")}
+            <select
+              className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              value={shift}
+              onChange={(event) => setShift(event.target.value)}
+            >
+              <option value="">{t("alerts.inbox.filters.allShifts")}</option>
+              {shifts
+                .filter((row) => row.enabled)
+                .map((row) => (
+                  <option key={row.name} value={row.name}>
+                    {row.name}
+                  </option>
+                ))}
+            </select>
+          </label>
+          <label className="text-xs text-zinc-400">
+            {t("alerts.inbox.filters.type")}
+            <select
+              className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              value={eventType}
+              onChange={(event) => setEventType(event.target.value)}
+            >
+              <option value="">{t("alerts.inbox.filters.allTypes")}</option>
+              {eventTypes.map((value) => (
+                <option key={value} value={value}>
+                  {formatEventTypeLabel(value)}
+                </option>
+              ))}
+            </select>
+          </label>
+          <label className="text-xs text-zinc-400">
+            {t("alerts.inbox.filters.severity")}
+            <select
+              className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              value={severity}
+              onChange={(event) => setSeverity(event.target.value)}
+            >
+              <option value="">{t("alerts.inbox.filters.allSeverities")}</option>
+              {severities.map((value) => (
+                <option key={value} value={value}>
+                  {value}
+                </option>
+              ))}
+            </select>
+          </label>
+          <label className="text-xs text-zinc-400">
+            {t("alerts.inbox.filters.status")}
+            <select
+              className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              value={status}
+              onChange={(event) => setStatus(event.target.value)}
+            >
+              <option value="">{t("alerts.inbox.filters.allStatuses")}</option>
+              {statuses.map((value) => (
+                <option key={value} value={value}>
+                  {formatStatusLabel(value)}
+                </option>
+              ))}
+            </select>
+          </label>
+          <label className="text-xs text-zinc-400">
+            {t("alerts.inbox.filters.search")}
+            <input
+              className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              value={search}
+              onChange={(event) => setSearch(event.target.value)}
+              placeholder={t("alerts.inbox.filters.searchPlaceholder")}
+            />
+          </label>
+          <label className="flex items-center gap-2 text-xs text-zinc-400">
+            <input
+              type="checkbox"
+              checked={includeUpdates}
+              onChange={(event) => setIncludeUpdates(event.target.checked)}
+              className="h-4 w-4 rounded border border-white/20 bg-black/20"
+            />
+            {t("alerts.inbox.filters.includeUpdates")}
+          </label>
+        </div>
+      </div>
+
+      <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+        <div className="mb-4 flex flex-col gap-2 sm:flex-row sm:items-center sm:justify-between">
+          <div className="text-sm font-semibold text-white">{t("alerts.inbox.title")}</div>
+          {loadingEvents && <div className="text-xs text-zinc-500">{t("alerts.inbox.loading")}</div>}
+        </div>
+
+        {error && (
+          <div className="mb-4 rounded-xl border border-red-500/20 bg-red-500/10 p-3 text-sm text-red-200">
+            {error}
+          </div>
+        )}
+
+        {!loadingEvents && !filteredEvents.length && (
+          <div className="text-sm text-zinc-400">{t("alerts.inbox.empty")}</div>
+        )}
+
+        {!!filteredEvents.length && (
+          <div className="overflow-x-auto">
+            <table className="w-full border-collapse text-sm text-zinc-300">
+              <thead>
+                <tr className="text-xs uppercase text-zinc-500">
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.time")}</th>
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.machine")}</th>
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.site")}</th>
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.shift")}</th>
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.type")}</th>
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.severity")}</th>
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.status")}</th>
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.duration")}</th>
+                  <th className="border-b border-white/10 px-3 py-2 text-left">{t("alerts.inbox.table.title")}</th>
+                </tr>
+              </thead>
+              <tbody>
+                {filteredEvents.map((ev) => (
+                  <tr key={ev.id} className="border-b border-white/5">
+                    <td className="px-3 py-3 text-xs text-zinc-400">
+                      {new Date(ev.ts).toLocaleString(locale)}
+                    </td>
+                    <td className="px-3 py-3">{ev.machineName || t("alerts.inbox.table.unknown")}</td>
+                    <td className="px-3 py-3">{ev.location || t("alerts.inbox.table.unknown")}</td>
+                    <td className="px-3 py-3">{ev.shift || t("alerts.inbox.table.unknown")}</td>
+                    <td className="px-3 py-3">{formatEventTypeLabel(ev.eventType)}</td>
+                    <td className="px-3 py-3">{ev.severity || t("alerts.inbox.table.unknown")}</td>
+                    <td className="px-3 py-3">{formatStatusLabel(ev.status)}</td>
+                    <td className="px-3 py-3">{formatDuration(ev.durationSec, t)}</td>
+                    <td className="px-3 py-3">
+                      <div className="text-sm text-white">{ev.title}</div>
+                      {ev.description && (
+                        <div className="mt-1 text-xs text-zinc-400">{ev.description}</div>
+                      )}
+                      {(ev.workOrderId || ev.sku) && (
+                        <div className="mt-1 text-[11px] text-zinc-500">
+                          {ev.workOrderId ? `${t("alerts.inbox.meta.workOrder")}: ${ev.workOrderId}` : null}
+                          {ev.workOrderId && ev.sku ? " • " : null}
+                          {ev.sku ? `${t("alerts.inbox.meta.sku")}: ${ev.sku}` : null}
+                        </div>
+                      )}
+                    </td>
+                  </tr>
+                ))}
+              </tbody>
+            </table>
+          </div>
+        )}
+      </div>
+    </div>
+  );
+}

app/(app)/alerts/page.tsx

@@ -0,0 +1,46 @@
+import { redirect } from "next/navigation";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getAlertsInboxData } from "@/lib/alerts/getAlertsInboxData";
+import AlertsClient from "./AlertsClient";
+
+export default async function AlertsPage() {
+  const session = await requireSession();
+  if (!session) redirect("/login?next=/alerts");
+
+  const [machines, shiftRows, inbox] = await Promise.all([
+    prisma.machine.findMany({
+      where: { orgId: session.orgId },
+      orderBy: { createdAt: "desc" },
+      select: { id: true, name: true, location: true },
+    }),
+    prisma.orgShift.findMany({
+      where: { orgId: session.orgId },
+      orderBy: { sortOrder: "asc" },
+      select: { name: true, enabled: true },
+    }),
+    getAlertsInboxData({
+      orgId: session.orgId,
+      range: "24h",
+      limit: 250,
+    }),
+  ]);
+
+  const initialEvents = inbox.events.map((event) => ({
+    ...event,
+    ts: event.ts ? event.ts.toISOString() : "",
+  }));
+
+  const initialShifts = shiftRows.map((shift) => ({
+    name: shift.name,
+    enabled: shift.enabled !== false,
+  }));
+
+  return (
+    <AlertsClient
+      initialMachines={machines}
+      initialShifts={initialShifts}
+      initialEvents={initialEvents}
+    />
+  );
+}

app/(app)/downtime/layout.tsx

@@ -0,0 +1,29 @@
+import { redirect } from "next/navigation";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+
+function isPlainObject(value: unknown): value is Record<string, unknown> {
+  return !!value && typeof value === "object" && !Array.isArray(value);
+}
+
+function getScreenlessMode(defaultsJson: unknown) {
+  const defaults = isPlainObject(defaultsJson) ? defaultsJson : {};
+  const modules = isPlainObject(defaults.modules) ? defaults.modules : {};
+  return modules.screenlessMode === true;
+}
+
+export default async function DowntimeLayout({ children }: { children: React.ReactNode }) {
+  const session = await requireSession();
+  if (!session) redirect("/login?next=/downtime");
+
+  const settings = await prisma.orgSettings.findUnique({
+    where: { orgId: session.orgId },
+    select: { defaultsJson: true },
+  });
+
+  if (getScreenlessMode(settings?.defaultsJson)) {
+    redirect("/overview");
+  }
+
+  return <>{children}</>;
+}

app/(app)/downtime/page.tsx

@@ -0,0 +1,5 @@
+import DowntimePageClient from "@/components/downtime/DowntimePageClient";
+
+export default function DowntimePage() {
+  return <DowntimePageClient />;
+}

app/(app)/error.tsx

@@ -0,0 +1,31 @@
+"use client";
+
+import { useEffect } from "react";
+
+export default function AppError({
+  error,
+  reset,
+}: {
+  error: Error & { digest?: string };
+  reset: () => void;
+}) {
+  useEffect(() => {
+    console.error("[App Error]", error);
+  }, [error]);
+
+  return (
+    <div className="flex min-h-[50vh] flex-col items-center justify-center gap-4 p-6">
+      <h2 className="text-lg font-semibold text-white">Something went wrong</h2>
+      <p className="max-w-md text-center text-sm text-zinc-400">
+        An error occurred while loading this page. Please try again.
+      </p>
+      <button
+        type="button"
+        onClick={() => reset()}
+        className="rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-sm text-white hover:bg-white/10"
+      >
+        Try again
+      </button>
+    </div>
+  );
+}

app/(app)/financial/FinancialClient.tsx

@@ -0,0 +1,405 @@
+"use client";
+
+import { useEffect, useMemo, useRef, useState } from "react";
+import Link from "next/link";
+import {
+  Area,
+  AreaChart,
+  CartesianGrid,
+  ResponsiveContainer,
+  Tooltip,
+  XAxis,
+  YAxis,
+} from "recharts";
+import { useI18n } from "@/lib/i18n/useI18n";
+
+type MachineRow = {
+  id: string;
+  name: string;
+  location?: string | null;
+};
+
+type ImpactSummary = {
+  currency: string;
+  totals: {
+    total: number;
+    slowCycle: number;
+    microstop: number;
+    macrostop: number;
+    scrap: number;
+  };
+  byDay: Array<{
+    day: string;
+    total: number;
+    slowCycle: number;
+    microstop: number;
+    macrostop: number;
+    scrap: number;
+  }>;
+};
+
+type ImpactResponse = {
+  ok: boolean;
+  currencySummaries: ImpactSummary[];
+};
+
+function formatMoney(value: number, currency: string, locale: string) {
+  if (!Number.isFinite(value)) return "--";
+  try {
+    return new Intl.NumberFormat(locale, {
+      style: "currency",
+      currency,
+      maximumFractionDigits: 0,
+    }).format(value);
+  } catch {
+    return `${value.toFixed(0)} ${currency}`;
+  }
+}
+
+export default function FinancialClient({
+  initialRole = null,
+  initialMachines = [],
+  initialImpact = null,
+}: {
+  initialRole?: string | null;
+  initialMachines?: MachineRow[];
+  initialImpact?: ImpactResponse | null;
+}) {
+  const { locale, t } = useI18n();
+  const [role, setRole] = useState<string | null>(initialRole);
+  const [machines, setMachines] = useState<MachineRow[]>(() => initialMachines);
+  const [impact, setImpact] = useState<ImpactResponse | null>(initialImpact);
+  const [range, setRange] = useState("7d");
+  const [machineFilter, setMachineFilter] = useState("");
+  const [locationFilter, setLocationFilter] = useState("");
+  const [skuFilter, setSkuFilter] = useState("");
+  const [currencyFilter, setCurrencyFilter] = useState("");
+  const [loading, setLoading] = useState(() => initialMachines.length === 0);
+  const skipInitialImpactRef = useRef(true);
+  const forceRefreshRef = useRef(false);
+  const [refreshSeed, setRefreshSeed] = useState(0);
+
+  const locations = useMemo(() => {
+    const seen = new Set<string>();
+    for (const m of machines) {
+      if (!m.location) continue;
+      seen.add(m.location);
+    }
+    return Array.from(seen).sort();
+  }, [machines]);
+
+  useEffect(() => {
+    if (initialRole != null) return;
+    let alive = true;
+
+    async function loadMe() {
+      try {
+        const res = await fetch("/api/me", { cache: "no-store" });
+        const data = await res.json().catch(() => ({}));
+        if (!alive) return;
+        setRole(data?.membership?.role ?? null);
+      } catch {
+        if (alive) setRole(null);
+      }
+    }
+
+    loadMe();
+    return () => {
+      alive = false;
+    };
+  }, [initialRole]);
+
+  useEffect(() => {
+    if (initialMachines.length) {
+      setLoading(false);
+      return;
+    }
+    let alive = true;
+
+    async function loadMachines() {
+      try {
+        const res = await fetch("/api/machines", { cache: "no-store" });
+        const json = await res.json().catch(() => ({}));
+        if (!alive) return;
+        setMachines(json.machines ?? []);
+      } catch {
+        if (!alive) return;
+      } finally {
+        if (alive) setLoading(false);
+      }
+    }
+
+    loadMachines();
+    return () => {
+      alive = false;
+    };
+  }, [initialMachines]);
+
+  useEffect(() => {
+    let alive = true;
+    const controller = new AbortController();
+
+    async function loadImpact() {
+      if (role == null) return;
+      if (role !== "OWNER") return;
+
+      const isDefault =
+        range === "7d" &&
+        !machineFilter &&
+        !locationFilter &&
+        !skuFilter &&
+        !currencyFilter;
+      if (skipInitialImpactRef.current) {
+        skipInitialImpactRef.current = false;
+        if (initialImpact && isDefault) return;
+      }
+
+      const params = new URLSearchParams();
+      params.set("range", range);
+      if (machineFilter) params.set("machineId", machineFilter);
+      if (locationFilter) params.set("location", locationFilter);
+      if (skuFilter) params.set("sku", skuFilter);
+      if (currencyFilter) params.set("currency", currencyFilter);
+      const forceRefresh = forceRefreshRef.current;
+      if (forceRefresh) params.set("refresh", "1");
+
+      try {
+        const res = await fetch(`/api/financial/impact?${params.toString()}`, {
+          cache: "no-store",
+          signal: controller.signal,
+        });
+        const json = await res.json().catch(() => ({}));
+        if (!alive) return;
+        setImpact(json);
+      } catch {
+        if (alive) setImpact(null);
+      } finally {
+        if (forceRefresh) forceRefreshRef.current = false;
+      }
+    }
+
+    loadImpact();
+    return () => {
+      alive = false;
+      controller.abort();
+    };
+  }, [currencyFilter, initialImpact, locationFilter, machineFilter, range, refreshSeed, role, skuFilter]);
+
+  const selectedSummary = impact?.currencySummaries?.[0] ?? null;
+  const chartData = selectedSummary?.byDay ?? [];
+  const exportQuery = useMemo(() => {
+    const params = new URLSearchParams();
+    params.set("range", range);
+    if (machineFilter) params.set("machineId", machineFilter);
+    if (locationFilter) params.set("location", locationFilter);
+    if (skuFilter) params.set("sku", skuFilter);
+    if (currencyFilter) params.set("currency", currencyFilter);
+    return params.toString();
+  }, [range, machineFilter, locationFilter, skuFilter, currencyFilter]);
+
+  const htmlHref = `/api/financial/export/pdf?${exportQuery}`;
+  const csvHref = `/api/financial/export/excel?${exportQuery}`;
+  const handleRefresh = () => {
+    forceRefreshRef.current = true;
+    setRefreshSeed((prev) => prev + 1);
+  };
+
+  if (role && role !== "OWNER") {
+    return (
+      <div className="p-4 sm:p-6">
+        <div className="rounded-2xl border border-white/10 bg-black/40 p-6 text-zinc-300">
+          {t("financial.ownerOnly")}
+        </div>
+      </div>
+    );
+  }
+
+  return (
+    <div className="p-4 sm:p-6 space-y-6">
+      <div className="flex flex-col gap-4 sm:flex-row sm:items-start sm:justify-between">
+        <div>
+          <h1 className="text-2xl font-semibold text-white">{t("financial.title")}</h1>
+          <p className="text-sm text-zinc-400">{t("financial.subtitle")}</p>
+        </div>
+        <div className="flex w-full flex-col gap-3 sm:w-auto sm:flex-row">
+          <button
+            type="button"
+            onClick={handleRefresh}
+            className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-zinc-200 hover:bg-white/10 sm:w-auto"
+          >
+            {t("financial.refresh")}
+          </button>
+          <a
+            className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-zinc-200 hover:bg-white/10 sm:w-auto"
+            href={htmlHref}
+            target="_blank"
+            rel="noreferrer"
+          >
+            {t("financial.export.html")}
+          </a>
+          <a
+            className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-zinc-200 hover:bg-white/10 sm:w-auto"
+            href={csvHref}
+            target="_blank"
+            rel="noreferrer"
+          >
+            {t("financial.export.csv")}
+          </a>
+        </div>
+      </div>
+
+      <div className="rounded-2xl border border-white/10 bg-black/40 p-4 text-sm text-zinc-300">
+        {t("financial.costsMoved")}{" "}
+        <Link className="text-emerald-200 hover:text-emerald-100" href="/settings">
+          {t("financial.costsMovedLink")}
+        </Link>
+        .
+      </div>
+
+      <div className="grid gap-4 lg:grid-cols-4">
+        {(impact?.currencySummaries ?? []).slice(0, 4).map((summary) => (
+          <div key={summary.currency} className="rounded-2xl border border-white/10 bg-black/40 p-4">
+            <div className="text-xs uppercase tracking-wide text-zinc-500">{t("financial.totalLoss")}</div>
+            <div className="mt-2 text-2xl font-semibold text-white">
+              {formatMoney(summary.totals.total, summary.currency, locale)}
+            </div>
+            <div className="mt-3 text-xs text-zinc-400">
+              {t("financial.currencyLabel", { currency: summary.currency })}
+            </div>
+          </div>
+        ))}
+        {!impact?.currencySummaries?.length && (
+          <div className="rounded-2xl border border-white/10 bg-black/40 p-4 text-sm text-zinc-400">
+            {t("financial.noImpact")}
+          </div>
+        )}
+      </div>
+
+      <div className="grid gap-4 lg:grid-cols-[2fr_1fr]">
+        <div className="rounded-2xl border border-white/10 bg-black/40 p-4">
+          <div className="flex items-center justify-between">
+            <div>
+              <h2 className="text-lg font-semibold text-white">{t("financial.chart.title")}</h2>
+              <p className="text-xs text-zinc-500">{t("financial.chart.subtitle")}</p>
+            </div>
+            <div className="flex gap-2">
+              {["24h", "7d", "30d"].map((value) => (
+                <button
+                  key={value}
+                  type="button"
+                  onClick={() => setRange(value)}
+                  className={
+                    value === range
+                      ? "rounded-full bg-emerald-500/20 px-3 py-1 text-xs text-emerald-200"
+                      : "rounded-full border border-white/10 px-3 py-1 text-xs text-zinc-300"
+                  }
+                >
+                  {value === "24h"
+                    ? t("financial.range.day")
+                    : value === "7d"
+                      ? t("financial.range.week")
+                      : t("financial.range.month")}
+                </button>
+              ))}
+            </div>
+          </div>
+
+          <div className="mt-4 h-64">
+            <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+              <AreaChart data={chartData}>
+                <defs>
+                  <linearGradient id="slowFill" x1="0" y1="0" x2="0" y2="1">
+                    <stop offset="5%" stopColor="#facc15" stopOpacity={0.5} />
+                    <stop offset="95%" stopColor="#facc15" stopOpacity={0.05} />
+                  </linearGradient>
+                  <linearGradient id="microFill" x1="0" y1="0" x2="0" y2="1">
+                    <stop offset="5%" stopColor="#fb7185" stopOpacity={0.5} />
+                    <stop offset="95%" stopColor="#fb7185" stopOpacity={0.05} />
+                  </linearGradient>
+                  <linearGradient id="macroFill" x1="0" y1="0" x2="0" y2="1">
+                    <stop offset="5%" stopColor="#f97316" stopOpacity={0.5} />
+                    <stop offset="95%" stopColor="#f97316" stopOpacity={0.05} />
+                  </linearGradient>
+                  <linearGradient id="scrapFill" x1="0" y1="0" x2="0" y2="1">
+                    <stop offset="5%" stopColor="#38bdf8" stopOpacity={0.5} />
+                    <stop offset="95%" stopColor="#38bdf8" stopOpacity={0.05} />
+                  </linearGradient>
+                </defs>
+                <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                <XAxis dataKey="day" tick={{ fill: "var(--app-chart-tick)", fontSize: 10 }} />
+                <YAxis tick={{ fill: "var(--app-chart-tick)", fontSize: 10 }} />
+                <Tooltip
+                  contentStyle={{
+                    background: "var(--app-chart-tooltip-bg)",
+                    border: "1px solid var(--app-chart-tooltip-border)",
+                  }}
+                  labelStyle={{ color: "var(--app-chart-label)" }}
+                />
+                <Area type="monotone" dataKey="slowCycle" stackId="1" stroke="#facc15" fill="url(#slowFill)" />
+                <Area type="monotone" dataKey="microstop" stackId="1" stroke="#fb7185" fill="url(#microFill)" />
+                <Area type="monotone" dataKey="macrostop" stackId="1" stroke="#f97316" fill="url(#macroFill)" />
+                <Area type="monotone" dataKey="scrap" stackId="1" stroke="#38bdf8" fill="url(#scrapFill)" />
+              </AreaChart>
+            </ResponsiveContainer>
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-black/40 p-4 space-y-4">
+          <h2 className="text-lg font-semibold text-white">{t("financial.filters.title")}</h2>
+          <div className="space-y-3 text-sm text-zinc-300">
+            <div>
+              <label className="text-xs uppercase text-zinc-500">{t("financial.filters.machine")}</label>
+              <select
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2"
+                value={machineFilter}
+                onChange={(event) => setMachineFilter(event.target.value)}
+              >
+                <option value="">{t("financial.filters.allMachines")}</option>
+                {machines.map((machine) => (
+                  <option key={machine.id} value={machine.id}>
+                    {machine.name}
+                  </option>
+                ))}
+              </select>
+            </div>
+            <div>
+              <label className="text-xs uppercase text-zinc-500">{t("financial.filters.location")}</label>
+              <select
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2"
+                value={locationFilter}
+                onChange={(event) => setLocationFilter(event.target.value)}
+              >
+                <option value="">{t("financial.filters.allLocations")}</option>
+                {locations.map((loc) => (
+                  <option key={loc} value={loc}>
+                    {loc}
+                  </option>
+                ))}
+              </select>
+            </div>
+            <div>
+              <label className="text-xs uppercase text-zinc-500">{t("financial.filters.sku")}</label>
+              <input
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2"
+                value={skuFilter}
+                onChange={(event) => setSkuFilter(event.target.value)}
+                placeholder={t("financial.filters.skuPlaceholder")}
+              />
+            </div>
+            <div>
+              <label className="text-xs uppercase text-zinc-500">{t("financial.filters.currency")}</label>
+              <input
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2"
+                value={currencyFilter}
+                onChange={(event) => setCurrencyFilter(event.target.value.toUpperCase())}
+                placeholder={t("financial.filters.currencyPlaceholder")}
+              />
+            </div>
+          </div>
+        </div>
+      </div>
+
+      {loading && <div className="text-xs text-zinc-500">{t("financial.loadingMachines")}</div>}
+    </div>
+  );
+}

app/(app)/financial/page.tsx

@@ -0,0 +1,45 @@
+import { redirect } from "next/navigation";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getFinancialImpactCached } from "@/lib/financial/cache";
+import FinancialClient from "./FinancialClient";
+
+const RANGE_MS = 7 * 24 * 60 * 60 * 1000;
+
+export default async function FinancialPage() {
+  const session = await requireSession();
+  if (!session) redirect("/login?next=/financial");
+
+  const membership = await prisma.orgUser.findUnique({
+    where: { orgId_userId: { orgId: session.orgId, userId: session.userId } },
+    select: { role: true },
+  });
+
+  const role = membership?.role ?? null;
+  if (role !== "OWNER") {
+    return <FinancialClient initialRole={role ?? "GUEST"} />;
+  }
+
+  const machines = await prisma.machine.findMany({
+    where: { orgId: session.orgId },
+    orderBy: { createdAt: "desc" },
+    select: { id: true, name: true, location: true },
+  });
+
+  const end = new Date();
+  const start = new Date(end.getTime() - RANGE_MS);
+  const impact = await getFinancialImpactCached({
+    orgId: session.orgId,
+    start,
+    end,
+    includeEvents: false,
+  });
+
+  return (
+    <FinancialClient
+      initialRole={role}
+      initialMachines={machines}
+      initialImpact={{ ok: true, currencySummaries: impact.currencySummaries }}
+    />
+  );
+}

app/(app)/layout.tsx

@@ -1,33 +1,22 @@
-import { Sidebar } from "@/components/layout/Sidebar";
+import { AppShell } from "@/components/layout/AppShell";
 import { cookies } from "next/headers";
 import { redirect } from "next/navigation";
-import { prisma } from "@/lib/prisma";
 
 const COOKIE_NAME = "mis_session";
 
-export default async function AppLayout({ children }: { children: React.ReactNode }) {
-  const sessionId = (await cookies()).get(COOKIE_NAME)?.value;
+export const dynamic = "force-dynamic";
 
-  if (!sessionId) redirect("/login?next=/machines");
+export default async function AppLayout({
+  children,
+}: {
+  children: React.ReactNode;
+}) {
+  const cookieJar = await cookies();
+  const sessionId = cookieJar.get(COOKIE_NAME)?.value;
+  const themeCookie = cookieJar.get("mis_theme")?.value;
+  const initialTheme = themeCookie === "light" ? "light" : "dark";
 
-  // validate session in DB (don’t trust cookie existence)
-  const session = await prisma.session.findFirst({
-    where: {
-      id: sessionId,
-      revokedAt: null,
-      expiresAt: { gt: new Date() },
-    },
-    include: { user: true, org: true },
-  });
+  if (!sessionId) redirect("/login");
 
-  if (!session) redirect("/login?next=/machines");
-
-  return (
-    <div className="min-h-screen bg-black text-white">
-      <div className="flex">
-        <Sidebar />
-        <main className="flex-1 min-h-screen">{children}</main>
-      </div>
-    </div>
-  );
+  return <AppShell initialTheme={initialTheme}>{children}</AppShell>;
 }

app/(app)/loading.tsx

@@ -0,0 +1,13 @@
+export default function AppLoading() {
+  return (
+    <div className="p-4 sm:p-6 space-y-6 animate-pulse">
+      <div className="h-7 w-48 rounded-lg bg-white/10" />
+      <div className="grid gap-4 md:grid-cols-2 xl:grid-cols-3">
+        {Array.from({ length: 3 }).map((_, idx) => (
+          <div key={idx} className="h-28 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+      <div className="h-80 rounded-2xl border border-white/10 bg-white/5" />
+    </div>
+  );
+}

app/(app)/machines/MachinesClient.tsx

@@ -0,0 +1,391 @@
+"use client";
+
+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;
+  name: string;
+  code?: string | null;
+  location?: string | null;
+  latestHeartbeat: null | {
+    ts: string;
+    tsServer?: string | null;
+    status: string;
+    message?: string | null;
+    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;
+
+function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
+  if (!ts) return fallback;
+  const diff = Math.floor((Date.now() - new Date(ts).getTime()) / 1000);
+  const rtf = new Intl.RelativeTimeFormat(locale, { numeric: "auto" });
+  if (diff < 60) return rtf.format(-diff, "second");
+  return rtf.format(-Math.floor(diff / 60), "minute");
+}
+
+function isOffline(ts?: string) {
+  if (!ts) return true;
+  return Date.now() - new Date(ts).getTime() > OFFLINE_MS;
+}
+
+function normalizeStatus(status?: string) {
+  const s = (status ?? "").toUpperCase();
+  if (s === "ONLINE") return "RUN";
+  return s;
+}
+
+function badgeClass(status?: string, offline?: boolean) {
+  if (offline) return "bg-white/10 text-zinc-300";
+  const s = (status ?? "").toUpperCase();
+  if (s === "RUN") return "bg-emerald-500/15 text-emerald-300";
+  if (s === "IDLE") return "bg-yellow-500/15 text-yellow-300";
+  if (s === "STOP" || s === "DOWN") return "bg-red-500/15 text-red-300";
+  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();
+  const [machines, setMachines] = useState<MachineRow[]>(() => initialMachines);
+  const [loading, setLoading] = useState(() => initialMachines.length === 0);
+  const [showCreate, setShowCreate] = useState(false);
+  const [createName, setCreateName] = useState("");
+  const [createCode, setCreateCode] = useState("");
+  const [createLocation, setCreateLocation] = useState("");
+  const [creating, setCreating] = useState(false);
+  const [createError, setCreateError] = useState<string | null>(null);
+  const [createdMachine, setCreatedMachine] = useState<{
+    id: string;
+    name: string;
+    pairingCode: string;
+    pairingExpiresAt: string;
+  } | null>(null);
+  const [copyStatus, setCopyStatus] = useState<string | null>(null);
+
+  useEffect(() => {
+    let alive = true;
+    let timer: ReturnType<typeof setTimeout> | null = null;
+
+    async function load(initial: boolean) {
+      try {
+        if (!initial && typeof document !== "undefined" && document.hidden) {
+          return;
+        }
+
+        const res = await fetch("/api/machines", { cache: "no-store" });
+        const json = await res.json();
+        if (alive) {
+          setMachines(json.machines ?? []);
+          if (initial) setLoading(false);
+        }
+      } catch {
+        if (alive && initial) setLoading(false);
+      } finally {
+        if (!alive) return;
+        timer = setTimeout(() => {
+          void load(false);
+        }, LIVE_REFRESH_MS);
+      }
+    }
+
+    void load(initialMachines.length === 0);
+    return () => {
+      alive = false;
+      if (timer) clearTimeout(timer);
+    };
+  }, [initialMachines.length]);
+
+  async function createMachine() {
+    if (!createName.trim()) {
+      setCreateError(t("machines.create.error.nameRequired"));
+      return;
+    }
+
+    setCreating(true);
+    setCreateError(null);
+
+    try {
+      const res = await fetch("/api/machines", {
+        method: "POST",
+        headers: { "Content-Type": "application/json" },
+        body: JSON.stringify({
+          name: createName,
+          code: createCode,
+          location: createLocation,
+        }),
+      });
+      const data = await res.json().catch(() => ({}));
+      if (!res.ok || !data.ok) {
+        throw new Error(data.error || t("machines.create.error.failed"));
+      }
+
+      const nextMachine = {
+        ...data.machine,
+        latestHeartbeat: null,
+      };
+      setMachines((prev) => [nextMachine, ...prev]);
+      setCreatedMachine({
+        id: data.machine.id,
+        name: data.machine.name,
+        pairingCode: data.machine.pairingCode,
+        pairingExpiresAt: data.machine.pairingCodeExpiresAt,
+      });
+      setCreateName("");
+      setCreateCode("");
+      setCreateLocation("");
+      setShowCreate(false);
+    } catch (err: unknown) {
+      const message = err instanceof Error ? err.message : null;
+      setCreateError(message || t("machines.create.error.failed"));
+    } finally {
+      setCreating(false);
+    }
+  }
+
+  async function copyText(text: string) {
+    try {
+      if (navigator.clipboard?.writeText) {
+        await navigator.clipboard.writeText(text);
+        setCopyStatus(t("machines.pairing.copied"));
+      } else {
+        setCopyStatus(t("machines.pairing.copyUnsupported"));
+      }
+    } catch {
+      setCopyStatus(t("machines.pairing.copyFailed"));
+    }
+    setTimeout(() => setCopyStatus(null), 2000);
+  }
+
+  function handleCardKeyDown(event: KeyboardEvent<HTMLDivElement>, machineId: string) {
+    if (event.key === "Enter" || event.key === " ") {
+      event.preventDefault();
+      router.push(`/machines/${machineId}`);
+    }
+  }
+
+  const showCreateCard = showCreate || (!loading && machines.length === 0);
+
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-6 flex flex-col gap-4 sm:flex-row sm:items-center sm:justify-between">
+        <div>
+          <h1 className="text-2xl font-semibold text-white">{t("machines.title")}</h1>
+          <p className="text-sm text-zinc-400">{t("machines.subtitle")}</p>
+        </div>
+
+        <div className="flex w-full flex-wrap items-center gap-2 sm:w-auto">
+          <button
+            type="button"
+            onClick={() => setShowCreate((prev) => !prev)}
+            className="w-full rounded-xl border border-emerald-400/40 bg-emerald-500/20 px-4 py-2 text-sm text-emerald-100 hover:bg-emerald-500/30 sm:w-auto"
+          >
+            {showCreate ? t("machines.cancel") : t("machines.addMachine")}
+          </button>
+          <Link
+            href="/overview"
+            className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-white hover:bg-white/10 sm:w-auto"
+          >
+            {t("machines.backOverview")}
+          </Link>
+        </div>
+      </div>
+
+      {showCreateCard && (
+        <div className="mb-6 rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="flex flex-col gap-2 sm:flex-row sm:items-center sm:justify-between">
+            <div>
+              <div className="text-sm font-semibold text-white">{t("machines.addCardTitle")}</div>
+              <div className="text-xs text-zinc-400">{t("machines.addCardSubtitle")}</div>
+            </div>
+          </div>
+
+          <div className="mt-4 grid grid-cols-1 gap-3 md:grid-cols-3">
+            <label className="rounded-xl border border-white/10 bg-black/20 p-3 text-xs text-zinc-400">
+              {t("machines.field.name")}
+              <input
+                value={createName}
+                onChange={(event) => setCreateName(event.target.value)}
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              />
+            </label>
+            <label className="rounded-xl border border-white/10 bg-black/20 p-3 text-xs text-zinc-400">
+              {t("machines.field.code")}
+              <input
+                value={createCode}
+                onChange={(event) => setCreateCode(event.target.value)}
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              />
+            </label>
+            <label className="rounded-xl border border-white/10 bg-black/20 p-3 text-xs text-zinc-400">
+              {t("machines.field.location")}
+              <input
+                value={createLocation}
+                onChange={(event) => setCreateLocation(event.target.value)}
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              />
+            </label>
+          </div>
+
+          <div className="mt-4 flex flex-wrap items-center gap-3">
+            <button
+              type="button"
+              onClick={createMachine}
+              disabled={creating}
+              className="rounded-xl border border-emerald-400/40 bg-emerald-500/20 px-4 py-2 text-sm text-emerald-100 hover:bg-emerald-500/30 disabled:opacity-60"
+            >
+            {creating ? t("machines.create.loading") : t("machines.create.default")}
+          </button>
+            {createError && <div className="text-xs text-red-200">{createError}</div>}
+          </div>
+        </div>
+      )}
+
+      {createdMachine && (
+      <div className="mb-6 rounded-2xl border border-emerald-500/20 bg-emerald-500/10 p-5">
+          <div className="text-sm font-semibold text-white">{t("machines.pairing.title")}</div>
+          <div className="mt-2 text-xs text-zinc-300">
+            {t("machines.pairing.machine")} <span className="text-white">{createdMachine.name}</span>
+          </div>
+          <div className="mt-3 rounded-xl border border-white/10 bg-black/30 p-4">
+            <div className="text-xs uppercase tracking-wide text-zinc-400">{t("machines.pairing.codeLabel")}</div>
+            <div className="mt-2 text-3xl font-semibold text-white">{createdMachine.pairingCode}</div>
+            <div className="mt-2 text-xs text-zinc-400">
+              {t("machines.pairing.expires")}{" "}
+              {createdMachine.pairingExpiresAt
+                ? new Date(createdMachine.pairingExpiresAt).toLocaleString(locale)
+                : t("machines.pairing.soon")}
+            </div>
+          </div>
+          <div className="mt-3 text-xs text-zinc-300">
+            {t("machines.pairing.instructions")}
+          </div>
+          <div className="mt-3 flex flex-wrap items-center gap-3">
+            <button
+              type="button"
+              onClick={() => copyText(createdMachine.pairingCode)}
+              className="rounded-xl border border-white/10 bg-white/5 px-3 py-2 text-sm text-white hover:bg-white/10"
+            >
+              {t("machines.pairing.copy")}
+            </button>
+            {copyStatus && <div className="text-xs text-zinc-300">{copyStatus}</div>}
+          </div>
+        </div>
+      )}
+
+      {loading && <div className="mb-4 text-sm text-zinc-400">{t("machines.loading")}</div>}
+
+      {!loading && machines.length === 0 && (
+        <div className="mb-4 text-sm text-zinc-400">{t("machines.empty")}</div>
+      )}
+
+      <div className="grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-3">
+        {(!loading ? machines : []).map((m) => {
+          const hb = m.latestHeartbeat;
+          const hbTs = hb?.tsServer ?? hb?.ts;
+          const offline = isOffline(hbTs);
+          const normalizedStatus = normalizeStatus(hb?.status);
+          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}
+              role="link"
+              tabIndex={0}
+              onClick={() => router.push(`/machines/${m.id}`)}
+              onKeyDown={(event) => handleCardKeyDown(event, m.id)}
+              className={cardClass}
+            >
+              <div className="flex items-center justify-between gap-3">
+                <div className="min-w-0">
+                  <div className="truncate text-lg font-semibold text-white">{m.name}</div>
+                  <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 ${productionBadgeClass}`}
+                >
+                  {productionBadgeLabel}
+                </span>
+              </div>
+
+              <div className="mt-4 text-sm text-zinc-400">{t("machines.status")}</div>
+              <div className="mt-1 flex items-center gap-2 text-sm font-semibold text-white">
+                {offline ? (
+                  <>
+                    <span className="inline-flex h-2.5 w-2.5 rounded-full bg-zinc-500" aria-hidden="true" />
+                    <span>{t("machines.status.noHeartbeat")}</span>
+                  </>
+                ) : (
+                  <>
+                    <span className="relative flex h-2.5 w-2.5" aria-hidden="true">
+                      <span className="animate-ping absolute inline-flex h-full w-full rounded-full bg-emerald-400 opacity-75" />
+                      <span className="relative inline-flex h-2.5 w-2.5 rounded-full bg-emerald-400" />
+                    </span>
+                    <span>{t("machines.status.ok")}</span>
+                  </>
+                )}
+              </div>
+
+            </div>
+          );
+        })}
+      </div>
+    </div>
+  );
+}

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

@@ -0,0 +1,349 @@
+"use client";
+
+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;
+  name: string;
+  code?: string | null;
+  location?: string | null;
+  latestHeartbeat: null | {
+    ts: string;
+    tsServer?: string | null;
+    status: string;
+    message?: string | null;
+    ip?: string | null;
+    fwVersion?: string | null;
+  };
+};
+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;
+  const diff = Math.floor((Date.now() - new Date(ts).getTime()) / 1000);
+  const rtf = new Intl.RelativeTimeFormat(locale, { numeric: "auto" });
+  if (diff < 60) return rtf.format(-diff, "second");
+  return rtf.format(-Math.floor(diff / 60), "minute");
+}
+
+function isOffline(ts?: string) {
+  if (!ts) return true;
+  return Date.now() - new Date(ts).getTime() > OFFLINE_MS;
+}
+
+function normalizeStatus(status?: string) {
+  const s = (status ?? "").toUpperCase();
+  if (s === "ONLINE") return "RUN";
+  return s;
+}
+
+function badgeClass(status?: string, offline?: boolean) {
+  if (offline) return "bg-white/10 text-zinc-300";
+  const s = (status ?? "").toUpperCase();
+  if (s === "RUN") return "bg-emerald-500/15 text-emerald-300";
+  if (s === "IDLE") return "bg-yellow-500/15 text-yellow-300";
+  if (s === "STOP" || s === "DOWN") return "bg-red-500/15 text-red-300";
+  return "bg-white/10 text-white";
+}
+
+export default function MachinesClient({ initialMachines = [] }: { initialMachines?: MachineRow[] }) {
+  const { t, locale } = useI18n();
+  const router = useRouter();
+  const [machines, setMachines] = useState<MachineRow[]>(() => initialMachines);
+  const [loading, setLoading] = useState(() => initialMachines.length === 0);
+  const [showCreate, setShowCreate] = useState(false);
+  const [createName, setCreateName] = useState("");
+  const [createCode, setCreateCode] = useState("");
+  const [createLocation, setCreateLocation] = useState("");
+  const [creating, setCreating] = useState(false);
+  const [createError, setCreateError] = useState<string | null>(null);
+  const [createdMachine, setCreatedMachine] = useState<{
+    id: string;
+    name: string;
+    pairingCode: string;
+    pairingExpiresAt: string;
+  } | null>(null);
+  const [copyStatus, setCopyStatus] = useState<string | null>(null);
+
+  useEffect(() => {
+    let alive = true;
+    let timer: ReturnType<typeof setTimeout> | null = null;
+
+    async function load(initial: boolean) {
+      try {
+        if (!initial && typeof document !== "undefined" && document.hidden) {
+          return;
+        }
+
+        const res = await fetch("/api/machines", { cache: "no-store" });
+        const json = await res.json();
+        if (alive) {
+          setMachines(json.machines ?? []);
+          if (initial) setLoading(false);
+        }
+      } catch {
+        if (alive && initial) setLoading(false);
+      } finally {
+        if (!alive) return;
+        timer = setTimeout(() => {
+          void load(false);
+        }, LIVE_REFRESH_MS);
+      }
+    }
+
+    void load(initialMachines.length === 0);
+    return () => {
+      alive = false;
+      if (timer) clearTimeout(timer);
+    };
+  }, [initialMachines.length]);
+
+  async function createMachine() {
+    if (!createName.trim()) {
+      setCreateError(t("machines.create.error.nameRequired"));
+      return;
+    }
+
+    setCreating(true);
+    setCreateError(null);
+
+    try {
+      const res = await fetch("/api/machines", {
+        method: "POST",
+        headers: { "Content-Type": "application/json" },
+        body: JSON.stringify({
+          name: createName,
+          code: createCode,
+          location: createLocation,
+        }),
+      });
+      const data = await res.json().catch(() => ({}));
+      if (!res.ok || !data.ok) {
+        throw new Error(data.error || t("machines.create.error.failed"));
+      }
+
+      const nextMachine = {
+        ...data.machine,
+        latestHeartbeat: null,
+      };
+      setMachines((prev) => [nextMachine, ...prev]);
+      setCreatedMachine({
+        id: data.machine.id,
+        name: data.machine.name,
+        pairingCode: data.machine.pairingCode,
+        pairingExpiresAt: data.machine.pairingCodeExpiresAt,
+      });
+      setCreateName("");
+      setCreateCode("");
+      setCreateLocation("");
+      setShowCreate(false);
+    } catch (err: unknown) {
+      const message = err instanceof Error ? err.message : null;
+      setCreateError(message || t("machines.create.error.failed"));
+    } finally {
+      setCreating(false);
+    }
+  }
+
+  async function copyText(text: string) {
+    try {
+      if (navigator.clipboard?.writeText) {
+        await navigator.clipboard.writeText(text);
+        setCopyStatus(t("machines.pairing.copied"));
+      } else {
+        setCopyStatus(t("machines.pairing.copyUnsupported"));
+      }
+    } catch {
+      setCopyStatus(t("machines.pairing.copyFailed"));
+    }
+    setTimeout(() => setCopyStatus(null), 2000);
+  }
+
+  function handleCardKeyDown(event: KeyboardEvent<HTMLDivElement>, machineId: string) {
+    if (event.key === "Enter" || event.key === " ") {
+      event.preventDefault();
+      router.push(`/machines/${machineId}`);
+    }
+  }
+
+  const showCreateCard = showCreate || (!loading && machines.length === 0);
+
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-6 flex flex-col gap-4 sm:flex-row sm:items-center sm:justify-between">
+        <div>
+          <h1 className="text-2xl font-semibold text-white">{t("machines.title")}</h1>
+          <p className="text-sm text-zinc-400">{t("machines.subtitle")}</p>
+        </div>
+
+        <div className="flex w-full flex-wrap items-center gap-2 sm:w-auto">
+          <button
+            type="button"
+            onClick={() => setShowCreate((prev) => !prev)}
+            className="w-full rounded-xl border border-emerald-400/40 bg-emerald-500/20 px-4 py-2 text-sm text-emerald-100 hover:bg-emerald-500/30 sm:w-auto"
+          >
+            {showCreate ? t("machines.cancel") : t("machines.addMachine")}
+          </button>
+          <Link
+            href="/overview"
+            className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-white hover:bg-white/10 sm:w-auto"
+          >
+            {t("machines.backOverview")}
+          </Link>
+        </div>
+      </div>
+
+      {showCreateCard && (
+        <div className="mb-6 rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="flex flex-col gap-2 sm:flex-row sm:items-center sm:justify-between">
+            <div>
+              <div className="text-sm font-semibold text-white">{t("machines.addCardTitle")}</div>
+              <div className="text-xs text-zinc-400">{t("machines.addCardSubtitle")}</div>
+            </div>
+          </div>
+
+          <div className="mt-4 grid grid-cols-1 gap-3 md:grid-cols-3">
+            <label className="rounded-xl border border-white/10 bg-black/20 p-3 text-xs text-zinc-400">
+              {t("machines.field.name")}
+              <input
+                value={createName}
+                onChange={(event) => setCreateName(event.target.value)}
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              />
+            </label>
+            <label className="rounded-xl border border-white/10 bg-black/20 p-3 text-xs text-zinc-400">
+              {t("machines.field.code")}
+              <input
+                value={createCode}
+                onChange={(event) => setCreateCode(event.target.value)}
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              />
+            </label>
+            <label className="rounded-xl border border-white/10 bg-black/20 p-3 text-xs text-zinc-400">
+              {t("machines.field.location")}
+              <input
+                value={createLocation}
+                onChange={(event) => setCreateLocation(event.target.value)}
+                className="mt-2 w-full rounded-lg border border-white/10 bg-black/30 px-3 py-2 text-sm text-white"
+              />
+            </label>
+          </div>
+
+          <div className="mt-4 flex flex-wrap items-center gap-3">
+            <button
+              type="button"
+              onClick={createMachine}
+              disabled={creating}
+              className="rounded-xl border border-emerald-400/40 bg-emerald-500/20 px-4 py-2 text-sm text-emerald-100 hover:bg-emerald-500/30 disabled:opacity-60"
+            >
+            {creating ? t("machines.create.loading") : t("machines.create.default")}
+          </button>
+            {createError && <div className="text-xs text-red-200">{createError}</div>}
+          </div>
+        </div>
+      )}
+
+      {createdMachine && (
+      <div className="mb-6 rounded-2xl border border-emerald-500/20 bg-emerald-500/10 p-5">
+          <div className="text-sm font-semibold text-white">{t("machines.pairing.title")}</div>
+          <div className="mt-2 text-xs text-zinc-300">
+            {t("machines.pairing.machine")} <span className="text-white">{createdMachine.name}</span>
+          </div>
+          <div className="mt-3 rounded-xl border border-white/10 bg-black/30 p-4">
+            <div className="text-xs uppercase tracking-wide text-zinc-400">{t("machines.pairing.codeLabel")}</div>
+            <div className="mt-2 text-3xl font-semibold text-white">{createdMachine.pairingCode}</div>
+            <div className="mt-2 text-xs text-zinc-400">
+              {t("machines.pairing.expires")}{" "}
+              {createdMachine.pairingExpiresAt
+                ? new Date(createdMachine.pairingExpiresAt).toLocaleString(locale)
+                : t("machines.pairing.soon")}
+            </div>
+          </div>
+          <div className="mt-3 text-xs text-zinc-300">
+            {t("machines.pairing.instructions")}
+          </div>
+          <div className="mt-3 flex flex-wrap items-center gap-3">
+            <button
+              type="button"
+              onClick={() => copyText(createdMachine.pairingCode)}
+              className="rounded-xl border border-white/10 bg-white/5 px-3 py-2 text-sm text-white hover:bg-white/10"
+            >
+              {t("machines.pairing.copy")}
+            </button>
+            {copyStatus && <div className="text-xs text-zinc-300">{copyStatus}</div>}
+          </div>
+        </div>
+      )}
+
+      {loading && <div className="mb-4 text-sm text-zinc-400">{t("machines.loading")}</div>}
+
+      {!loading && machines.length === 0 && (
+        <div className="mb-4 text-sm text-zinc-400">{t("machines.empty")}</div>
+      )}
+
+      <div className="grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-3">
+        {(!loading ? machines : []).map((m) => {
+          const hb = m.latestHeartbeat;
+          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"));
+
+          return (
+            <div
+              key={m.id}
+              role="link"
+              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"
+            >
+              <div className="flex items-center justify-between gap-3">
+                <div className="min-w-0">
+                  <div className="truncate text-lg font-semibold text-white">{m.name}</div>
+                  <div className="mt-1 text-xs text-zinc-400">
+                    {m.code ? m.code : t("common.na")} - {t("machines.lastSeen", { time: lastSeen })}
+                  </div>
+                </div>
+
+                <span
+                  className={`shrink-0 rounded-full px-3 py-1 text-xs ${badgeClass(
+                    normalizedStatus,
+                    offline
+                  )}`}
+                >
+                  {statusLabel}
+                </span>
+              </div>
+
+              <div className="mt-4 text-sm text-zinc-400">{t("machines.status")}</div>
+              <div className="mt-1 flex items-center gap-2 text-sm font-semibold text-white">
+                {offline ? (
+                  <>
+                    <span className="inline-flex h-2.5 w-2.5 rounded-full bg-zinc-500" aria-hidden="true" />
+                    <span>{t("machines.status.noHeartbeat")}</span>
+                  </>
+                ) : (
+                  <>
+                    <span className="relative flex h-2.5 w-2.5" aria-hidden="true">
+                      <span className="animate-ping absolute inline-flex h-full w-full rounded-full bg-emerald-400 opacity-75" />
+                      <span className="relative inline-flex h-2.5 w-2.5 rounded-full bg-emerald-400" />
+                    </span>
+                    <span>{t("machines.status.ok")}</span>
+                  </>
+                )}
+              </div>
+
+            </div>
+          );
+        })}
+      </div>
+    </div>
+  );
+}

app/(app)/machines/loading.tsx

@@ -0,0 +1,22 @@
+export default function MachinesLoading() {
+  return (
+    <div className="p-4 sm:p-6 space-y-6 animate-pulse">
+      <div className="flex flex-col gap-3 sm:flex-row sm:items-center sm:justify-between">
+        <div className="space-y-2">
+          <div className="h-6 w-36 rounded-lg bg-white/10" />
+          <div className="h-4 w-60 rounded-lg bg-white/5" />
+        </div>
+        <div className="flex w-full gap-2 sm:w-auto">
+          <div className="h-9 w-full rounded-xl border border-emerald-400/40 bg-emerald-500/10 sm:w-36" />
+          <div className="h-9 w-full rounded-xl border border-white/10 bg-white/5 sm:w-32" />
+        </div>
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-3">
+        {Array.from({ length: 6 }).map((_, idx) => (
+          <div key={idx} className="h-40 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+    </div>
+  );
+}

app/(app)/machines/page.tsx

@@ -1,133 +1,47 @@
-"use client";
+import { redirect } from "next/navigation";
+import { requireSession } from "@/lib/auth/requireSession";
+import {
+  fetchLatestHeartbeats,
+  fetchMachineBase,
+  mergeMachineOverviewRows,
+} from "@/lib/machines/withLatest";
+import MachinesClient from "./MachinesClient";
 
-import Link from "next/link";
-import { useEffect, useState } from "react";
-
-type MachineRow = {
-  id: string;
-  name: string;
-  code?: string | null;
-  location?: string | null;
-  latestHeartbeat: null | {
-    ts: string;
-    status: string;
-    message?: string | null;
-    ip?: string | null;
-    fwVersion?: string | null;
-  };
-};
-
-function secondsAgo(ts?: string) {
-  if (!ts) return "never";
-  const diff = Math.floor((Date.now() - new Date(ts).getTime()) / 1000);
-  if (diff < 60) return `${diff}s ago`;
-  return `${Math.floor(diff / 60)}m ago`;
+function toIso(value?: Date | null) {
+  return value ? value.toISOString() : null;
 }
 
-function isOffline(ts?: string) {
-  if (!ts) return true;
-  return Date.now() - new Date(ts).getTime() > 15000; // 15s threshold
-}
+export default async function MachinesPage() {
+  const session = await requireSession();
+  if (!session) redirect("/login?next=/machines");
 
-function badgeClass(status?: string, offline?: boolean) {
-  if (offline) return "bg-white/10 text-zinc-300";
-  const s = (status ?? "").toUpperCase();
-  if (s === "RUN") return "bg-emerald-500/15 text-emerald-300";
-  if (s === "IDLE") return "bg-yellow-500/15 text-yellow-300";
-  if (s === "STOP" || s === "DOWN") return "bg-red-500/15 text-red-300";
-  return "bg-white/10 text-white";
-}
-
-export default function MachinesPage() {
-  const [machines, setMachines] = useState<MachineRow[]>([]);
-  const [loading, setLoading] = useState(true);
-
-  useEffect(() => {
-    let alive = true;
-
-    async function load() {
-      try {
-        const res = await fetch("/api/machines", { cache: "no-store" });
-        const json = await res.json();
-        if (alive) {
-          setMachines(json.machines ?? []);
-          setLoading(false);
-        }
-      } catch {
-        if (alive) setLoading(false);
-      }
-    }
-
-    load();
-    const t = setInterval(load, 5000);
-
-    return () => {
-      alive = false;
-      clearInterval(t);
-    };
-  }, []);
-
-  return (
-    <div className="p-6">
-      <div className="mb-6 flex items-center justify-between">
-        <div>
-          <h1 className="text-2xl font-semibold text-white">Machines</h1>
-          <p className="text-sm text-zinc-400">Select a machine to view live KPIs.</p>
-        </div>
-
-        <Link
-          href="/overview"
-          className="rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-sm text-white hover:bg-white/10"
-        >
-          Back to Overview
-        </Link>
-      </div>
-
-      {loading && <div className="mb-4 text-sm text-zinc-400">Loading machines…</div>}
-
-      {!loading && machines.length === 0 && (
-        <div className="mb-4 text-sm text-zinc-400">No machines found for this org.</div>
-      )}
-
-      <div className="grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-3">
-        {(!loading ? machines : []).map((m) => {
-          const hb = m.latestHeartbeat;
-          const offline = isOffline(hb?.ts);
-          const statusLabel = offline ? "OFFLINE" : hb?.status ?? "UNKNOWN";
-          const lastSeen = secondsAgo(hb?.ts);
-
-          return (
-            <Link
-              key={m.id}
-              href={`/machines/${m.id}`}
-              className="rounded-2xl border border-white/10 bg-white/5 p-5 hover:bg-white/10"
-            >
-              <div className="flex items-center justify-between gap-3">
-                <div className="min-w-0">
-                  <div className="truncate text-lg font-semibold text-white">{m.name}</div>
-                  <div className="mt-1 text-xs text-zinc-400">
-                    {m.code ? m.code : "—"} • Last seen {lastSeen}
-                  </div>
-                </div>
-
-                <span
-                  className={`shrink-0 rounded-full px-3 py-1 text-xs ${badgeClass(
-                    hb?.status,
-                    offline
-                  )}`}
-                >
-                  {statusLabel}
-                </span>
-              </div>
-
-              <div className="mt-4 text-sm text-zinc-400">Status</div>
-              <div className="text-xl font-semibold text-white">
-                {offline ? "No heartbeat" : hb?.message ?? "OK"}
-              </div>
-            </Link>
-          );
-        })}
-      </div>
-    </div>
+  const machines = await fetchMachineBase(session.orgId);
+  const heartbeats = await fetchLatestHeartbeats(
+    session.orgId,
+    machines.map((machine) => machine.id)
   );
+  const rows = mergeMachineOverviewRows({
+    machines,
+    heartbeats,
+    includeKpi: false,
+  });
+
+  const initialMachines = rows.map((machine) => ({
+    id: machine.id,
+    name: machine.name,
+    code: machine.code ?? null,
+    location: machine.location ?? null,
+    latestHeartbeat: machine.latestHeartbeat
+      ? {
+          ts: toIso(machine.latestHeartbeat.ts) ?? "",
+          tsServer: toIso(machine.latestHeartbeat.tsServer),
+          status: machine.latestHeartbeat.status,
+          message: machine.latestHeartbeat.message ?? null,
+          ip: machine.latestHeartbeat.ip ?? null,
+          fwVersion: machine.latestHeartbeat.fwVersion ?? null,
+        }
+      : null,
+  }));
+
+  return <MachinesClient initialMachines={initialMachines} />;
 }

app/(app)/overview/OverviewClient.tsx

@@ -0,0 +1,445 @@
+"use client";
+
+import Link from "next/link";
+import { Suspense, lazy, useEffect, useMemo, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+import { RECAP_HEARTBEAT_STALE_MS } from "@/lib/recap/recapUiConstants";
+import type { EventRow, Heartbeat, MachineRow } from "./types";
+
+const OFFLINE_MS = RECAP_HEARTBEAT_STALE_MS;
+const MAX_EVENT_MACHINES = 6;
+const OverviewTimeline = lazy(() => import("./OverviewTimeline"));
+
+function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
+  if (!ts) return fallback;
+  const diff = Math.floor((Date.now() - new Date(ts).getTime()) / 1000);
+  const rtf = new Intl.RelativeTimeFormat(locale, { numeric: "auto" });
+  if (diff < 60) return rtf.format(-diff, "second");
+  if (diff < 3600) return rtf.format(-Math.floor(diff / 60), "minute");
+  return rtf.format(-Math.floor(diff / 3600), "hour");
+}
+
+function isOffline(ts?: string) {
+  if (!ts) return true;
+  return Date.now() - new Date(ts).getTime() > OFFLINE_MS;
+}
+
+function normalizeStatus(status?: string) {
+  const s = (status ?? "").toUpperCase();
+  if (s === "ONLINE") return "RUN";
+  return s;
+}
+
+function heartbeatTime(hb?: Heartbeat | null) {
+  return hb?.tsServer ?? hb?.ts;
+}
+
+function fmtPct(v?: number | null) {
+  if (v === null || v === undefined || Number.isNaN(v)) return "--";
+  return `${v.toFixed(1)}%`;
+}
+
+function fmtNum(v?: number | null) {
+  if (v === null || v === undefined || Number.isNaN(v)) return "--";
+  return `${Math.round(v)}`;
+}
+
+function OverviewTimelineSkeleton() {
+  return (
+    <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-2">
+      <div className="mb-3 flex items-center justify-between">
+        <div className="h-4 w-32 rounded bg-white/10" />
+        <div className="h-3 w-20 rounded bg-white/5" />
+      </div>
+      <div className="space-y-3">
+        {Array.from({ length: 4 }).map((_, idx) => (
+          <div key={idx} className="h-20 rounded-xl border border-white/10 bg-black/20" />
+        ))}
+      </div>
+    </div>
+  );
+}
+
+export default function OverviewClient({
+  initialMachines = [],
+  initialEvents = [],
+}: {
+  initialMachines?: MachineRow[];
+  initialEvents?: EventRow[];
+}) {
+  const { t, locale } = useI18n();
+  const [machines, setMachines] = useState<MachineRow[]>(() => initialMachines);
+  const [events, setEvents] = useState<EventRow[]>(() => initialEvents);
+  const [loading, setLoading] = useState(false);
+  const [eventsLoading, setEventsLoading] = useState(() => initialEvents.length === 0);
+
+  useEffect(() => {
+    let alive = true;
+
+    async function load() {
+      try {
+        setEventsLoading(true);
+        const res = await fetch(
+          `/api/overview?detail=1&events=critical&eventMachines=${MAX_EVENT_MACHINES}`,
+          {
+            cache: "no-cache",
+          }
+        );
+        if (res.status === 304) {
+          if (alive) setLoading(false);
+          return;
+        }
+        const json = await res.json().catch(() => ({}));
+        if (!alive) return;
+        setMachines(json.machines ?? []);
+        setEvents(json.events ?? []);
+        setLoading(false);
+      } catch {
+        if (!alive) return;
+        setMachines([]);
+        setEvents([]);
+        setLoading(false);
+      } finally {
+        if (alive) setEventsLoading(false);
+      }
+    }
+
+    load();
+    const t = setInterval(load, 30000);
+    return () => {
+      alive = false;
+      clearInterval(t);
+    };
+  }, []);
+
+  const stats = useMemo(() => {
+    const total = machines.length;
+    let online = 0;
+    let running = 0;
+    let idle = 0;
+    let stopped = 0;
+    let oeeSum = 0;
+    let oeeCount = 0;
+    let availSum = 0;
+    let availCount = 0;
+    let perfSum = 0;
+    let perfCount = 0;
+    let qualSum = 0;
+    let qualCount = 0;
+    let goodSum = 0;
+    let scrapSum = 0;
+    let targetSum = 0;
+    let hasKpi = false;
+
+    for (const m of machines) {
+      const hb = m.latestHeartbeat;
+      const offline = isOffline(heartbeatTime(hb));
+      if (!offline) online += 1;
+
+      const status = normalizeStatus(hb?.status);
+      if (!offline) {
+        if (status === "RUN") running += 1;
+        else if (status === "IDLE") idle += 1;
+        else if (status === "STOP" || status === "DOWN") stopped += 1;
+      }
+
+      const k = m.latestKpi;
+      if (k?.oee != null) {
+        oeeSum += Number(k.oee);
+        oeeCount += 1;
+        hasKpi = true;
+      }
+      if (k?.availability != null) {
+        availSum += Number(k.availability);
+        availCount += 1;
+        hasKpi = true;
+      }
+      if (k?.performance != null) {
+        perfSum += Number(k.performance);
+        perfCount += 1;
+        hasKpi = true;
+      }
+      if (k?.quality != null) {
+        qualSum += Number(k.quality);
+        qualCount += 1;
+        hasKpi = true;
+      }
+      if (k?.good != null) {
+        goodSum += Number(k.good);
+        hasKpi = true;
+      }
+      if (k?.scrap != null) {
+        scrapSum += Number(k.scrap);
+        hasKpi = true;
+      }
+      if (k?.target != null) {
+        targetSum += Number(k.target);
+        hasKpi = true;
+      }
+    }
+
+    return {
+      total,
+      online,
+      offline: total - online,
+      running,
+      idle,
+      stopped,
+      oee: oeeCount ? oeeSum / oeeCount : null,
+      availability: availCount ? availSum / availCount : null,
+      performance: perfCount ? perfSum / perfCount : null,
+      quality: qualCount ? qualSum / qualCount : null,
+      goodSum: hasKpi ? goodSum : null,
+      scrapSum: hasKpi ? scrapSum : null,
+      targetSum: hasKpi ? targetSum : null,
+    };
+  }, [machines]);
+
+  const attention = useMemo(() => {
+    const list = machines
+      .map((m) => {
+        const hb = m.latestHeartbeat;
+        const offline = isOffline(heartbeatTime(hb));
+        const status = normalizeStatus(hb?.status);
+        const k = m.latestKpi;
+        const oee = k?.oee ?? null;
+        const good = k?.good ?? null;
+        const scrap = k?.scrap ?? null;
+        const availability = k?.availability ?? null;
+
+        const reasons: string[] = [];
+        let score = 0;
+
+        // Trigger 1: offline (highest priority — can't tell what's wrong)
+        if (offline) {
+          score += 100;
+          reasons.push(t("overview.attention.offline"));
+        }
+
+        // Trigger 2: stopped right now (and online — operator should act)
+        if (!offline && (status === "STOP" || status === "DOWN")) {
+          score += 60;
+          reasons.push(t("overview.attention.stopped"));
+        }
+
+        // Trigger 3: low OEE
+        if (!offline && oee != null) {
+          if (oee < 50) {
+            score += 50;
+            reasons.push(t("overview.attention.oeeCritical", { value: oee.toFixed(0) }));
+          } else if (oee < 75) {
+            score += 30;
+            reasons.push(t("overview.attention.oeeLow", { value: oee.toFixed(0) }));
+          }
+        }
+
+        // Trigger 4: scrap rate >5% on active WO
+        if (!offline && good != null && scrap != null && good + scrap > 0) {
+          const scrapPct = (scrap / (good + scrap)) * 100;
+          if (scrapPct > 10) {
+            score += 40;
+            reasons.push(t("overview.attention.scrapHigh", { value: scrapPct.toFixed(1) }));
+          } else if (scrapPct > 5) {
+            score += 20;
+            reasons.push(t("overview.attention.scrapMod", { value: scrapPct.toFixed(1) }));
+          }
+        }
+
+        // Trigger 5: availability collapse (often means undeclared stops)
+        if (!offline && availability != null && availability < 60) {
+          score += 25;
+          reasons.push(t("overview.attention.availLow", { value: availability.toFixed(0) }));
+        }
+
+        return { machine: m, offline, oee, score, reasons };
+      })
+      .filter((x) => x.score > 0)
+      .sort((a, b) => b.score - a.score)
+      .slice(0, 6);
+
+    return list;
+  }, [machines, t]);
+
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-6 flex flex-col gap-4 sm:flex-row sm:items-start sm:justify-between">
+        <div>
+          <h1 className="text-2xl font-semibold text-white">{t("overview.title")}</h1>
+          <p className="text-sm text-zinc-400">{t("overview.subtitle")}</p>
+        </div>
+
+        <Link
+          href="/machines"
+          className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-white hover:bg-white/10 sm:w-auto"
+        >
+          {t("overview.viewMachines")}
+        </Link>
+      </div>
+
+      {loading && <div className="mb-4 text-sm text-zinc-400">{t("overview.loading")}</div>}
+
+      <div className="mb-4 rounded-2xl border border-white/10 bg-black/40 p-4">
+        <div className="flex flex-col gap-3 sm:flex-row sm:items-center sm:justify-between">
+          <div>
+            <div className="text-sm font-semibold text-white">{t("overview.recap.title")}</div>
+            <div className="text-xs text-zinc-400">{t("overview.recap.subtitle")}</div>
+          </div>
+          <Link
+            href="/recap"
+            className="rounded-xl border border-emerald-500/30 bg-emerald-500/10 px-3 py-2 text-sm text-emerald-300 hover:bg-emerald-500/20"
+          >
+            {t("overview.recap.cta")}
+          </Link>
+        </div>
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 xl:grid-cols-3">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.fleetHealth")}</div>
+          <div className="mt-2 text-3xl font-semibold text-white">{stats.total}</div>
+          <div className="mt-2 text-xs text-zinc-400">{t("overview.machinesTotal")}</div>
+          <div className="mt-4 flex flex-wrap gap-2 text-xs">
+            <span className="rounded-full bg-emerald-500/15 px-2 py-0.5 text-emerald-300">
+              {t("overview.online")} {stats.online}
+            </span>
+            <span className="rounded-full bg-white/10 px-2 py-0.5 text-zinc-300">
+              {t("overview.offline")} {stats.offline}
+            </span>
+            <span className="rounded-full bg-emerald-500/10 px-2 py-0.5 text-emerald-200">
+              {t("overview.run")} {stats.running}
+            </span>
+            <span className="rounded-full bg-yellow-500/15 px-2 py-0.5 text-yellow-300">
+              {t("overview.idle")} {stats.idle}
+            </span>
+            <span className="rounded-full bg-red-500/15 px-2 py-0.5 text-red-300">
+              {t("overview.stop")} {stats.stopped}
+            </span>
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.productionTotals")}</div>
+          <div className="mt-2 grid grid-cols-1 gap-3 sm:grid-cols-3">
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-[11px] text-zinc-400">{t("overview.good")}</div>
+              <div className="mt-1 text-sm font-semibold text-white">{fmtNum(stats.goodSum)}</div>
+            </div>
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-[11px] text-zinc-400">{t("overview.scrap")}</div>
+              <div className="mt-1 text-sm font-semibold text-white">{fmtNum(stats.scrapSum)}</div>
+            </div>
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-[11px] text-zinc-400">{t("overview.target")}</div>
+              <div className="mt-1 text-sm font-semibold text-white">{fmtNum(stats.targetSum)}</div>
+            </div>
+          </div>
+          <div className="mt-3 text-xs text-zinc-400">{t("overview.kpiSumNote")}</div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.activityFeed")}</div>
+          <div className="mt-2 text-3xl font-semibold text-white">{events.length}</div>
+          <div className="mt-2 text-xs text-zinc-400">
+            {eventsLoading ? t("overview.eventsRefreshing") : t("overview.eventsLast30")}
+          </div>
+          <div className="mt-4 space-y-2">
+            {events.slice(0, 3).map((e) => (
+              <div key={e.id} className="flex items-center justify-between text-xs text-zinc-300">
+                <div className="truncate">
+                  {e.machineName ? `${e.machineName}: ` : ""}
+                  {e.title}
+                </div>
+                <div className="shrink-0 text-zinc-500">
+                  {secondsAgo(e.ts, locale, t("common.never"))}
+                </div>
+              </div>
+            ))}
+            {events.length === 0 && !eventsLoading ? (
+              <div className="text-xs text-zinc-500">{t("overview.eventsNone")}</div>
+            ) : null}
+          </div>
+        </div>
+      </div>
+
+      <div className="mt-6 grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-4">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.oeeAvg")}</div>
+          <div className="mt-2 text-3xl font-semibold text-emerald-300">{fmtPct(stats.oee)}</div>
+        </div>
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.availabilityAvg")}</div>
+          <div className="mt-2 text-2xl font-semibold text-white">{fmtPct(stats.availability)}</div>
+        </div>
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.performanceAvg")}</div>
+          <div className="mt-2 text-2xl font-semibold text-white">{fmtPct(stats.performance)}</div>
+        </div>
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.qualityAvg")}</div>
+          <div className="mt-2 text-2xl font-semibold text-white">{fmtPct(stats.quality)}</div>
+        </div>
+      </div>
+
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-3">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-1">
+          <div className="mb-3 flex items-center justify-between">
+            <div className="text-sm font-semibold text-white">{t("overview.attentionList")}</div>
+            <div className="text-xs text-zinc-400">
+              {attention.length} {t("overview.shown")}
+            </div>
+          </div>
+          {attention.length === 0 ? (
+            <div className="text-sm text-zinc-400">{t("overview.noUrgent")}</div>
+          ) : (
+            <div className="space-y-3">
+              {attention.map(({ machine, offline, oee, reasons }) => (
+                <Link
+                  key={machine.id}
+                  href={`/recap/${machine.id}`}
+                  className="block rounded-xl border border-white/10 bg-black/20 p-3 hover:border-white/20 hover:bg-black/30 transition"
+                >
+                  <div className="flex items-center justify-between gap-3">
+                    <div className="min-w-0">
+                      <div className="truncate text-sm font-semibold text-white">{machine.name}</div>
+                      <div className="mt-1 text-xs text-zinc-400">
+                        {machine.code ?? ""} {machine.location ? `- ${machine.location}` : ""}
+                      </div>
+                    </div>
+                    <div className="text-xs text-zinc-400">
+                      {secondsAgo(heartbeatTime(machine.latestHeartbeat), locale, t("common.never"))}
+                    </div>
+                  </div>
+                  <div className="mt-2 flex flex-wrap items-center gap-1.5 text-xs">
+                    <span
+                      className={`rounded-full px-2 py-0.5 ${
+                        offline ? "bg-white/10 text-zinc-300" : "bg-emerald-500/15 text-emerald-300"
+                      }`}
+                    >
+                      {offline ? t("overview.status.offline") : t("overview.status.online")}
+                    </span>
+                    {oee != null && !offline && (
+                      <span className="rounded-full bg-yellow-500/15 px-2 py-0.5 text-yellow-300">
+                        OEE {fmtPct(oee)}
+                      </span>
+                    )}
+                  </div>
+                  {reasons.length > 0 && (
+                    <ul className="mt-2 space-y-0.5 text-[11px] text-zinc-400">
+                      {reasons.map((r, i) => (
+                        <li key={i}>· {r}</li>
+                      ))}
+                    </ul>
+                  )}
+                </Link>
+              ))}
+            </div>
+          )}
+        </div>
+
+        <Suspense fallback={<OverviewTimelineSkeleton />}>
+          <OverviewTimeline events={events} eventsLoading={eventsLoading} locale={locale} t={t} />
+        </Suspense>
+      </div>
+    </div>
+  );
+}

app/(app)/overview/OverviewClient.tsx.bak

@@ -0,0 +1,388 @@
+"use client";
+
+import Link from "next/link";
+import { Suspense, lazy, useEffect, useMemo, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+import type { EventRow, Heartbeat, MachineRow } from "./types";
+
+const OFFLINE_MS = 30000;
+const MAX_EVENT_MACHINES = 6;
+const OverviewTimeline = lazy(() => import("./OverviewTimeline"));
+
+function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
+  if (!ts) return fallback;
+  const diff = Math.floor((Date.now() - new Date(ts).getTime()) / 1000);
+  const rtf = new Intl.RelativeTimeFormat(locale, { numeric: "auto" });
+  if (diff < 60) return rtf.format(-diff, "second");
+  if (diff < 3600) return rtf.format(-Math.floor(diff / 60), "minute");
+  return rtf.format(-Math.floor(diff / 3600), "hour");
+}
+
+function isOffline(ts?: string) {
+  if (!ts) return true;
+  return Date.now() - new Date(ts).getTime() > OFFLINE_MS;
+}
+
+function normalizeStatus(status?: string) {
+  const s = (status ?? "").toUpperCase();
+  if (s === "ONLINE") return "RUN";
+  return s;
+}
+
+function heartbeatTime(hb?: Heartbeat | null) {
+  return hb?.tsServer ?? hb?.ts;
+}
+
+function fmtPct(v?: number | null) {
+  if (v === null || v === undefined || Number.isNaN(v)) return "--";
+  return `${v.toFixed(1)}%`;
+}
+
+function fmtNum(v?: number | null) {
+  if (v === null || v === undefined || Number.isNaN(v)) return "--";
+  return `${Math.round(v)}`;
+}
+
+function OverviewTimelineSkeleton() {
+  return (
+    <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-2">
+      <div className="mb-3 flex items-center justify-between">
+        <div className="h-4 w-32 rounded bg-white/10" />
+        <div className="h-3 w-20 rounded bg-white/5" />
+      </div>
+      <div className="space-y-3">
+        {Array.from({ length: 4 }).map((_, idx) => (
+          <div key={idx} className="h-20 rounded-xl border border-white/10 bg-black/20" />
+        ))}
+      </div>
+    </div>
+  );
+}
+
+export default function OverviewClient({
+  initialMachines = [],
+  initialEvents = [],
+}: {
+  initialMachines?: MachineRow[];
+  initialEvents?: EventRow[];
+}) {
+  const { t, locale } = useI18n();
+  const [machines, setMachines] = useState<MachineRow[]>(() => initialMachines);
+  const [events, setEvents] = useState<EventRow[]>(() => initialEvents);
+  const [loading, setLoading] = useState(false);
+  const [eventsLoading, setEventsLoading] = useState(() => initialEvents.length === 0);
+
+  useEffect(() => {
+    let alive = true;
+
+    async function load() {
+      try {
+        setEventsLoading(true);
+        const res = await fetch(
+          `/api/overview?detail=1&events=critical&eventMachines=${MAX_EVENT_MACHINES}`,
+          {
+            cache: "no-cache",
+          }
+        );
+        if (res.status === 304) {
+          if (alive) setLoading(false);
+          return;
+        }
+        const json = await res.json().catch(() => ({}));
+        if (!alive) return;
+        setMachines(json.machines ?? []);
+        setEvents(json.events ?? []);
+        setLoading(false);
+      } catch {
+        if (!alive) return;
+        setMachines([]);
+        setEvents([]);
+        setLoading(false);
+      } finally {
+        if (alive) setEventsLoading(false);
+      }
+    }
+
+    load();
+    const t = setInterval(load, 30000);
+    return () => {
+      alive = false;
+      clearInterval(t);
+    };
+  }, []);
+
+  const stats = useMemo(() => {
+    const total = machines.length;
+    let online = 0;
+    let running = 0;
+    let idle = 0;
+    let stopped = 0;
+    let oeeSum = 0;
+    let oeeCount = 0;
+    let availSum = 0;
+    let availCount = 0;
+    let perfSum = 0;
+    let perfCount = 0;
+    let qualSum = 0;
+    let qualCount = 0;
+    let goodSum = 0;
+    let scrapSum = 0;
+    let targetSum = 0;
+    let hasKpi = false;
+
+    for (const m of machines) {
+      const hb = m.latestHeartbeat;
+      const offline = isOffline(heartbeatTime(hb));
+      if (!offline) online += 1;
+
+      const status = normalizeStatus(hb?.status);
+      if (!offline) {
+        if (status === "RUN") running += 1;
+        else if (status === "IDLE") idle += 1;
+        else if (status === "STOP" || status === "DOWN") stopped += 1;
+      }
+
+      const k = m.latestKpi;
+      if (k?.oee != null) {
+        oeeSum += Number(k.oee);
+        oeeCount += 1;
+        hasKpi = true;
+      }
+      if (k?.availability != null) {
+        availSum += Number(k.availability);
+        availCount += 1;
+        hasKpi = true;
+      }
+      if (k?.performance != null) {
+        perfSum += Number(k.performance);
+        perfCount += 1;
+        hasKpi = true;
+      }
+      if (k?.quality != null) {
+        qualSum += Number(k.quality);
+        qualCount += 1;
+        hasKpi = true;
+      }
+      if (k?.good != null) {
+        goodSum += Number(k.good);
+        hasKpi = true;
+      }
+      if (k?.scrap != null) {
+        scrapSum += Number(k.scrap);
+        hasKpi = true;
+      }
+      if (k?.target != null) {
+        targetSum += Number(k.target);
+        hasKpi = true;
+      }
+    }
+
+    return {
+      total,
+      online,
+      offline: total - online,
+      running,
+      idle,
+      stopped,
+      oee: oeeCount ? oeeSum / oeeCount : null,
+      availability: availCount ? availSum / availCount : null,
+      performance: perfCount ? perfSum / perfCount : null,
+      quality: qualCount ? qualSum / qualCount : null,
+      goodSum: hasKpi ? goodSum : null,
+      scrapSum: hasKpi ? scrapSum : null,
+      targetSum: hasKpi ? targetSum : null,
+    };
+  }, [machines]);
+
+  const attention = useMemo(() => {
+    const list = machines
+      .map((m) => {
+        const hb = m.latestHeartbeat;
+        const offline = isOffline(heartbeatTime(hb));
+        const k = m.latestKpi;
+        const oee = k?.oee ?? null;
+        let score = 0;
+        if (offline) score += 100;
+        if (oee != null && oee < 75) score += 50;
+        if (oee != null && oee < 85) score += 25;
+        return { machine: m, offline, oee, score };
+      })
+      .filter((x) => x.score > 0)
+      .sort((a, b) => b.score - a.score)
+      .slice(0, 6);
+
+    return list;
+  }, [machines]);
+
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-6 flex flex-col gap-4 sm:flex-row sm:items-start sm:justify-between">
+        <div>
+          <h1 className="text-2xl font-semibold text-white">{t("overview.title")}</h1>
+          <p className="text-sm text-zinc-400">{t("overview.subtitle")}</p>
+        </div>
+
+        <Link
+          href="/machines"
+          className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-center text-sm text-white hover:bg-white/10 sm:w-auto"
+        >
+          {t("overview.viewMachines")}
+        </Link>
+      </div>
+
+      {loading && <div className="mb-4 text-sm text-zinc-400">{t("overview.loading")}</div>}
+
+      <div className="mb-4 rounded-2xl border border-white/10 bg-black/40 p-4">
+        <div className="flex flex-col gap-3 sm:flex-row sm:items-center sm:justify-between">
+          <div>
+            <div className="text-sm font-semibold text-white">{t("overview.recap.title")}</div>
+            <div className="text-xs text-zinc-400">{t("overview.recap.subtitle")}</div>
+          </div>
+          <Link
+            href="/recap"
+            className="rounded-xl border border-emerald-500/30 bg-emerald-500/10 px-3 py-2 text-sm text-emerald-300 hover:bg-emerald-500/20"
+          >
+            {t("overview.recap.cta")}
+          </Link>
+        </div>
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 xl:grid-cols-3">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.fleetHealth")}</div>
+          <div className="mt-2 text-3xl font-semibold text-white">{stats.total}</div>
+          <div className="mt-2 text-xs text-zinc-400">{t("overview.machinesTotal")}</div>
+          <div className="mt-4 flex flex-wrap gap-2 text-xs">
+            <span className="rounded-full bg-emerald-500/15 px-2 py-0.5 text-emerald-300">
+              {t("overview.online")} {stats.online}
+            </span>
+            <span className="rounded-full bg-white/10 px-2 py-0.5 text-zinc-300">
+              {t("overview.offline")} {stats.offline}
+            </span>
+            <span className="rounded-full bg-emerald-500/10 px-2 py-0.5 text-emerald-200">
+              {t("overview.run")} {stats.running}
+            </span>
+            <span className="rounded-full bg-yellow-500/15 px-2 py-0.5 text-yellow-300">
+              {t("overview.idle")} {stats.idle}
+            </span>
+            <span className="rounded-full bg-red-500/15 px-2 py-0.5 text-red-300">
+              {t("overview.stop")} {stats.stopped}
+            </span>
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.productionTotals")}</div>
+          <div className="mt-2 grid grid-cols-1 gap-3 sm:grid-cols-3">
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-[11px] text-zinc-400">{t("overview.good")}</div>
+              <div className="mt-1 text-sm font-semibold text-white">{fmtNum(stats.goodSum)}</div>
+            </div>
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-[11px] text-zinc-400">{t("overview.scrap")}</div>
+              <div className="mt-1 text-sm font-semibold text-white">{fmtNum(stats.scrapSum)}</div>
+            </div>
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-[11px] text-zinc-400">{t("overview.target")}</div>
+              <div className="mt-1 text-sm font-semibold text-white">{fmtNum(stats.targetSum)}</div>
+            </div>
+          </div>
+          <div className="mt-3 text-xs text-zinc-400">{t("overview.kpiSumNote")}</div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.activityFeed")}</div>
+          <div className="mt-2 text-3xl font-semibold text-white">{events.length}</div>
+          <div className="mt-2 text-xs text-zinc-400">
+            {eventsLoading ? t("overview.eventsRefreshing") : t("overview.eventsLast30")}
+          </div>
+          <div className="mt-4 space-y-2">
+            {events.slice(0, 3).map((e) => (
+              <div key={e.id} className="flex items-center justify-between text-xs text-zinc-300">
+                <div className="truncate">
+                  {e.machineName ? `${e.machineName}: ` : ""}
+                  {e.title}
+                </div>
+                <div className="shrink-0 text-zinc-500">
+                  {secondsAgo(e.ts, locale, t("common.never"))}
+                </div>
+              </div>
+            ))}
+            {events.length === 0 && !eventsLoading ? (
+              <div className="text-xs text-zinc-500">{t("overview.eventsNone")}</div>
+            ) : null}
+          </div>
+        </div>
+      </div>
+
+      <div className="mt-6 grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-4">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.oeeAvg")}</div>
+          <div className="mt-2 text-3xl font-semibold text-emerald-300">{fmtPct(stats.oee)}</div>
+        </div>
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.availabilityAvg")}</div>
+          <div className="mt-2 text-2xl font-semibold text-white">{fmtPct(stats.availability)}</div>
+        </div>
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.performanceAvg")}</div>
+          <div className="mt-2 text-2xl font-semibold text-white">{fmtPct(stats.performance)}</div>
+        </div>
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="text-xs text-zinc-400">{t("overview.qualityAvg")}</div>
+          <div className="mt-2 text-2xl font-semibold text-white">{fmtPct(stats.quality)}</div>
+        </div>
+      </div>
+
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-3">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-1">
+          <div className="mb-3 flex items-center justify-between">
+            <div className="text-sm font-semibold text-white">{t("overview.attentionList")}</div>
+            <div className="text-xs text-zinc-400">
+              {attention.length} {t("overview.shown")}
+            </div>
+          </div>
+          {attention.length === 0 ? (
+            <div className="text-sm text-zinc-400">{t("overview.noUrgent")}</div>
+          ) : (
+            <div className="space-y-3">
+              {attention.map(({ machine, offline, oee }) => (
+                <div key={machine.id} className="rounded-xl border border-white/10 bg-black/20 p-3">
+                  <div className="flex items-center justify-between gap-3">
+                    <div className="min-w-0">
+                      <div className="truncate text-sm font-semibold text-white">{machine.name}</div>
+                      <div className="mt-1 text-xs text-zinc-400">
+                        {machine.code ?? ""} {machine.location ? `- ${machine.location}` : ""}
+                      </div>
+                    </div>
+                    <div className="text-xs text-zinc-400">
+                      {secondsAgo(heartbeatTime(machine.latestHeartbeat), locale, t("common.never"))}
+                    </div>
+                  </div>
+                  <div className="mt-2 flex items-center gap-2 text-xs">
+                    <span
+                      className={`rounded-full px-2 py-0.5 ${
+                        offline ? "bg-white/10 text-zinc-300" : "bg-emerald-500/15 text-emerald-300"
+                      }`}
+                    >
+                      {offline ? t("overview.status.offline") : t("overview.status.online")}
+                    </span>
+                    {oee != null && (
+                      <span className="rounded-full bg-yellow-500/15 px-2 py-0.5 text-yellow-300">
+                        OEE {fmtPct(oee)}
+                      </span>
+                    )}
+                  </div>
+                </div>
+              ))}
+            </div>
+          )}
+        </div>
+
+        <Suspense fallback={<OverviewTimelineSkeleton />}>
+          <OverviewTimeline events={events} eventsLoading={eventsLoading} locale={locale} t={t} />
+        </Suspense>
+      </div>
+    </div>
+  );
+}

app/(app)/overview/OverviewTimeline.tsx

@@ -0,0 +1,129 @@
+"use client";
+
+import type { EventRow } from "./types";
+
+type Translator = (key: string, vars?: Record<string, string | number>) => string;
+
+function secondsAgo(ts: string | undefined, locale: string, fallback: string) {
+  if (!ts) return fallback;
+  const diff = Math.floor((Date.now() - new Date(ts).getTime()) / 1000);
+  const rtf = new Intl.RelativeTimeFormat(locale, { numeric: "auto" });
+  if (diff < 60) return rtf.format(-diff, "second");
+  if (diff < 3600) return rtf.format(-Math.floor(diff / 60), "minute");
+  return rtf.format(-Math.floor(diff / 3600), "hour");
+}
+
+function severityClass(sev?: string) {
+  const s = (sev ?? "").toLowerCase();
+  if (s === "critical") return "bg-red-500/15 text-red-300";
+  if (s === "warning") return "bg-yellow-500/15 text-yellow-300";
+  if (s === "info") return "bg-blue-500/15 text-blue-300";
+  return "bg-white/10 text-zinc-200";
+}
+
+function sourceClass(src: EventRow["source"]) {
+  if (src === "ingested") return "bg-white/10 text-zinc-200";
+  return "bg-white/10 text-zinc-200";
+}
+
+function formatEventType(eventType: string | undefined, t: Translator) {
+  if (!eventType) return "";
+  const key = `overview.event.${eventType}`;
+  const label = t(key);
+  return label === key ? eventType : label;
+}
+
+function formatSource(source: string | undefined, t: Translator) {
+  if (!source) return "";
+  const key = `overview.source.${source}`;
+  const label = t(key);
+  return label === key ? source : label;
+}
+
+function formatSeverity(severity: string | undefined, t: Translator) {
+  if (!severity) return "";
+  const key = `overview.severity.${severity}`;
+  const label = t(key);
+  return label === key ? severity.toUpperCase() : label;
+}
+
+export default function OverviewTimeline({
+  events,
+  eventsLoading,
+  locale,
+  t,
+}: {
+  events: EventRow[];
+  eventsLoading: boolean;
+  locale: string;
+  t: Translator;
+}) {
+  if (eventsLoading && events.length === 0) {
+    return (
+      <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-2 animate-pulse">
+        <div className="mb-3 flex items-center justify-between">
+          <div className="h-4 w-32 rounded bg-white/10" />
+          <div className="h-3 w-20 rounded bg-white/5" />
+        </div>
+        <div className="space-y-3">
+          {Array.from({ length: 4 }).map((_, idx) => (
+            <div key={idx} className="h-20 rounded-xl border border-white/10 bg-black/20" />
+          ))}
+        </div>
+      </div>
+    );
+  }
+
+  return (
+    <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-2">
+      <div className="mb-3 flex items-center justify-between">
+        <div className="text-sm font-semibold text-white">{t("overview.timeline")}</div>
+        <div className="text-xs text-zinc-400">
+          {events.length} {t("overview.items")}
+        </div>
+      </div>
+
+      {events.length === 0 && !eventsLoading ? (
+        <div className="text-sm text-zinc-400">{t("overview.noEvents")}</div>
+      ) : (
+        <div className="h-[360px] space-y-3 overflow-y-auto no-scrollbar">
+          {events.map((e) => (
+            <div key={`${e.id}-${e.source}`} className="rounded-xl border border-white/10 bg-black/20 p-4">
+              <div className="flex items-start justify-between gap-3">
+                <div className="min-w-0">
+                  <div className="flex flex-wrap items-center gap-2">
+                    <span className={`rounded-full px-2 py-0.5 text-xs ${severityClass(e.severity)}`}>
+                      {formatSeverity(e.severity, t)}
+                    </span>
+                    <span className="rounded-full bg-white/10 px-2 py-0.5 text-xs text-zinc-200">
+                      {formatEventType(e.eventType, t)}
+                    </span>
+                    <span className={`rounded-full px-2 py-0.5 text-xs ${sourceClass(e.source)}`}>
+                      {formatSource(e.source, t)}
+                    </span>
+                    {e.requiresAck ? (
+                      <span className="rounded-full bg-white/10 px-2 py-0.5 text-xs text-white">
+                        {t("overview.ack")}
+                      </span>
+                    ) : null}
+                  </div>
+
+                  <div className="mt-2 truncate text-sm font-semibold text-white">
+                    {e.machineName ? `${e.machineName}: ` : ""}
+                    {e.title}
+                  </div>
+                  {e.description ? (
+                    <div className="mt-1 text-sm text-zinc-300">{e.description}</div>
+                  ) : null}
+                </div>
+                <div className="shrink-0 text-xs text-zinc-400">
+                  {secondsAgo(e.ts, locale, t("common.never"))}
+                </div>
+              </div>
+            </div>
+          ))}
+        </div>
+      )}
+    </div>
+  );
+}

app/(app)/overview/loading.tsx

@@ -0,0 +1,30 @@
+export default function OverviewLoading() {
+  return (
+    <div className="p-4 sm:p-6 space-y-6 animate-pulse">
+      <div className="flex flex-col gap-3 sm:flex-row sm:items-center sm:justify-between">
+        <div className="space-y-2">
+          <div className="h-6 w-40 rounded-lg bg-white/10" />
+          <div className="h-4 w-64 rounded-lg bg-white/5" />
+        </div>
+        <div className="h-9 w-40 rounded-xl border border-white/10 bg-white/5" />
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 xl:grid-cols-3">
+        {Array.from({ length: 3 }).map((_, idx) => (
+          <div key={idx} className="h-36 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-4">
+        {Array.from({ length: 4 }).map((_, idx) => (
+          <div key={idx} className="h-24 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+
+      <div className="grid grid-cols-1 gap-4 xl:grid-cols-3">
+        <div className="h-64 rounded-2xl border border-white/10 bg-white/5 xl:col-span-1" />
+        <div className="h-64 rounded-2xl border border-white/10 bg-white/5 xl:col-span-2" />
+      </div>
+    </div>
+  );
+}

app/(app)/overview/page.tsx

@@ -0,0 +1,55 @@
+import { redirect } from "next/navigation";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getOverviewSummary } from "@/lib/overview/getOverviewSummary";
+import type { getOverviewData } from "@/lib/overview/getOverviewData";
+import { logLine } from "@/lib/logger";
+import OverviewClient from "./OverviewClient";
+
+function toIso(value?: Date | null) {
+  return value ? value.toISOString() : null;
+}
+
+export default async function OverviewPage() {
+  const session = await requireSession();
+  if (!session) redirect("/login?next=/overview");
+
+  let machines: Awaited<ReturnType<typeof getOverviewData>>["machines"];
+  let events: Awaited<ReturnType<typeof getOverviewData>>["events"] = [];
+  try {
+    const data = await getOverviewSummary({ orgId: session.orgId });
+    machines = data.machines;
+  } catch (err) {
+    const message = err instanceof Error ? err.message : String(err);
+    const stack = err instanceof Error ? err.stack : undefined;
+    logLine("OverviewPage.getOverviewSummary.error", { message, stack });
+    console.error("[OverviewPage] getOverviewSummary:", err);
+    machines = [];
+  }
+
+  const initialMachines = machines.map((machine) => ({
+    ...machine,
+    createdAt: toIso(machine.createdAt),
+    updatedAt: toIso(machine.updatedAt),
+    latestHeartbeat: machine.latestHeartbeat
+      ? {
+          ...machine.latestHeartbeat,
+          ts: toIso(machine.latestHeartbeat.ts) ?? "",
+          tsServer: toIso(machine.latestHeartbeat.tsServer),
+        }
+      : null,
+    latestKpi: machine.latestKpi
+      ? {
+          ...machine.latestKpi,
+          ts: toIso(machine.latestKpi.ts) ?? "",
+        }
+      : null,
+  }));
+
+  const initialEvents = events.map((event) => ({
+    ...event,
+    ts: event.ts ? event.ts.toISOString() : "",
+    machineName: event.machineName ?? undefined,
+  }));
+
+  return <OverviewClient initialMachines={initialMachines} initialEvents={initialEvents} />;
+}

app/(app)/overview/types.ts

@@ -0,0 +1,45 @@
+export type Heartbeat = {
+  ts: string;
+  tsServer?: string | null;
+  status: string;
+  message?: string | null;
+  ip?: string | null;
+  fwVersion?: string | null;
+};
+
+export type Kpi = {
+  ts: string;
+  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 type MachineRow = {
+  id: string;
+  name: string;
+  code?: string | null;
+  location?: string | null;
+  latestHeartbeat: Heartbeat | null;
+  latestKpi?: Kpi | null;
+};
+
+export type EventRow = {
+  id: string;
+  ts: string;
+  topic?: string;
+  eventType: string;
+  severity: string;
+  title: string;
+  description?: string | null;
+  requiresAck: boolean;
+  machineId?: string;
+  machineName?: string;
+  source: "ingested";
+};

app/(app)/recap/RecapGridClient.tsx

@@ -0,0 +1,154 @@
+"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");
+  if (status === "idle") return t("recap.status.idle");
+  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", "idle", "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/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/RecapPageSkeletons.tsx

@@ -0,0 +1,30 @@
+/**
+ * Shared markup for loading states (used by `loading.tsx` and explicit `<Suspense>` in pages)
+ * so the recap UI always shows the same skeleton while server data is pending.
+ */
+export function RecapGridPageSkeleton() {
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-4 h-24 animate-pulse rounded-2xl border border-white/10 bg-black/40" />
+      <div className="grid grid-cols-1 gap-4 sm:grid-cols-2 xl:grid-cols-3">
+        {Array.from({ length: 6 }).map((_, index) => (
+          <div key={index} className="h-[220px] animate-pulse rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+    </div>
+  );
+}
+
+export function RecapDetailPageSkeleton() {
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="h-16 animate-pulse rounded-2xl border border-white/10 bg-black/40" />
+      <div className="mt-4 grid grid-cols-1 gap-3 sm:grid-cols-2 xl:grid-cols-4">
+        {Array.from({ length: 4 }).map((_, index) => (
+          <div key={index} className="h-24 animate-pulse rounded-2xl border border-white/10 bg-black/30" />
+        ))}
+      </div>
+      <div className="mt-4 h-48 animate-pulse rounded-2xl border border-white/10 bg-black/30" />
+    </div>
+  );
+}

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

@@ -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)/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)/recap/[machineId]/loading.tsx

@@ -0,0 +1,5 @@
+import { RecapDetailPageSkeleton } from "../RecapPageSkeletons";
+
+export default function LoadingRecapDetail() {
+  return <RecapDetailPageSkeleton />;
+}

app/(app)/recap/[machineId]/page.tsx

@@ -0,0 +1,51 @@
+import { Suspense } from "react";
+import { notFound, redirect } from "next/navigation";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getRecapMachineDetailCached, parseRecapDetailRangeInput } from "@/lib/recap/redesign";
+import { RecapDetailPageSkeleton } from "../RecapPageSkeletons";
+import RecapDetailClient from "./RecapDetailClient";
+
+async function RecapDetailData({
+  params,
+  searchParams,
+}: {
+  params: Promise<{ machineId: string }>;
+  searchParams?: Promise<Record<string, string | string[] | undefined>>;
+}) {
+  const session = await requireSession();
+  const { machineId } = await params;
+  if (!session) redirect(`/login?next=/recap/${machineId}`);
+
+  const rawSearchParams = (await searchParams) ?? {};
+  const input = parseRecapDetailRangeInput(rawSearchParams);
+
+  const initialData = await getRecapMachineDetailCached({
+    orgId: session.orgId,
+    machineId,
+    input,
+  });
+
+  if (!initialData) notFound();
+
+  return (
+    <RecapDetailClient
+      key={`${machineId}:${initialData.range.mode}:${initialData.range.start}:${initialData.range.end}`}
+      machineId={machineId}
+      initialData={initialData}
+    />
+  );
+}
+
+export default function RecapMachineDetailPage({
+  params,
+  searchParams,
+}: {
+  params: Promise<{ machineId: string }>;
+  searchParams?: Promise<Record<string, string | string[] | undefined>>;
+}) {
+  return (
+    <Suspense fallback={<RecapDetailPageSkeleton />}>
+      <RecapDetailData params={params} searchParams={searchParams} />
+    </Suspense>
+  );
+}

app/(app)/recap/loading.tsx

@@ -0,0 +1,5 @@
+import { RecapGridPageSkeleton } from "./RecapPageSkeletons";
+
+export default function LoadingRecapGrid() {
+  return <RecapGridPageSkeleton />;
+}

app/(app)/recap/page.tsx

@@ -0,0 +1,26 @@
+import { Suspense } from "react";
+import { redirect } from "next/navigation";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getRecapSummaryCached } from "@/lib/recap/redesign";
+import RecapGridClient from "./RecapGridClient";
+import { RecapGridPageSkeleton } from "./RecapPageSkeletons";
+
+async function RecapGridData() {
+  const session = await requireSession();
+  if (!session) redirect("/login?next=/recap");
+
+  const initialData = await getRecapSummaryCached({
+    orgId: session.orgId,
+    hours: 24,
+  });
+
+  return <RecapGridClient initialData={initialData} />;
+}
+
+export default function RecapPage() {
+  return (
+    <Suspense fallback={<RecapGridPageSkeleton />}>
+      <RecapGridData />
+    </Suspense>
+  );
+}

app/(app)/reports/ReportsCharts.tsx

@@ -0,0 +1,256 @@
+"use client";
+
+import {
+  Bar,
+  BarChart,
+  CartesianGrid,
+  Cell,
+  Line,
+  LineChart,
+  ResponsiveContainer,
+  Tooltip,
+  XAxis,
+  YAxis,
+} from "recharts";
+
+type Translator = (key: string, vars?: Record<string, string | number>) => string;
+type TooltipPayload<T> = { payload?: T; name?: string; value?: number | string };
+type SimpleTooltipProps<T> = {
+  active?: boolean;
+  payload?: Array<TooltipPayload<T>>;
+  label?: string | number;
+};
+
+type ChartPoint = { ts: string; label: string; value: number | null };
+type CycleHistogramRow = {
+  label: string;
+  count: number;
+  rangeStart?: number;
+  rangeEnd?: number;
+  overflow?: "low" | "high";
+  minValue?: number;
+  maxValue?: number;
+};
+
+function CycleTooltip({ active, payload, t }: SimpleTooltipProps<CycleHistogramRow> & { t: Translator }) {
+  if (!active || !payload?.length) return null;
+  const p = payload[0]?.payload;
+  if (!p) return null;
+
+  let detail = "";
+  if (p.overflow === "low") {
+    detail = `${t("reports.tooltip.below")} ${p.rangeEnd?.toFixed(1)}s`;
+  } else if (p.overflow === "high") {
+    detail = `${t("reports.tooltip.above")} ${p.rangeStart?.toFixed(1)}s`;
+  } else if (p.rangeStart != null && p.rangeEnd != null) {
+    detail = `${p.rangeStart.toFixed(1)}s - ${p.rangeEnd.toFixed(1)}s`;
+  }
+
+  const extreme =
+    p.overflow && (p.minValue != null || p.maxValue != null)
+      ? `${t("reports.tooltip.extremes")}: ${p.minValue?.toFixed(1) ?? "--"}s - ${p.maxValue?.toFixed(1) ?? "--"}s`
+      : "";
+
+  return (
+    <div className="rounded-xl border border-white/10 bg-zinc-950/95 px-4 py-3 shadow-lg">
+      <div className="text-sm font-semibold text-white">{p.label}</div>
+      <div className="mt-2 space-y-1 text-xs text-zinc-300">
+        <div>
+          {t("reports.tooltip.cycles")}: <span className="text-white">{p.count}</span>
+        </div>
+        {detail ? (
+          <div>
+            {t("reports.tooltip.range")}: <span className="text-white">{detail}</span>
+          </div>
+        ) : null}
+        {extreme ? <div className="text-zinc-400">{extreme}</div> : null}
+      </div>
+    </div>
+  );
+}
+
+function DowntimeTooltip({
+  active,
+  payload,
+  t,
+}: SimpleTooltipProps<{ name?: string; value?: number }> & { t: Translator }) {
+  if (!active || !payload?.length) return null;
+  const row = payload[0]?.payload ?? {};
+  const label = row.name ?? payload[0]?.name ?? "";
+  const value = row.value ?? payload[0]?.value ?? 0;
+
+  return (
+    <div className="rounded-xl border border-white/10 bg-zinc-950/95 px-4 py-3 shadow-lg">
+      <div className="text-sm font-semibold text-white">{label}</div>
+      <div className="mt-2 text-xs text-zinc-300">
+        {t("reports.tooltip.downtime")}: <span className="text-white">{Number(value)} min</span>
+      </div>
+    </div>
+  );
+}
+
+export default function ReportsCharts({
+  oeeSeries,
+  downtimeSeries,
+  downtimeColors,
+  cycleHistogram,
+  scrapSeries,
+  lossRows,
+  locale,
+  t,
+}: {
+  oeeSeries: ChartPoint[];
+  downtimeSeries: { name: string; value: number }[];
+  downtimeColors: Record<string, string>;
+  cycleHistogram: CycleHistogramRow[];
+  scrapSeries: ChartPoint[];
+  lossRows: Array<{ label: string; value: string }>;
+  locale: string;
+  t: Translator;
+}) {
+  return (
+    <>
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-2">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.oeeTrend")}</div>
+          <div className="h-[260px] rounded-2xl border border-white/10 bg-black/25 p-4">
+            {oeeSeries.length ? (
+              <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+                <LineChart data={oeeSeries}>
+                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)" }} />
+                  <YAxis domain={[0, 100]} tick={{ fill: "var(--app-chart-tick)" }} />
+                  <Tooltip
+                    contentStyle={{
+                      background: "var(--app-chart-tooltip-bg)",
+                      border: "1px solid var(--app-chart-tooltip-border)",
+                    }}
+                    labelStyle={{ color: "var(--app-chart-label)" }}
+                    labelFormatter={(_, payload) => {
+                      const row = payload?.[0]?.payload;
+                      return row?.ts ? new Date(row.ts).toLocaleString(locale) : "";
+                    }}
+                    formatter={(val: number | string | undefined) => [
+                      val == null ? "--" : `${Number(val).toFixed(1)}%`,
+                      "OEE",
+                    ]}
+                  />
+                  <Line
+                    type="linear"
+                    dataKey="value"
+                    stroke="#34d399"
+                    dot={false}
+                    strokeWidth={2}
+                    connectNulls={false}
+                  />
+                </LineChart>
+              </ResponsiveContainer>
+            ) : (
+              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
+                {t("reports.noTrend")}
+              </div>
+            )}
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.downtimePareto")}</div>
+          <div className="h-[260px] rounded-2xl border border-white/10 bg-black/25 p-4">
+            {downtimeSeries.length ? (
+              <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+                <BarChart data={downtimeSeries}>
+                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                  <XAxis dataKey="name" tick={{ fill: "var(--app-chart-tick)" }} />
+                  <YAxis tick={{ fill: "var(--app-chart-tick)" }} />
+                  <Tooltip content={<DowntimeTooltip t={t} />} />
+                  <Bar dataKey="value" radius={[10, 10, 0, 0]} isAnimationActive={false}>
+                    {downtimeSeries.map((row, idx) => (
+                      <Cell key={`${row.name}-${idx}`} fill={downtimeColors[row.name] ?? "#94a3b8"} />
+                    ))}
+                  </Bar>
+                </BarChart>
+              </ResponsiveContainer>
+            ) : (
+              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
+                {t("reports.noTrend")}
+              </div>
+            )}
+          </div>
+        </div>
+      </div>
+
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-3">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.cycleDistribution")}</div>
+          <div className="h-[220px] rounded-2xl border border-white/10 bg-black/25 p-4">
+            {cycleHistogram.length ? (
+              <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+                <BarChart data={cycleHistogram}>
+                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)", fontSize: 10 }} />
+                  <YAxis tick={{ fill: "var(--app-chart-tick)" }} />
+                  <Tooltip content={<CycleTooltip t={t} />} />
+                  <Bar dataKey="count" radius={[8, 8, 0, 0]} fill="#60a5fa" isAnimationActive={false} />
+                </BarChart>
+              </ResponsiveContainer>
+            ) : (
+              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
+                {t("reports.noCycle")}
+              </div>
+            )}
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.scrapTrend")}</div>
+          <div className="h-[220px] rounded-2xl border border-white/10 bg-black/25 p-4">
+            {scrapSeries.length ? (
+              <ResponsiveContainer width="100%" height="100%" minHeight={200}>
+                <LineChart data={scrapSeries}>
+                  <CartesianGrid strokeDasharray="3 3" stroke="var(--app-chart-grid)" />
+                  <XAxis dataKey="label" tick={{ fill: "var(--app-chart-tick)" }} />
+                  <YAxis domain={[0, 100]} tick={{ fill: "var(--app-chart-tick)" }} />
+                  <Tooltip
+                    contentStyle={{
+                      background: "var(--app-chart-tooltip-bg)",
+                      border: "1px solid var(--app-chart-tooltip-border)",
+                    }}
+                    labelStyle={{ color: "var(--app-chart-label)" }}
+                    labelFormatter={(_, payload) => {
+                      const row = payload?.[0]?.payload;
+                      return row?.ts ? new Date(row.ts).toLocaleString(locale) : "";
+                    }}
+                    formatter={(val: number | string | undefined) => [
+                      val == null ? "--" : `${Number(val).toFixed(1)}%`,
+                      t("reports.scrapRate"),
+                    ]}
+                  />
+                  <Line type="monotone" dataKey="value" stroke="#f97316" dot={false} strokeWidth={2} />
+                </LineChart>
+              </ResponsiveContainer>
+            ) : (
+              <div className="flex h-full items-center justify-center text-sm text-zinc-500">
+                {t("reports.noDowntime")}
+              </div>
+            )}
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-2 text-sm font-semibold text-white">{t("reports.topLossDrivers")}</div>
+          <div className="space-y-3 text-sm text-zinc-300">
+            {lossRows.map((row) => (
+              <div
+                key={row.label}
+                className="flex items-center justify-between rounded-xl border border-white/10 bg-black/20 p-3"
+              >
+                <span>{row.label}</span>
+                <span className="text-xs text-zinc-400">{row.value}</span>
+              </div>
+            ))}
+          </div>
+        </div>
+      </div>
+    </>
+  );
+}

app/(app)/reports/ReportsPageClient.tsx

@@ -0,0 +1,706 @@
+"use client";
+
+import { Suspense, lazy, useEffect, useMemo, useState } from "react";
+import { useI18n } from "@/lib/i18n/useI18n";
+
+const ReportsCharts = lazy(() => import("./ReportsCharts"));
+
+type RangeKey = "24h" | "7d" | "30d" | "custom";
+
+type ReportSummary = {
+  oeeAvg: number | null;
+  availabilityAvg: number | null;
+  performanceAvg: number | null;
+  qualityAvg: number | null;
+  goodTotal: number | null;
+  scrapTotal: number | null;
+  targetTotal: number | null;
+  scrapRate: number | null;
+  topScrapSku?: string | null;
+  topScrapWorkOrder?: string | null;
+};
+
+type ReportDowntime = {
+  macrostopSec: number;
+  microstopSec: number;
+  slowCycleCount: number;
+  qualitySpikeCount: number;
+  performanceDegradationCount: number;
+  oeeDropCount: number;
+};
+
+type ReportTrendPoint = { t: string; v: number | null };
+
+type ReportPayload = {
+  summary: ReportSummary;
+  downtime: ReportDowntime;
+  trend: {
+    oee: ReportTrendPoint[];
+    availability: ReportTrendPoint[];
+    performance: ReportTrendPoint[];
+    quality: ReportTrendPoint[];
+    scrapRate: ReportTrendPoint[];
+  };
+  distribution: {
+    cycleTime: {
+      label: string;
+      count: number;
+      rangeStart?: number;
+      rangeEnd?: number;
+      overflow?: "low" | "high";
+      minValue?: number;
+      maxValue?: number;
+    }[];
+  };
+  insights?: string[];
+};
+
+type MachineOption = { id: string; name: string };
+type FilterOptions = { workOrders: string[]; skus: string[] };
+type Translator = (key: string, vars?: Record<string, string | number>) => string;
+
+function fmtPct(v?: number | null) {
+  if (v === null || v === undefined || Number.isNaN(v)) return "--";
+  return `${v.toFixed(1)}%`;
+}
+
+function fmtDuration(sec?: number | null) {
+  if (!sec) return "--";
+  const h = Math.floor(sec / 3600);
+  const m = Math.floor((sec % 3600) / 60);
+  if (h > 0) return `${h}h ${m}m`;
+  return `${m}m`;
+}
+
+function downsample<T>(rows: T[], max: number) {
+  if (rows.length <= max) return rows;
+  const step = Math.ceil(rows.length / max);
+  return rows.filter((_, idx) => idx % step === 0);
+}
+
+function downsampleTrendPreserveGaps(rows: ReportTrendPoint[], max: number) {
+  if (rows.length <= max) return rows;
+  const step = Math.ceil(rows.length / max);
+  const picked = new Set<number>();
+
+  picked.add(0);
+  picked.add(rows.length - 1);
+  for (let idx = 0; idx < rows.length; idx += step) picked.add(idx);
+
+  // Keep both sides of null/non-null transitions so chart gaps remain visible.
+  for (let idx = 1; idx < rows.length; idx += 1) {
+    const prevIsNull = rows[idx - 1]?.v == null;
+    const currIsNull = rows[idx]?.v == null;
+    if (prevIsNull !== currIsNull) {
+      picked.add(idx - 1);
+      picked.add(idx);
+    }
+  }
+
+  return [...picked]
+    .sort((a, b) => a - b)
+    .map((idx) => rows[idx])
+    .filter((row): row is ReportTrendPoint => row != null);
+}
+
+function formatTickLabel(ts: string, range: RangeKey) {
+  const d = new Date(ts);
+  if (Number.isNaN(d.getTime())) return ts;
+  const hh = String(d.getHours()).padStart(2, "0");
+  const mm = String(d.getMinutes()).padStart(2, "0");
+  const month = String(d.getMonth() + 1).padStart(2, "0");
+  const day = String(d.getDate()).padStart(2, "0");
+  if (range === "24h") return `${hh}:${mm}`;
+  return `${month}-${day}`;
+}
+
+function ReportsChartsSkeleton() {
+  return (
+    <>
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-2">
+        {Array.from({ length: 2 }).map((_, idx) => (
+          <div key={idx} className="h-[320px] rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-3">
+        {Array.from({ length: 3 }).map((_, idx) => (
+          <div key={idx} className="h-[280px] rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+    </>
+  );
+}
+
+function buildCsv(report: ReportPayload, t: Translator) {
+  const rows = new Map<string, Record<string, string | number | null>>();
+  const addSeries = (series: ReportTrendPoint[], key: string) => {
+    for (const p of series) {
+      const row = rows.get(p.t) ?? { timestamp: p.t };
+      row[key] = p.v;
+      rows.set(p.t, row);
+    }
+  };
+
+  addSeries(report.trend.oee, "oee");
+  addSeries(report.trend.availability, "availability");
+  addSeries(report.trend.performance, "performance");
+  addSeries(report.trend.quality, "quality");
+  addSeries(report.trend.scrapRate, "scrapRate");
+
+  const ordered = [...rows.values()].sort((a, b) => {
+    const at = new Date(String(a.timestamp)).getTime();
+    const bt = new Date(String(b.timestamp)).getTime();
+    return at - bt;
+  });
+
+  const header = ["timestamp", "oee", "availability", "performance", "quality", "scrapRate"].join(",");
+  const lines = ordered.map((row) =>
+    [
+      row.timestamp,
+      row.oee ?? "",
+      row.availability ?? "",
+      row.performance ?? "",
+      row.quality ?? "",
+      row.scrapRate ?? "",
+    ]
+      .map((v) => (v == null ? "" : String(v)))
+      .join(",")
+  );
+
+  const summary = report.summary;
+  const downtime = report.downtime;
+
+  const sectionLines: string[] = [];
+  sectionLines.push(
+    [t("reports.csv.section"), t("reports.csv.key"), t("reports.csv.value")].join(",")
+  );
+  const addRow = (section: string, key: string, value: string | number | null | undefined) => {
+    sectionLines.push(
+      [section, key, value == null ? "" : String(value)]
+        .map((v) => (v.includes(",") ? `"${v.replace(/\"/g, '""')}"` : v))
+        .join(",")
+    );
+  };
+
+  addRow("summary", "oeeAvg", summary.oeeAvg);
+  addRow("summary", "availabilityAvg", summary.availabilityAvg);
+  addRow("summary", "performanceAvg", summary.performanceAvg);
+  addRow("summary", "qualityAvg", summary.qualityAvg);
+  addRow("summary", "goodTotal", summary.goodTotal);
+  addRow("summary", "scrapTotal", summary.scrapTotal);
+  addRow("summary", "targetTotal", summary.targetTotal);
+  addRow("summary", "scrapRate", summary.scrapRate);
+  addRow("summary", "topScrapSku", summary.topScrapSku ?? "");
+  addRow("summary", "topScrapWorkOrder", summary.topScrapWorkOrder ?? "");
+
+  addRow("loss_drivers", "macrostopSec", downtime.macrostopSec);
+  addRow("loss_drivers", "microstopSec", downtime.microstopSec);
+  addRow("loss_drivers", "slowCycleCount", downtime.slowCycleCount);
+  addRow("loss_drivers", "qualitySpikeCount", downtime.qualitySpikeCount);
+  addRow("loss_drivers", "performanceDegradationCount", downtime.performanceDegradationCount);
+  addRow("loss_drivers", "oeeDropCount", downtime.oeeDropCount);
+
+  for (const bin of report.distribution.cycleTime) {
+    addRow("cycle_distribution", bin.label, bin.count);
+  }
+
+  if (report.insights?.length) {
+    report.insights.forEach((note, idx) => addRow("insights", String(idx + 1), note));
+  }
+
+  return [header, ...lines, "", ...sectionLines].join("\n");
+}
+
+function downloadText(filename: string, content: string) {
+  const blob = new Blob([content], { type: "text/csv;charset=utf-8;" });
+  const url = URL.createObjectURL(blob);
+  const link = document.createElement("a");
+  link.href = url;
+  link.setAttribute("download", filename);
+  document.body.appendChild(link);
+  link.click();
+  document.body.removeChild(link);
+  URL.revokeObjectURL(url);
+}
+
+function buildPdfHtml(
+  report: ReportPayload,
+  rangeLabel: string,
+  filters: { machine: string; workOrder: string; sku: string },
+  t: Translator
+) {
+  const summary = report.summary;
+  const downtime = report.downtime;
+  const cycleBins = report.distribution.cycleTime;
+  const insights = report.insights ?? [];
+
+  return `
+<!doctype html>
+<html>
+<head>
+  <meta charset="utf-8" />
+  <title>${t("reports.pdf.title")}</title>
+  <style>
+    body { font-family: Arial, sans-serif; color: #111; margin: 24px; }
+    h1 { margin: 0 0 6px; }
+    .meta { margin-bottom: 16px; color: #555; }
+    .grid { display: grid; grid-template-columns: repeat(2, minmax(0, 1fr)); gap: 16px; }
+    .card { border: 1px solid #ddd; border-radius: 8px; padding: 12px; }
+    .label { color: #666; font-size: 12px; text-transform: uppercase; letter-spacing: .03em; }
+    .value { font-size: 18px; font-weight: 600; margin-top: 6px; }
+    table { width: 100%; border-collapse: collapse; margin-top: 12px; }
+    th, td { border: 1px solid #ddd; padding: 6px 8px; font-size: 12px; }
+    th { background: #f5f5f5; text-align: left; }
+  </style>
+</head>
+<body>
+  <h1>${t("reports.title")}</h1>
+  <div class="meta">${t("reports.pdf.range")}: ${rangeLabel} | ${t("reports.pdf.machine")}: ${filters.machine} | ${t("reports.pdf.workOrder")}: ${filters.workOrder} | ${t("reports.pdf.sku")}: ${filters.sku}</div>
+
+  <div class="grid">
+    <div class="card">
+      <div class="label">OEE (avg)</div>
+      <div class="value">${summary.oeeAvg != null ? summary.oeeAvg.toFixed(1) + "%" : "--"}</div>
+    </div>
+    <div class="card">
+      <div class="label">Availability (avg)</div>
+      <div class="value">${summary.availabilityAvg != null ? summary.availabilityAvg.toFixed(1) + "%" : "--"}</div>
+    </div>
+    <div class="card">
+      <div class="label">Performance (avg)</div>
+      <div class="value">${summary.performanceAvg != null ? summary.performanceAvg.toFixed(1) + "%" : "--"}</div>
+    </div>
+    <div class="card">
+      <div class="label">Quality (avg)</div>
+      <div class="value">${summary.qualityAvg != null ? summary.qualityAvg.toFixed(1) + "%" : "--"}</div>
+    </div>
+  </div>
+
+  <div class="card" style="margin-top: 16px;">
+    <div class="label">${t("reports.pdf.topLoss")}</div>
+    <table>
+      <thead>
+        <tr><th>${t("reports.pdf.metric")}</th><th>${t("reports.pdf.value")}</th></tr>
+      </thead>
+      <tbody>
+        <tr><td>${t("reports.loss.macrostop")} (sec)</td><td>${downtime.macrostopSec}</td></tr>
+        <tr><td>${t("reports.loss.microstop")} (sec)</td><td>${downtime.microstopSec}</td></tr>
+        <tr><td>${t("reports.loss.slowCycle")}</td><td>${downtime.slowCycleCount}</td></tr>
+        <tr><td>${t("reports.loss.qualitySpike")}</td><td>${downtime.qualitySpikeCount}</td></tr>
+        <tr><td>${t("reports.loss.perfDegradation")}</td><td>${downtime.performanceDegradationCount}</td></tr>
+        <tr><td>${t("reports.loss.oeeDrop")}</td><td>${downtime.oeeDropCount}</td></tr>
+      </tbody>
+    </table>
+  </div>
+
+  <div class="card" style="margin-top: 16px;">
+    <div class="label">${t("reports.pdf.qualitySummary")}</div>
+    <table>
+      <thead>
+        <tr><th>${t("reports.pdf.metric")}</th><th>${t("reports.pdf.value")}</th></tr>
+      </thead>
+      <tbody>
+        <tr><td>${t("reports.scrapRate")}</td><td>${summary.scrapRate != null ? summary.scrapRate.toFixed(1) + "%" : "--"}</td></tr>
+        <tr><td>${t("overview.good")}</td><td>${summary.goodTotal ?? "--"}</td></tr>
+        <tr><td>${t("overview.scrap")}</td><td>${summary.scrapTotal ?? "--"}</td></tr>
+        <tr><td>${t("overview.target")}</td><td>${summary.targetTotal ?? "--"}</td></tr>
+        <tr><td>${t("reports.topScrapSku")}</td><td>${summary.topScrapSku ?? "--"}</td></tr>
+        <tr><td>${t("reports.topScrapWorkOrder")}</td><td>${summary.topScrapWorkOrder ?? "--"}</td></tr>
+      </tbody>
+    </table>
+  </div>
+
+  <div class="card" style="margin-top: 16px;">
+    <div class="label">${t("reports.pdf.cycleDistribution")}</div>
+    <table>
+      <thead>
+        <tr><th>${t("reports.tooltip.range")}</th><th>${t("reports.tooltip.cycles")}</th></tr>
+      </thead>
+      <tbody>
+        ${cycleBins
+          .map((bin) => `<tr><td>${bin.label}</td><td>${bin.count}</td></tr>`)
+          .join("")}
+      </tbody>
+    </table>
+  </div>
+
+  <div class="card" style="margin-top: 16px;">
+    <div class="label">${t("reports.pdf.notes")}</div>
+    ${insights.length ? `<ul>${insights.map((n) => `<li>${n}</li>`).join("")}</ul>` : `<div>${t("reports.pdf.none")}</div>`}
+  </div>
+</body>
+</html>
+  `.trim();
+}
+
+export default function ReportsPageClient({
+  initialMachines = [],
+}: {
+  initialMachines?: MachineOption[];
+}) {
+  const { t, locale } = useI18n();
+  const [range, setRange] = useState<RangeKey>("24h");
+  const [report, setReport] = useState<ReportPayload | null>(null);
+  const [loading, setLoading] = useState(true);
+  const [error, setError] = useState<string | null>(null);
+  const [machines] = useState<MachineOption[]>(() => initialMachines);
+  const [filterOptions, setFilterOptions] = useState<FilterOptions>({ workOrders: [], skus: [] });
+  const [machineId, setMachineId] = useState("");
+  const [workOrderId, setWorkOrderId] = useState("");
+  const [sku, setSku] = useState("");
+
+  const rangeLabel = useMemo(() => {
+    if (range === "24h") return t("reports.rangeLabel.last24");
+    if (range === "7d") return t("reports.rangeLabel.last7");
+    if (range === "30d") return t("reports.rangeLabel.last30");
+    return t("reports.rangeLabel.custom");
+  }, [range, t]);
+
+  useEffect(() => {
+    let alive = true;
+    const controller = new AbortController();
+
+    async function load() {
+      setLoading(true);
+      setError(null);
+      try {
+        const params = new URLSearchParams({ range });
+        if (machineId) params.set("machineId", machineId);
+        if (workOrderId) params.set("workOrderId", workOrderId);
+        if (sku) params.set("sku", sku);
+
+        const res = await fetch(`/api/reports?${params.toString()}`, {
+          cache: "no-cache",
+          signal: controller.signal,
+        });
+        const json = await res.json();
+        if (!alive) return;
+        if (!res.ok || json?.ok === false) {
+          setError(json?.error ?? t("reports.error.failed"));
+          setReport(null);
+        } else {
+          setReport(json);
+        }
+      } catch {
+        if (!alive) return;
+        setError(t("reports.error.network"));
+        setReport(null);
+      } finally {
+        if (alive) setLoading(false);
+      }
+    }
+
+    load();
+    return () => {
+      alive = false;
+      controller.abort();
+    };
+  }, [range, machineId, workOrderId, sku, t]);
+
+  useEffect(() => {
+    let alive = true;
+    const controller = new AbortController();
+
+    async function loadFilters() {
+      try {
+        const params = new URLSearchParams({ range });
+        if (machineId) params.set("machineId", machineId);
+        const res = await fetch(`/api/reports/filters?${params.toString()}`, {
+          cache: "no-cache",
+          signal: controller.signal,
+        });
+        const json = await res.json();
+        if (!alive) return;
+        if (!res.ok || json?.ok === false) {
+          setFilterOptions({ workOrders: [], skus: [] });
+        } else {
+          setFilterOptions({
+            workOrders: json.workOrders ?? [],
+            skus: json.skus ?? [],
+          });
+        }
+      } catch {
+        if (!alive) return;
+        setFilterOptions({ workOrders: [], skus: [] });
+      }
+    }
+
+    loadFilters();
+    return () => {
+      alive = false;
+      controller.abort();
+    };
+  }, [range, machineId]);
+
+  const summary = report?.summary;
+  const downtime = report?.downtime;
+  const trend = report?.trend;
+  const distribution = report?.distribution;
+
+  const oeeSeries = useMemo(() => {
+    const rows = trend?.oee ?? [];
+    const trimmed = downsampleTrendPreserveGaps(rows, 600);
+    return trimmed.map((p) => ({
+      ts: p.t,
+      label: formatTickLabel(p.t, range),
+      value: p.v,
+    }));
+  }, [trend?.oee, range]);
+
+  const scrapSeries = useMemo(() => {
+    const rows = trend?.scrapRate ?? [];
+    const trimmed = downsample(rows, 600);
+    return trimmed.map((p) => ({
+      ts: p.t,
+      label: formatTickLabel(p.t, range),
+      value: p.v,
+    }));
+  }, [trend?.scrapRate, range]);
+
+  const cycleHistogram = useMemo(() => {
+    return distribution?.cycleTime ?? [];
+  }, [distribution?.cycleTime]);
+
+  const downtimeSeries = useMemo(() => {
+    if (!downtime) return [];
+    return [
+      { name: "Macrostop", value: Math.round(downtime.macrostopSec / 60) },
+      { name: "Microstop", value: Math.round(downtime.microstopSec / 60) },
+    ];
+  }, [downtime]);
+
+  const downtimeColors: Record<string, string> = {
+    Macrostop: "#FF3B5C",
+    Microstop: "#FF7A00",
+  };
+
+  const lossRows = useMemo(
+    () => [
+      { label: t("reports.loss.macrostop"), value: fmtDuration(downtime?.macrostopSec) },
+      { label: t("reports.loss.microstop"), value: fmtDuration(downtime?.microstopSec) },
+      { label: t("reports.loss.slowCycle"), value: downtime ? `${downtime.slowCycleCount}` : "--" },
+      { label: t("reports.loss.qualitySpike"), value: downtime ? `${downtime.qualitySpikeCount}` : "--" },
+      { label: t("reports.loss.oeeDrop"), value: downtime ? `${downtime.oeeDropCount}` : "--" },
+      {
+        label: t("reports.loss.perfDegradation"),
+        value: downtime ? `${downtime.performanceDegradationCount}` : "--",
+      },
+    ],
+    [downtime, t]
+  );
+
+  const machineLabel = useMemo(() => {
+    if (!machineId) return t("reports.filter.allMachines");
+    return machines.find((m) => m.id === machineId)?.name ?? machineId;
+  }, [machineId, machines, t]);
+
+  const workOrderLabel = workOrderId || t("reports.filter.allWorkOrders");
+  const skuLabel = sku || t("reports.filter.allSkus");
+
+  const handleExportCsv = () => {
+    if (!report) return;
+    const csv = buildCsv(report, t);
+    downloadText("reports.csv", csv);
+  };
+
+  const handleExportPdf = () => {
+    if (!report) return;
+    const html = buildPdfHtml(
+      report,
+      rangeLabel,
+      {
+        machine: machineLabel,
+        workOrder: workOrderLabel,
+        sku: skuLabel,
+      },
+      t
+    );
+
+    const win = window.open("", "_blank", "width=900,height=650");
+    if (!win) return;
+    win.document.open();
+    win.document.write(html);
+    win.document.close();
+    win.focus();
+    setTimeout(() => win.print(), 300);
+  };
+
+  return (
+    <div className="p-4 sm:p-6">
+      <div className="mb-6 flex flex-col gap-4 sm:flex-row sm:items-start sm:justify-between">
+        <div>
+          <h1 className="text-2xl font-semibold text-white">{t("reports.title")}</h1>
+          <p className="text-sm text-zinc-400">{t("reports.subtitle")}</p>
+        </div>
+
+        <div className="flex w-full flex-wrap items-center gap-2 sm:w-auto">
+          <button
+            onClick={handleExportCsv}
+            className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-sm text-white hover:bg-white/10 sm:w-auto"
+          >
+            {t("reports.exportCsv")}
+          </button>
+          <button
+            onClick={handleExportPdf}
+            className="w-full rounded-xl border border-white/10 bg-white/5 px-4 py-2 text-sm text-white hover:bg-white/10 sm:w-auto"
+          >
+            {t("reports.exportPdf")}
+          </button>
+        </div>
+      </div>
+
+      <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+        <div className="flex flex-wrap items-center justify-between gap-4">
+          <div className="text-sm font-semibold text-white">{t("reports.filters")}</div>
+          <div className="text-xs text-zinc-400">{rangeLabel}</div>
+        </div>
+
+        <div className="mt-4 grid grid-cols-1 gap-3 md:grid-cols-2 xl:grid-cols-4">
+          <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+            <div className="text-[11px] text-zinc-400">{t("reports.filter.range")}</div>
+            <div className="mt-2 flex flex-wrap gap-2">
+              {(["24h", "7d", "30d", "custom"] as RangeKey[]).map((k) => (
+                <button
+                  key={k}
+                  onClick={() => setRange(k)}
+                  className={`rounded-full border px-3 py-1 text-xs ${
+                    range === k
+                      ? "border-emerald-500/30 bg-emerald-500/15 text-emerald-200"
+                      : "border-white/10 bg-white/5 text-zinc-300 hover:bg-white/10"
+                  }`}
+                >
+                  {k.toUpperCase()}
+                </button>
+              ))}
+            </div>
+          </div>
+
+          <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+            <div className="text-[11px] text-zinc-400">{t("reports.filter.machine")}</div>
+            <select
+              value={machineId}
+              onChange={(e) => setMachineId(e.target.value)}
+              className="mt-2 w-full rounded-lg border border-white/10 bg-white/5 px-3 py-2 text-sm text-zinc-300"
+            >
+              <option value="">{t("reports.filter.allMachines")}</option>
+              {machines.map((m) => (
+                <option key={m.id} value={m.id}>
+                  {m.name}
+                </option>
+              ))}
+            </select>
+          </div>
+
+          <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+            <div className="text-[11px] text-zinc-400">{t("reports.filter.workOrder")}</div>
+            <input
+              list="work-order-list"
+              value={workOrderId}
+              onChange={(e) => setWorkOrderId(e.target.value)}
+              placeholder={t("reports.filter.allWorkOrders")}
+              className="mt-2 w-full rounded-lg border border-white/10 bg-white/5 px-3 py-2 text-sm text-zinc-300 placeholder:text-zinc-500"
+            />
+            <datalist id="work-order-list">
+              {filterOptions.workOrders.map((wo) => (
+                <option key={wo} value={wo} />
+              ))}
+            </datalist>
+          </div>
+
+          <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+            <div className="text-[11px] text-zinc-400">{t("reports.filter.sku")}</div>
+            <input
+              list="sku-list"
+              value={sku}
+              onChange={(e) => setSku(e.target.value)}
+              placeholder={t("reports.filter.allSkus")}
+              className="mt-2 w-full rounded-lg border border-white/10 bg-white/5 px-3 py-2 text-sm text-zinc-300 placeholder:text-zinc-500"
+            />
+            <datalist id="sku-list">
+              {filterOptions.skus.map((s) => (
+                <option key={s} value={s} />
+              ))}
+            </datalist>
+          </div>
+        </div>
+      </div>
+
+      <div className="mt-4">
+        {loading && <div className="text-sm text-zinc-400">{t("reports.loading")}</div>}
+        {error && !loading && (
+          <div className="rounded-2xl border border-red-500/20 bg-red-500/10 p-4 text-sm text-red-200">
+            {error}
+          </div>
+        )}
+      </div>
+
+      <div className="mt-4 grid grid-cols-1 gap-4 md:grid-cols-2 xl:grid-cols-4">
+        {[
+          { label: "OEE", value: fmtPct(summary?.oeeAvg), tone: "text-emerald-300" },
+          { label: "Availability", value: fmtPct(summary?.availabilityAvg), tone: "text-white" },
+          { label: "Performance", value: fmtPct(summary?.performanceAvg), tone: "text-white" },
+          { label: "Quality", value: fmtPct(summary?.qualityAvg), tone: "text-white" },
+        ].map((kpi) => (
+          <div key={kpi.label} className="rounded-2xl border border-white/10 bg-white/5 p-5">
+            <div className="text-xs text-zinc-400">{kpi.label} (avg)</div>
+            <div className={`mt-2 text-3xl font-semibold ${kpi.tone}`}>{kpi.value}</div>
+            <div className="mt-2 text-xs text-zinc-500">
+              {summary ? t("reports.kpi.note.withData") : t("reports.kpi.note.noData")}
+            </div>
+          </div>
+        ))}
+      </div>
+
+      <Suspense fallback={<ReportsChartsSkeleton />}>
+        <ReportsCharts
+          oeeSeries={oeeSeries}
+          downtimeSeries={downtimeSeries}
+          downtimeColors={downtimeColors}
+          cycleHistogram={cycleHistogram}
+          scrapSeries={scrapSeries}
+          lossRows={lossRows}
+          locale={locale}
+          t={t}
+        />
+      </Suspense>
+
+      <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-2">
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-3 text-sm font-semibold text-white">{t("reports.qualitySummary")}</div>
+          <div className="space-y-3 text-sm text-zinc-300">
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-xs text-zinc-400">{t("reports.scrapRate")}</div>
+              <div className="mt-1 text-lg font-semibold text-white">
+                {summary?.scrapRate != null ? fmtPct(summary.scrapRate) : "--"}
+              </div>
+            </div>
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-xs text-zinc-400">{t("reports.topScrapSku")}</div>
+              <div className="mt-1 text-sm text-zinc-300">{summary?.topScrapSku ?? "--"}</div>
+            </div>
+            <div className="rounded-xl border border-white/10 bg-black/20 p-3">
+              <div className="text-xs text-zinc-400">{t("reports.topScrapWorkOrder")}</div>
+              <div className="mt-1 text-sm text-zinc-300">{summary?.topScrapWorkOrder ?? "--"}</div>
+            </div>
+          </div>
+        </div>
+
+        <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+          <div className="mb-3 text-sm font-semibold text-white">{t("reports.notes")}</div>
+          <div className="rounded-xl border border-white/10 bg-black/20 p-4 text-sm text-zinc-300">
+            <div className="mb-2 text-xs text-zinc-400">{t("reports.notes.suggested")}</div>
+            {report?.insights && report.insights.length > 0 ? (
+              <div className="space-y-2">
+                {report.insights.map((note, idx) => (
+                  <div key={idx}>{note}</div>
+                ))}
+              </div>
+            ) : (
+              <div>{t("reports.notes.none")}</div>
+            )}
+          </div>
+        </div>
+      </div>
+    </div>
+  );
+}

app/(app)/reports/downtime-pareto/page.tsx

@@ -0,0 +1,16 @@
+import { redirect } from "next/navigation";
+
+export default async function LegacyDowntimeParetoPage({
+  searchParams,
+}: {
+  searchParams: Promise<Record<string, string | string[] | undefined>>;
+}) {
+  const params = await searchParams;
+  const qs = new URLSearchParams();
+  for (const [k, v] of Object.entries(params)) {
+    if (typeof v === "string") qs.set(k, v);
+    else if (Array.isArray(v)) v.forEach((vv) => qs.append(k, vv));
+  }
+  const q = qs.toString();
+  redirect(q ? `/downtime?${q}` : "/downtime");
+}

app/(app)/reports/loading.tsx

@@ -0,0 +1,21 @@
+export default function ReportsLoading() {
+  return (
+    <div className="p-4 sm:p-6 space-y-6">
+      <div className="h-8 w-56 rounded-lg bg-white/5" />
+      <div className="grid gap-4 lg:grid-cols-4">
+        {Array.from({ length: 4 }).map((_, idx) => (
+          <div key={idx} className="h-24 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+      <div className="grid gap-4 lg:grid-cols-[2fr_1fr]">
+        <div className="h-80 rounded-2xl border border-white/10 bg-white/5" />
+        <div className="h-80 rounded-2xl border border-white/10 bg-white/5" />
+      </div>
+      <div className="grid gap-4 lg:grid-cols-3">
+        {Array.from({ length: 3 }).map((_, idx) => (
+          <div key={idx} className="h-24 rounded-2xl border border-white/10 bg-white/5" />
+        ))}
+      </div>
+    </div>
+  );
+}

app/(app)/reports/page.tsx

@@ -0,0 +1,17 @@
+import { redirect } from "next/navigation";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import ReportsPageClient from "./ReportsPageClient";
+
+export default async function ReportsPage() {
+  const session = await requireSession();
+  if (!session) redirect("/login?next=/reports");
+
+  const machines = await prisma.machine.findMany({
+    where: { orgId: session.orgId },
+    orderBy: { createdAt: "desc" },
+    select: { id: true, name: true },
+  });
+
+  return <ReportsPageClient initialMachines={machines} />;
+}

app/api/alerts/contacts/[id]/route.ts

@@ -0,0 +1,89 @@
+import { NextResponse } from "next/server";
+import { z } from "zod";
+import { Prisma } from "@prisma/client";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+
+const roleScopeSchema = z.preprocess(
+  (value) => (typeof value === "string" ? value.trim().toUpperCase() : value),
+  z.enum(["MEMBER", "ADMIN", "OWNER", "CUSTOM"])
+);
+
+const contactPatchSchema = z.object({
+  name: z.string().trim().min(1).max(120).optional(),
+  roleScope: roleScopeSchema.optional(),
+  email: z.string().trim().email().optional().nullable(),
+  phone: z.string().trim().min(6).max(40).optional().nullable(),
+  userId: z.string().uuid().optional().nullable(),
+  eventTypes: z.array(z.string().trim().min(1)).optional().nullable(),
+  isActive: z.boolean().optional(),
+});
+
+function canManageAlerts(role?: string | null) {
+  return role === "OWNER";
+}
+
+export async function PATCH(req: Request, { params }: { params: Promise<{ id: string }> }) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageAlerts(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const body = await req.json().catch(() => ({}));
+  const parsed = contactPatchSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid contact payload" }, { status: 400 });
+  }
+
+  const { id } = await params;
+  const existing = await prisma.alertContact.findFirst({
+    where: { id, orgId: session.orgId },
+  });
+  if (!existing) {
+    return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+  }
+
+  const { userId: _userId, eventTypes, ...updateData } = parsed.data;
+  void _userId;
+  const normalizedEventTypes =
+    eventTypes === null ? Prisma.DbNull : eventTypes ?? undefined;
+  const data = normalizedEventTypes === undefined
+    ? updateData
+    : { ...updateData, eventTypes: normalizedEventTypes };
+  const updated = await prisma.alertContact.update({
+    where: { id },
+    data,
+  });
+
+  return NextResponse.json({ ok: true, contact: updated });
+}
+
+export async function DELETE(_req: Request, { params }: { params: Promise<{ id: string }> }) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageAlerts(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const { id } = await params;
+  const existing = await prisma.alertContact.findFirst({
+    where: { id, orgId: session.orgId },
+  });
+  if (!existing) {
+    return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+  }
+
+  await prisma.alertContact.delete({ where: { id } });
+  return NextResponse.json({ ok: true });
+}

app/api/alerts/contacts/route.ts

@@ -0,0 +1,77 @@
+import { NextResponse } from "next/server";
+import { z } from "zod";
+import { Prisma } from "@prisma/client";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+
+const roleScopeSchema = z.preprocess(
+  (value) => (typeof value === "string" ? value.trim().toUpperCase() : value),
+  z.enum(["MEMBER", "ADMIN", "OWNER", "CUSTOM"])
+);
+
+const contactSchema = z.object({
+  name: z.string().trim().min(1).max(120),
+  roleScope: roleScopeSchema,
+  email: z.string().trim().email().optional().nullable(),
+  phone: z.string().trim().min(6).max(40).optional().nullable(),
+  userId: z.string().uuid().optional().nullable(),
+  eventTypes: z.array(z.string().trim().min(1)).optional().nullable(),
+});
+
+function canManageAlerts(role?: string | null) {
+  return role === "OWNER";
+}
+
+export async function GET() {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const contacts = await prisma.alertContact.findMany({
+    where: { orgId: session.orgId },
+    orderBy: { createdAt: "asc" },
+  });
+
+  return NextResponse.json({ ok: true, contacts });
+}
+
+export async function POST(req: Request) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageAlerts(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const body = await req.json().catch(() => ({}));
+  const parsed = contactSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid contact payload" }, { status: 400 });
+  }
+
+  const data = parsed.data;
+  const hasChannel = !!(data.email || data.phone);
+  if (!data.userId && !hasChannel) {
+    return NextResponse.json({ ok: false, error: "email or phone required for external contact" }, { status: 400 });
+  }
+
+  const eventTypes =
+    data.eventTypes === null ? Prisma.DbNull : data.eventTypes ?? undefined;
+
+  const contact = await prisma.alertContact.create({
+    data: {
+      orgId: session.orgId,
+      userId: data.userId ?? null,
+      name: data.name,
+      roleScope: data.roleScope,
+      email: data.email ?? null,
+      phone: data.phone ?? null,
+      eventTypes,
+    },
+  });
+
+  return NextResponse.json({ ok: true, contact });
+}

app/api/alerts/inbox/route.ts

@@ -0,0 +1,48 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getAlertsInboxData } from "@/lib/alerts/getAlertsInboxData";
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (!Number.isNaN(n)) return new Date(n);
+  const d = new Date(input);
+  return Number.isNaN(d.getTime()) ? null : d;
+}
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "24h";
+  const machineId = url.searchParams.get("machineId") ?? undefined;
+  const location = url.searchParams.get("location") ?? undefined;
+  const eventType = url.searchParams.get("eventType") ?? undefined;
+  const severity = url.searchParams.get("severity") ?? undefined;
+  const status = url.searchParams.get("status") ?? undefined;
+  const shift = url.searchParams.get("shift") ?? undefined;
+  const includeUpdates = url.searchParams.get("includeUpdates") === "1";
+  const limitRaw = Number(url.searchParams.get("limit") ?? "200");
+  const limit = Number.isFinite(limitRaw) ? Math.min(Math.max(limitRaw, 1), 500) : 200;
+  const start = parseDate(url.searchParams.get("start"));
+  const end = parseDate(url.searchParams.get("end"));
+
+  const result = await getAlertsInboxData({
+    orgId: session.orgId,
+    range,
+    start,
+    end,
+    machineId,
+    location,
+    eventType,
+    severity,
+    status,
+    shift,
+    includeUpdates,
+    limit,
+  });
+
+  return NextResponse.json({ ok: true, range: result.range, events: result.events });
+}

app/api/alerts/notifications/route.ts

@@ -0,0 +1,23 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+
+export async function GET(req: Request) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const url = new URL(req.url);
+  const machineId = url.searchParams.get("machineId") || undefined;
+  const limit = Math.min(Number(url.searchParams.get("limit") ?? "50"), 200);
+
+  const notifications = await prisma.alertNotification.findMany({
+    where: {
+      orgId: session.orgId,
+      ...(machineId ? { machineId } : {}),
+    },
+    orderBy: { sentAt: "desc" },
+    take: Number.isFinite(limit) ? limit : 50,
+  });
+
+  return NextResponse.json({ ok: true, notifications });
+}

app/api/alerts/policy/route.ts

@@ -0,0 +1,55 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { AlertPolicySchema, DEFAULT_POLICY } from "@/lib/alerts/policy";
+
+function canManageAlerts(role?: string | null) {
+  return role === "OWNER";
+}
+
+export async function GET() {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  let policy = await prisma.alertPolicy.findUnique({
+    where: { orgId: session.orgId },
+    select: { policyJson: true },
+  });
+
+  if (!policy) {
+    await prisma.alertPolicy.create({
+      data: { orgId: session.orgId, policyJson: DEFAULT_POLICY },
+    });
+    policy = { policyJson: DEFAULT_POLICY };
+  }
+
+  const parsed = AlertPolicySchema.safeParse(policy.policyJson);
+  return NextResponse.json({ ok: true, policy: parsed.success ? parsed.data : DEFAULT_POLICY });
+}
+
+export async function PUT(req: Request) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageAlerts(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const body = await req.json().catch(() => ({}));
+  const parsed = AlertPolicySchema.safeParse(body?.policy ?? body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid policy payload" }, { status: 400 });
+  }
+
+  await prisma.alertPolicy.upsert({
+    where: { orgId: session.orgId },
+    create: { orgId: session.orgId, policyJson: parsed.data, updatedBy: session.userId },
+    update: { policyJson: parsed.data, updatedBy: session.userId },
+  });
+
+  return NextResponse.json({ ok: true });
+}

app/api/analytics/coverage/route.ts

@@ -0,0 +1,64 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { coerceDowntimeRange, rangeToStart } from "@/lib/analytics/downtimeRange";
+
+const bad = (status: number, error: string) =>
+  NextResponse.json({ ok: false, error }, { status });
+
+export async function GET(req: Request) {
+  const session = await requireSession();
+  if (!session) return bad(401, "Unauthorized");
+  const orgId = session.orgId;
+
+  const url = new URL(req.url);
+
+  // ✅ Parse params INSIDE handler
+  const range = coerceDowntimeRange(url.searchParams.get("range"));
+  const start = rangeToStart(range);
+
+  const machineId = url.searchParams.get("machineId"); // optional
+  const kind = (url.searchParams.get("kind") || "downtime").toLowerCase();
+
+  // coverage is only meaningful for downtime
+  if (kind !== "downtime") return bad(400, "Invalid kind (downtime only)");
+
+  let resolvedMachineId: string | null = null;
+
+  // If machineId provided, validate ownership
+  if (machineId) {
+    const m = await prisma.machine.findFirst({
+      where: { id: machineId, orgId },
+      select: { id: true },
+    });
+    if (!m) return bad(404, "Machine not found");
+    resolvedMachineId = m.id;
+  }
+
+  const rows = await prisma.reasonEntry.findMany({
+    where: {
+      orgId,
+      ...(resolvedMachineId ? { machineId: resolvedMachineId } : {}),
+      kind: "downtime",
+      capturedAt: { gte: start },
+    },
+    select: { durationSeconds: true, episodeId: true },
+  });
+
+  const receivedEpisodes = new Set(rows.map((r) => r.episodeId).filter(Boolean)).size;
+
+  const receivedMinutes =
+    Math.round((rows.reduce((acc, r) => acc + (r.durationSeconds ?? 0), 0) / 60) * 10) / 10;
+
+  return NextResponse.json({
+    ok: true,
+    orgId,
+    machineId: resolvedMachineId, // null => org-wide
+    range,
+    start,
+    receivedEpisodes,
+    receivedMinutes,
+    note:
+      "Control Tower received coverage (sync health). True coverage vs total downtime minutes can be added once CT has total downtime minutes per window.",
+  });
+}

app/api/analytics/downtime-events/route.ts

@@ -0,0 +1,159 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { coerceDowntimeRange, rangeToStart } from "@/lib/analytics/downtimeRange";
+import type { Prisma } from "@prisma/client";
+import {
+  applyDowntimeFilters,
+  loadDowntimeShiftContext,
+  normalizeMicrostopLtMin,
+  normalizeShiftFilter,
+  resolvePlannedFilter,
+} from "@/lib/analytics/downtimeFilters";
+
+const bad = (status: number, error: string) =>
+  NextResponse.json({ ok: false, error }, { status });
+
+function toISO(d: Date | null | undefined) {
+  return d ? d.toISOString() : null;
+}
+
+export async function GET(req: Request) {
+  // ✅ Session auth (cookie)
+  const session = await requireSession();
+  if (!session) return bad(401, "Unauthorized");
+  const orgId = session.orgId;
+
+  const url = new URL(req.url);
+
+  // ✅ Params
+  const range = coerceDowntimeRange(url.searchParams.get("range"));
+  const start = rangeToStart(range);
+
+  const machineId = url.searchParams.get("machineId"); // optional
+  const reasonCode = url.searchParams.get("reasonCode"); // optional
+  const includeMoldChange = url.searchParams.get("includeMoldChange") === "true";
+  const planned = resolvePlannedFilter(url.searchParams.get("planned"), includeMoldChange);
+  const shift = normalizeShiftFilter(url.searchParams.get("shift"));
+  const microstopLtMin = normalizeMicrostopLtMin(url.searchParams.get("microstopLtMin"));
+
+  const limitRaw = url.searchParams.get("limit");
+  const limit = Math.min(Math.max(Number(limitRaw || 200), 1), 500);
+
+  // Optional pagination: return events before this timestamp (capturedAt)
+  const before = url.searchParams.get("before"); // ISO string
+  const beforeDate = before ? new Date(before) : null;
+  if (before && isNaN(beforeDate!.getTime())) return bad(400, "Invalid before timestamp");
+
+  // ✅ If machineId provided, verify it belongs to this org
+  if (machineId) {
+    const m = await prisma.machine.findFirst({
+      where: { id: machineId, orgId },
+      select: { id: true },
+    });
+    if (!m) return bad(404, "Machine not found");
+  }
+
+  // ✅ Query ReasonEntry as the "episode" table for downtime
+  // We only return rows that have an episodeId (true downtime episodes)
+  const where: Prisma.ReasonEntryWhereInput = {
+    orgId,
+    kind: "downtime",
+    episodeId: { not: null },
+    capturedAt: {
+      gte: start,
+      ...(beforeDate ? { lt: beforeDate } : {}),
+    },
+    ...(machineId ? { machineId } : {}),
+    ...(reasonCode ? { reasonCode } : {}),
+  };
+
+  const scanTake = Math.min(Math.max(limit * 8, 1000), 5000);
+  const rowsRaw = await prisma.reasonEntry.findMany({
+    where,
+    orderBy: { capturedAt: "desc" },
+    take: scanTake,
+    select: {
+      id: true,
+      episodeId: true,
+      machineId: true,
+      reasonCode: true,
+      reasonLabel: true,
+      reasonText: true,
+      durationSeconds: true,
+      capturedAt: true,
+      episodeEndTs: true,
+      workOrderId: true,
+      meta: true,
+      createdAt: true,
+      machine: { select: { name: true } },
+    },
+  });
+
+  const shiftContext = shift === "all" ? null : await loadDowntimeShiftContext(orgId);
+  const rows = applyDowntimeFilters(rowsRaw, {
+    planned,
+    shift,
+    microstopLtMin,
+    shiftContext,
+  }).slice(0, limit);
+
+  const events = rows.map((r) => {
+    const startAt = r.capturedAt;
+    const endAt =
+      r.episodeEndTs ??
+      (r.durationSeconds != null
+        ? new Date(startAt.getTime() + r.durationSeconds * 1000)
+        : null);
+
+    const durationSeconds = r.durationSeconds ?? null;
+    const durationMinutes =
+      durationSeconds != null ? Math.round((durationSeconds / 60) * 10) / 10 : null;
+
+    return {
+      id: r.id,
+      episodeId: r.episodeId,
+      machineId: r.machineId,
+      machineName: r.machine?.name ?? null,
+
+      reasonCode: r.reasonCode,
+      reasonLabel: r.reasonLabel ?? r.reasonCode,
+      reasonText: r.reasonText ?? null,
+
+      durationSeconds,
+      durationMinutes,
+
+      startAt: toISO(startAt),
+      endAt: toISO(endAt),
+      capturedAt: toISO(r.capturedAt),
+
+      workOrderId: r.workOrderId ?? null,
+      meta: r.meta ?? null,
+      createdAt: toISO(r.createdAt),
+    };
+  });
+
+  const nextBefore =
+    events.length > 0
+      ? events[events.length - 1]?.capturedAt ?? null
+      : rowsRaw.length > 0
+      ? toISO(rowsRaw[rowsRaw.length - 1]?.capturedAt)
+      : null;
+
+  return NextResponse.json({
+    ok: true,
+    orgId,
+    range,
+    start,
+    machineId: machineId ?? null,
+    reasonCode: reasonCode ?? null,
+    planned,
+    shift,
+    microstopLtMin,
+    includeMoldChange,
+    limit,
+    before: before ?? null,
+    nextBefore, // pass this back for pagination
+    events,
+  });
+}

app/api/analytics/pareto/route.ts

@@ -0,0 +1,183 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { coerceDowntimeRange, rangeToStart } from "@/lib/analytics/downtimeRange";
+import {
+  applyDowntimeFilters,
+  loadDowntimeShiftContext,
+  normalizeMicrostopLtMin,
+  normalizeShiftFilter,
+  resolvePlannedFilter,
+} from "@/lib/analytics/downtimeFilters";
+
+const bad = (status: number, error: string) =>
+  NextResponse.json({ ok: false, error }, { status });
+
+export async function GET(req: Request) {
+  // ✅ Session auth (cookie)
+  const session = await requireSession();
+  if (!session) return bad(401, "Unauthorized");
+  const orgId = session.orgId;
+
+  const url = new URL(req.url);
+
+  // ✅ Parse params INSIDE handler
+  const range = coerceDowntimeRange(url.searchParams.get("range"));
+  const start = rangeToStart(range);
+
+  const machineId = url.searchParams.get("machineId"); // optional
+  const kind = (url.searchParams.get("kind") || "downtime").toLowerCase();
+  const includeMoldChange = url.searchParams.get("includeMoldChange") === "true";
+  const planned = resolvePlannedFilter(url.searchParams.get("planned"), includeMoldChange);
+  const shift = normalizeShiftFilter(url.searchParams.get("shift"));
+  const microstopLtMin = normalizeMicrostopLtMin(url.searchParams.get("microstopLtMin"));
+
+  if (kind !== "downtime" && kind !== "scrap" && kind !== "planned-downtime") {
+    return bad(400, "Invalid kind (downtime|scrap|planned-downtime)");
+  }
+
+  // ✅ If machineId provided, verify it belongs to this org
+  if (machineId) {
+    const m = await prisma.machine.findFirst({
+      where: { id: machineId, orgId },
+      select: { id: true },
+    });
+    if (!m) return bad(404, "Machine not found");
+  }
+
+  let itemsRaw: { reasonCode: string; reasonLabel: string; value: number; count: number }[] = [];
+
+  if (kind === "downtime" || kind === "planned-downtime") {
+    const baseRows = await prisma.reasonEntry.findMany({
+      where: {
+        orgId,
+        ...(machineId ? { machineId } : {}),
+        kind: "downtime",
+        capturedAt: { gte: start },
+      },
+      select: {
+        reasonCode: true,
+        reasonLabel: true,
+        durationSeconds: true,
+        capturedAt: true,
+        meta: true,
+        episodeId: true,
+      },
+    });
+
+    const effectivePlanned = kind === "planned-downtime" ? "planned" : planned;
+    const shiftContext = shift === "all" ? null : await loadDowntimeShiftContext(orgId);
+    const filteredRows = applyDowntimeFilters(baseRows, {
+      planned: effectivePlanned,
+      shift,
+      microstopLtMin,
+      shiftContext,
+    });
+
+    const grouped = new Map<string, { reasonCode: string; reasonLabel: string; durationSeconds: number; count: number }>();
+    for (const row of filteredRows) {
+      const key = `${row.reasonCode}:::${row.reasonLabel ?? row.reasonCode}`;
+      const slot =
+        grouped.get(key) ??
+        {
+          reasonCode: row.reasonCode,
+          reasonLabel: row.reasonLabel ?? row.reasonCode,
+          durationSeconds: 0,
+          count: 0,
+        };
+      slot.durationSeconds += Math.max(0, row.durationSeconds ?? 0);
+      slot.count += 1;
+      grouped.set(key, slot);
+    }
+
+    itemsRaw = [...grouped.values()]
+      .map((g) => ({
+        reasonCode: g.reasonCode,
+        reasonLabel: g.reasonLabel,
+        value: Math.round((g.durationSeconds / 60) * 10) / 10,
+        count: g.count,
+      }))
+      .filter((x) => x.value > 0 || x.count > 0);
+  } else {
+    // Scrap path unchanged.
+    const grouped = await prisma.reasonEntry.groupBy({
+      by: ["reasonCode", "reasonLabel"],
+      where: {
+        orgId,
+        ...(machineId ? { machineId } : {}),
+        kind,
+        capturedAt: { gte: start },
+      },
+      _sum: { scrapQty: true },
+      _count: { _all: true },
+    });
+
+    itemsRaw = grouped
+      .map((g) => ({
+        reasonCode: g.reasonCode,
+        reasonLabel: g.reasonLabel ?? g.reasonCode,
+        value: g._sum.scrapQty ?? 0,
+        count: g._count._all,
+      }))
+      .filter((x) => x.value > 0);
+  }
+
+  itemsRaw.sort((a, b) => b.value - a.value);
+
+  const total = itemsRaw.reduce((acc, x) => acc + x.value, 0);
+
+  let cum = 0;
+  let threshold80Index: number | null = null;
+
+  const rows = itemsRaw.map((x, idx) => {
+    const pctOfTotal = total > 0 ? (x.value / total) * 100 : 0;
+    cum += x.value;
+    const cumulativePct = total > 0 ? (cum / total) * 100 : 0;
+
+    if (threshold80Index === null && cumulativePct >= 80) threshold80Index = idx;
+
+    return {
+      reasonCode: x.reasonCode,
+      reasonLabel: x.reasonLabel,
+      minutesLost: kind === "downtime" || kind === "planned-downtime" ? x.value : undefined,
+      scrapQty: kind === "scrap" ? x.value : undefined,
+      pctOfTotal,
+      cumulativePct,
+      count: x.count,
+    };
+  });
+
+  const top3 = rows.slice(0, 3);
+  const threshold80 =
+    threshold80Index === null
+      ? null
+      : {
+          index: threshold80Index,
+          reasonCode: rows[threshold80Index].reasonCode,
+          reasonLabel: rows[threshold80Index].reasonLabel,
+        };
+
+  return NextResponse.json({
+    ok: true,
+    orgId,
+    machineId: machineId ?? null,
+    kind,
+    planned: kind === "downtime" ? planned : kind === "planned-downtime" ? "planned" : "all",
+    shift,
+    microstopLtMin,
+    includeMoldChange,
+    range,       // ✅ now defined correctly
+    start,       // ✅ now defined correctly
+    totalMinutesLost: kind === "downtime" || kind === "planned-downtime" ? total : undefined,
+    totalScrap: kind === "scrap" ? total : undefined,
+    rows,
+    top3,
+    threshold80,
+    // (optional) keep old shape if anything else uses it:
+    items: itemsRaw.map((x, i) => ({
+      ...x,
+      cumPct: rows[i]?.cumulativePct ?? 0,
+    })),
+    total,
+  });
+}

app/api/debug/logs/route.ts

@@ -0,0 +1,45 @@
+import type { NextRequest } from "next/server";
+import { NextResponse } from "next/server";
+import fs from "fs";
+import { getLogPath } from "@/lib/logger";
+
+const MAX_LINES = 100;
+
+/**
+ * GET /api/debug/logs?key=YOUR_DEBUG_LOGS_KEY
+ *
+ * Returns the last MAX_LINES from the app log file. Set DEBUG_LOGS_KEY in .env
+ * and call with ?key=... to view. If DEBUG_LOGS_KEY is unset, returns 401.
+ */
+export async function GET(req: NextRequest) {
+  const key = req.nextUrl.searchParams.get("key");
+  const secret = process.env.DEBUG_LOGS_KEY;
+
+  if (!secret || key !== secret) {
+    return NextResponse.json({ error: "Unauthorized" }, { status: 401 });
+  }
+
+  const logPath = getLogPath();
+  try {
+    const raw = fs.readFileSync(logPath, "utf8");
+    const lines = raw.split("\n").filter(Boolean);
+    const recent = lines.slice(-MAX_LINES);
+    return NextResponse.json({
+      logPath,
+      lines: recent.length,
+      entries: recent.map((line) => {
+        try {
+          return JSON.parse(line) as Record<string, unknown>;
+        } catch {
+          return { raw: line };
+        }
+      }),
+    });
+  } catch (err) {
+    const message = err instanceof Error ? err.message : String(err);
+    return NextResponse.json(
+      { error: "Failed to read log file", detail: message, logPath },
+      { status: 500 }
+    );
+  }
+}

app/api/debug/perf/route.ts

@@ -0,0 +1,31 @@
+import type { NextRequest } from "next/server";
+import { NextResponse } from "next/server";
+import { logLine } from "@/lib/logger";
+
+export const dynamic = "force-dynamic";
+
+type PerfPayload = {
+  event?: string;
+  data?: Record<string, unknown>;
+};
+
+export async function POST(req: NextRequest) {
+  try {
+    const body = (await req.json()) as PerfPayload;
+    const type = typeof body?.event === "string" ? body.event : "nav";
+    const data = body?.data && typeof body.data === "object" ? body.data : {};
+    const userAgent = req.headers.get("user-agent") ?? "";
+
+    logLine("perf.client", {
+      type,
+      userAgent,
+      ...data,
+    });
+
+    return NextResponse.json({ ok: true });
+  } catch (err) {
+    const message = err instanceof Error ? err.message : String(err);
+    logLine("perf.client.error", { message });
+    return NextResponse.json({ ok: false, error: "Bad payload" }, { status: 400 });
+  }
+}

app/api/downtime/actions/[id]/route.ts

@@ -0,0 +1,226 @@
+import { NextRequest, NextResponse } from "next/server";
+import { z } from "zod";
+import { Prisma } from "@prisma/client";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { buildDowntimeActionAssignedEmail, sendEmail } from "@/lib/email";
+import { getBaseUrl } from "@/lib/appUrl";
+
+const STATUS = ["open", "in_progress", "blocked", "done"] as const;
+const PRIORITY = ["low", "medium", "high"] as const;
+const DATE_RE = /^\d{4}-\d{2}-\d{2}$/;
+
+const updateSchema = z.object({
+  machineId: z.string().trim().min(1).optional().nullable(),
+  reasonCode: z.string().trim().min(1).max(64).optional().nullable(),
+  hmDay: z.number().int().min(0).max(6).optional().nullable(),
+  hmHour: z.number().int().min(0).max(23).optional().nullable(),
+  title: z.string().trim().min(1).max(160).optional(),
+  notes: z.string().trim().max(4000).optional().nullable(),
+  ownerUserId: z.string().trim().min(1).optional().nullable(),
+  dueDate: z.string().trim().regex(DATE_RE).optional().nullable(),
+  status: z.enum(STATUS).optional(),
+  priority: z.enum(PRIORITY).optional(),
+});
+
+function parseDueDate(value?: string | null) {
+  if (value === undefined) return undefined;
+  if (!value) return null;
+  return new Date(`${value}T00:00:00.000Z`);
+}
+
+function formatDueDate(value?: Date | null) {
+  if (!value) return null;
+  return value.toISOString().slice(0, 10);
+}
+
+function buildActionUrl(baseUrl: string, action: { machineId: string | null; reasonCode: string | null; hmDay: number | null; hmHour: number | null }) {
+  const params = new URLSearchParams();
+  if (action.machineId) params.set("machineId", action.machineId);
+  if (action.reasonCode) params.set("reasonCode", action.reasonCode);
+  if (action.hmDay != null && action.hmHour != null) {
+    params.set("hmDay", String(action.hmDay));
+    params.set("hmHour", String(action.hmHour));
+  }
+  const qs = params.toString();
+  return qs ? `${baseUrl}/downtime?${qs}` : `${baseUrl}/downtime`;
+}
+
+function serializeAction(action: {
+  id: string;
+  createdAt: Date;
+  updatedAt: Date;
+  machineId: string | null;
+  reasonCode: string | null;
+  hmDay: number | null;
+  hmHour: number | null;
+  title: string;
+  notes: string | null;
+  ownerUserId: string | null;
+  dueDate: Date | null;
+  status: string;
+  priority: string;
+  ownerUser?: { name: string | null; email: string } | null;
+}) {
+  return {
+    id: action.id,
+    createdAt: action.createdAt.toISOString(),
+    updatedAt: action.updatedAt.toISOString(),
+    machineId: action.machineId,
+    reasonCode: action.reasonCode,
+    hmDay: action.hmDay,
+    hmHour: action.hmHour,
+    title: action.title,
+    notes: action.notes ?? "",
+    ownerUserId: action.ownerUserId,
+    ownerName: action.ownerUser?.name ?? null,
+    ownerEmail: action.ownerUser?.email ?? null,
+    dueDate: formatDueDate(action.dueDate),
+    status: action.status,
+    priority: action.priority,
+  };
+}
+
+export async function PATCH(req: NextRequest, context: { params: Promise<{ id: string }> }) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const { id } = await context.params;
+  const body = await req.json().catch(() => ({}));
+  const parsed = updateSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid action payload" }, { status: 400 });
+  }
+
+  const data = parsed.data;
+  if (("hmDay" in data || "hmHour" in data) && (data.hmDay == null) !== (data.hmHour == null)) {
+    return NextResponse.json({ ok: false, error: "Heatmap requires hmDay and hmHour" }, { status: 400 });
+  }
+
+  const existing = await prisma.downtimeAction.findFirst({
+    where: { id, orgId: session.orgId },
+    include: { ownerUser: { select: { name: true, email: true } } },
+  });
+  if (!existing) {
+    return NextResponse.json({ ok: false, error: "Action not found" }, { status: 404 });
+  }
+
+  if (data.machineId) {
+    const machine = await prisma.machine.findFirst({
+      where: { id: data.machineId, orgId: session.orgId },
+      select: { id: true },
+    });
+    if (!machine) {
+      return NextResponse.json({ ok: false, error: "Invalid machineId" }, { status: 400 });
+    }
+  }
+
+  let ownerMembership: { user: { name: string | null; email: string } } | null = null;
+  if (data.ownerUserId) {
+    ownerMembership = await prisma.orgUser.findUnique({
+      where: { orgId_userId: { orgId: session.orgId, userId: data.ownerUserId } },
+      include: { user: { select: { name: true, email: true } } },
+    });
+    if (!ownerMembership) {
+      return NextResponse.json({ ok: false, error: "Invalid ownerUserId" }, { status: 400 });
+    }
+  }
+
+  let completedAt: Date | null | undefined = undefined;
+  if ("status" in data) {
+    completedAt = data.status === "done" ? existing.completedAt ?? new Date() : null;
+  }
+
+  const updateData: Prisma.DowntimeActionUncheckedUpdateInput = {};
+  let shouldResetReminder = false;
+  if ("machineId" in data) updateData.machineId = data.machineId;
+  if ("reasonCode" in data) updateData.reasonCode = data.reasonCode;
+  if ("hmDay" in data) updateData.hmDay = data.hmDay;
+  if ("hmHour" in data) updateData.hmHour = data.hmHour;
+  if ("title" in data) updateData.title = data.title?.trim();
+  if ("notes" in data) updateData.notes = data.notes == null ? null : data.notes.trim() || null;
+  if ("ownerUserId" in data) updateData.ownerUserId = data.ownerUserId;
+  if ("dueDate" in data) {
+    const nextDue = parseDueDate(data.dueDate);
+    const prev = formatDueDate(existing.dueDate);
+    const next = formatDueDate(nextDue ?? null);
+    updateData.dueDate = nextDue;
+    if (prev !== next) {
+      shouldResetReminder = true;
+    }
+  }
+  if ("status" in data) updateData.status = data.status;
+  if ("priority" in data) updateData.priority = data.priority;
+  if (completedAt !== undefined) updateData.completedAt = completedAt;
+  if (shouldResetReminder) {
+    updateData.reminderStage = null;
+    updateData.lastReminderAt = null;
+  }
+
+  const updated = await prisma.downtimeAction.update({
+    where: { id: existing.id },
+    data: updateData,
+    include: { ownerUser: { select: { name: true, email: true } } },
+  });
+
+  const ownerChanged = "ownerUserId" in data && data.ownerUserId !== existing.ownerUserId;
+  const dueChanged =
+    "dueDate" in data && formatDueDate(existing.dueDate) !== formatDueDate(updated.dueDate);
+
+  let emailSent = false;
+  let emailError: string | null = null;
+  if ((ownerChanged || dueChanged) && updated.ownerUser?.email) {
+    try {
+      const org = await prisma.org.findUnique({
+        where: { id: session.orgId },
+        select: { name: true },
+      });
+      const baseUrl = getBaseUrl(req);
+      const actionUrl = buildActionUrl(baseUrl, updated);
+      const content = buildDowntimeActionAssignedEmail({
+        appName: "MIS Control Tower",
+        orgName: org?.name || "your organization",
+        actionTitle: updated.title,
+        assigneeName: updated.ownerUser.name ?? updated.ownerUser.email,
+        dueDate: formatDueDate(updated.dueDate),
+        actionUrl,
+        priority: updated.priority,
+        status: updated.status,
+      });
+      await sendEmail({
+        to: updated.ownerUser.email,
+        subject: content.subject,
+        text: content.text,
+        html: content.html,
+      });
+      emailSent = true;
+    } catch (err: unknown) {
+      emailError = err instanceof Error ? err.message : "Failed to send assignment email";
+    }
+  }
+
+  return NextResponse.json({
+    ok: true,
+    action: serializeAction(updated),
+    emailSent,
+    emailError,
+  });
+}
+
+export async function DELETE(req: NextRequest, context: { params: Promise<{ id: string }> }) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const { id } = await context.params;
+  const existing = await prisma.downtimeAction.findFirst({
+    where: { id, orgId: session.orgId },
+    select: { id: true },
+  });
+  if (!existing) {
+    return NextResponse.json({ ok: false, error: "Action not found" }, { status: 404 });
+  }
+
+  await prisma.downtimeAction.delete({ where: { id: existing.id } });
+
+  return NextResponse.json({ ok: true });
+}

app/api/downtime/actions/reminders/route.ts

@@ -0,0 +1,123 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { buildDowntimeActionReminderEmail, sendEmail } from "@/lib/email";
+import { getBaseUrl } from "@/lib/appUrl";
+
+const DEFAULT_DUE_DAYS = 7;
+const DEFAULT_LIMIT = 100;
+const MS_PER_HOUR = 60 * 60 * 1000;
+
+type ReminderStage = "week" | "day" | "hour" | "overdue";
+
+function formatDueDate(value?: Date | null) {
+  if (!value) return null;
+  return value.toISOString().slice(0, 10);
+}
+
+function getReminderStage(dueDate: Date, now: Date): ReminderStage | null {
+  const diffMs = dueDate.getTime() - now.getTime();
+  if (diffMs <= 0) return "overdue";
+  if (diffMs <= MS_PER_HOUR) return "hour";
+  if (diffMs <= 24 * MS_PER_HOUR) return "day";
+  if (diffMs <= 7 * 24 * MS_PER_HOUR) return "week";
+  return null;
+}
+
+function buildActionUrl(baseUrl: string, action: { machineId: string | null; reasonCode: string | null; hmDay: number | null; hmHour: number | null }) {
+  const params = new URLSearchParams();
+  if (action.machineId) params.set("machineId", action.machineId);
+  if (action.reasonCode) params.set("reasonCode", action.reasonCode);
+  if (action.hmDay != null && action.hmHour != null) {
+    params.set("hmDay", String(action.hmDay));
+    params.set("hmHour", String(action.hmHour));
+  }
+  const qs = params.toString();
+  return qs ? `${baseUrl}/downtime?${qs}` : `${baseUrl}/downtime`;
+}
+
+async function authorizeRequest(req: Request) {
+  const secret = process.env.DOWNTIME_ACTION_REMINDER_SECRET;
+  if (!secret) {
+    const session = await requireSession();
+    return { ok: !!session };
+  }
+  const authHeader = req.headers.get("authorization") || "";
+  const token = authHeader.startsWith("Bearer ") ? authHeader.slice(7).trim() : null;
+  const urlToken = new URL(req.url).searchParams.get("token");
+  return { ok: token === secret || urlToken === secret };
+}
+
+export async function POST(req: Request) {
+  const auth = await authorizeRequest(req);
+  if (!auth.ok) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const sp = new URL(req.url).searchParams;
+  const dueInDays = Number(sp.get("dueInDays") || DEFAULT_DUE_DAYS);
+  const limit = Number(sp.get("limit") || DEFAULT_LIMIT);
+
+  const now = new Date();
+  const dueBy = new Date(now.getTime() + dueInDays * 24 * 60 * 60 * 1000);
+
+  const actions = await prisma.downtimeAction.findMany({
+    where: {
+      status: { not: "done" },
+      ownerUserId: { not: null },
+      dueDate: { not: null, lte: dueBy },
+    },
+    include: {
+      ownerUser: { select: { name: true, email: true } },
+      org: { select: { name: true } },
+    },
+    orderBy: { dueDate: "asc" },
+    take: Number.isFinite(limit) ? Math.max(1, Math.min(500, limit)) : DEFAULT_LIMIT,
+  });
+
+  const baseUrl = getBaseUrl(req);
+  const sentIds: string[] = [];
+  const failures: Array<{ id: string; error: string }> = [];
+
+  for (const action of actions) {
+    const email = action.ownerUser?.email;
+    if (!email) continue;
+    if (!action.dueDate) continue;
+    const stage = getReminderStage(action.dueDate, now);
+    if (!stage) continue;
+    if (action.reminderStage === stage) continue;
+    try {
+      const content = buildDowntimeActionReminderEmail({
+        appName: "MIS Control Tower",
+        orgName: action.org.name,
+        actionTitle: action.title,
+        assigneeName: action.ownerUser?.name ?? email,
+        dueDate: formatDueDate(action.dueDate),
+        actionUrl: buildActionUrl(baseUrl, action),
+        priority: action.priority,
+        status: action.status,
+      });
+      await sendEmail({
+        to: email,
+        subject: content.subject,
+        text: content.text,
+        html: content.html,
+      });
+      sentIds.push(action.id);
+      await prisma.downtimeAction.update({
+        where: { id: action.id },
+        data: { reminderStage: stage, lastReminderAt: now },
+      });
+    } catch (err: unknown) {
+      failures.push({
+        id: action.id,
+        error: err instanceof Error ? err.message : "Failed to send reminder email",
+      });
+    }
+  }
+
+  return NextResponse.json({
+    ok: true,
+    sent: sentIds.length,
+    failed: failures.length,
+    failures,
+  });
+}

app/api/downtime/actions/route.ts

@@ -0,0 +1,226 @@
+import { NextResponse } from "next/server";
+import { z } from "zod";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { buildDowntimeActionAssignedEmail, sendEmail } from "@/lib/email";
+import { getBaseUrl } from "@/lib/appUrl";
+
+const STATUS = ["open", "in_progress", "blocked", "done"] as const;
+const PRIORITY = ["low", "medium", "high"] as const;
+const DATE_RE = /^\d{4}-\d{2}-\d{2}$/;
+
+const createSchema = z.object({
+  machineId: z.string().trim().min(1).optional().nullable(),
+  reasonCode: z.string().trim().min(1).max(64).optional().nullable(),
+  hmDay: z.number().int().min(0).max(6).optional().nullable(),
+  hmHour: z.number().int().min(0).max(23).optional().nullable(),
+  title: z.string().trim().min(1).max(160),
+  notes: z.string().trim().max(4000).optional().nullable(),
+  ownerUserId: z.string().trim().min(1).optional().nullable(),
+  dueDate: z.string().trim().regex(DATE_RE).optional().nullable(),
+  status: z.enum(STATUS).optional(),
+  priority: z.enum(PRIORITY).optional(),
+});
+
+function parseDueDate(value?: string | null) {
+  if (!value) return null;
+  return new Date(`${value}T00:00:00.000Z`);
+}
+
+function formatDueDate(value?: Date | null) {
+  if (!value) return null;
+  return value.toISOString().slice(0, 10);
+}
+
+function buildActionUrl(baseUrl: string, action: { machineId: string | null; reasonCode: string | null; hmDay: number | null; hmHour: number | null }) {
+  const params = new URLSearchParams();
+  if (action.machineId) params.set("machineId", action.machineId);
+  if (action.reasonCode) params.set("reasonCode", action.reasonCode);
+  if (action.hmDay != null && action.hmHour != null) {
+    params.set("hmDay", String(action.hmDay));
+    params.set("hmHour", String(action.hmHour));
+  }
+  const qs = params.toString();
+  return qs ? `${baseUrl}/downtime?${qs}` : `${baseUrl}/downtime`;
+}
+
+function serializeAction(action: {
+  id: string;
+  createdAt: Date;
+  updatedAt: Date;
+  machineId: string | null;
+  reasonCode: string | null;
+  hmDay: number | null;
+  hmHour: number | null;
+  title: string;
+  notes: string | null;
+  ownerUserId: string | null;
+  dueDate: Date | null;
+  status: string;
+  priority: string;
+  ownerUser?: { name: string | null; email: string } | null;
+}) {
+  return {
+    id: action.id,
+    createdAt: action.createdAt.toISOString(),
+    updatedAt: action.updatedAt.toISOString(),
+    machineId: action.machineId,
+    reasonCode: action.reasonCode,
+    hmDay: action.hmDay,
+    hmHour: action.hmHour,
+    title: action.title,
+    notes: action.notes ?? "",
+    ownerUserId: action.ownerUserId,
+    ownerName: action.ownerUser?.name ?? null,
+    ownerEmail: action.ownerUser?.email ?? null,
+    dueDate: formatDueDate(action.dueDate),
+    status: action.status,
+    priority: action.priority,
+  };
+}
+
+export async function GET(req: Request) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const sp = new URL(req.url).searchParams;
+  const machineId = sp.get("machineId");
+  const reasonCode = sp.get("reasonCode");
+  const hmDayStr = sp.get("hmDay");
+  const hmHourStr = sp.get("hmHour");
+
+  const hmDay = hmDayStr != null ? Number(hmDayStr) : null;
+  const hmHour = hmHourStr != null ? Number(hmHourStr) : null;
+  if ((hmDayStr != null || hmHourStr != null) && (!Number.isFinite(hmDay) || !Number.isFinite(hmHour))) {
+    return NextResponse.json({ ok: false, error: "Invalid heatmap selection" }, { status: 400 });
+  }
+  if ((hmDayStr != null || hmHourStr != null) && (hmDay == null || hmHour == null)) {
+    return NextResponse.json({ ok: false, error: "Heatmap requires hmDay and hmHour" }, { status: 400 });
+  }
+
+  const where: {
+    orgId: string;
+    AND?: Array<Record<string, unknown>>;
+  } = { orgId: session.orgId };
+
+  if (machineId) {
+    where.AND = [...(where.AND ?? []), { OR: [{ machineId }, { machineId: null }] }];
+  }
+
+  if (reasonCode) {
+    where.AND = [...(where.AND ?? []), { OR: [{ reasonCode }, { reasonCode: null }] }];
+  }
+
+  if (hmDay != null && hmHour != null) {
+    where.AND = [
+      ...(where.AND ?? []),
+      { OR: [{ hmDay, hmHour }, { hmDay: null, hmHour: null }] },
+    ];
+  }
+
+  const actions = await prisma.downtimeAction.findMany({
+    where,
+    orderBy: { updatedAt: "desc" },
+    include: { ownerUser: { select: { name: true, email: true } } },
+  });
+
+  return NextResponse.json({
+    ok: true,
+    actions: actions.map(serializeAction),
+  });
+}
+
+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 = createSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid action payload" }, { status: 400 });
+  }
+
+  const data = parsed.data;
+  if ((data.hmDay == null) !== (data.hmHour == null)) {
+    return NextResponse.json({ ok: false, error: "Heatmap requires hmDay and hmHour" }, { status: 400 });
+  }
+
+  if (data.machineId) {
+    const machine = await prisma.machine.findFirst({
+      where: { id: data.machineId, orgId: session.orgId },
+      select: { id: true },
+    });
+    if (!machine) {
+      return NextResponse.json({ ok: false, error: "Invalid machineId" }, { status: 400 });
+    }
+  }
+
+  let ownerMembership: { user: { name: string | null; email: string } } | null = null;
+  if (data.ownerUserId) {
+    ownerMembership = await prisma.orgUser.findUnique({
+      where: { orgId_userId: { orgId: session.orgId, userId: data.ownerUserId } },
+      include: { user: { select: { name: true, email: true } } },
+    });
+    if (!ownerMembership) {
+      return NextResponse.json({ ok: false, error: "Invalid ownerUserId" }, { status: 400 });
+    }
+  }
+
+  const created = await prisma.downtimeAction.create({
+    data: {
+      orgId: session.orgId,
+      machineId: data.machineId ?? null,
+      reasonCode: data.reasonCode ?? null,
+      hmDay: data.hmDay ?? null,
+      hmHour: data.hmHour ?? null,
+      title: data.title.trim(),
+      notes: data.notes?.trim() || null,
+      ownerUserId: data.ownerUserId ?? null,
+      dueDate: parseDueDate(data.dueDate),
+      status: data.status ?? "open",
+      priority: data.priority ?? "medium",
+      completedAt: data.status === "done" ? new Date() : null,
+      createdBy: session.userId,
+    },
+    include: { ownerUser: { select: { name: true, email: true } } },
+  });
+
+  let emailSent = false;
+  let emailError: string | null = null;
+  if (ownerMembership?.user?.email) {
+    try {
+      const org = await prisma.org.findUnique({
+        where: { id: session.orgId },
+        select: { name: true },
+      });
+      const baseUrl = getBaseUrl(req);
+      const actionUrl = buildActionUrl(baseUrl, created);
+      const content = buildDowntimeActionAssignedEmail({
+        appName: "MIS Control Tower",
+        orgName: org?.name || "your organization",
+        actionTitle: created.title,
+        assigneeName: ownerMembership.user.name ?? ownerMembership.user.email,
+        dueDate: formatDueDate(created.dueDate),
+        actionUrl,
+        priority: created.priority,
+        status: created.status,
+      });
+      await sendEmail({
+        to: ownerMembership.user.email,
+        subject: content.subject,
+        text: content.text,
+        html: content.html,
+      });
+      emailSent = true;
+    } catch (err: unknown) {
+      emailError = err instanceof Error ? err.message : "Failed to send assignment email";
+    }
+  }
+
+  return NextResponse.json({
+    ok: true,
+    action: serializeAction(created),
+    emailSent,
+    emailError,
+  });
+}

app/api/financial/costs/route.ts

@@ -0,0 +1,309 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { createHash } from "crypto";
+import { revalidateTag } from "next/cache";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { Prisma } from "@prisma/client";
+import { z } from "zod";
+import {
+  FINANCIAL_CONFIG_SWR_SEC,
+  FINANCIAL_CONFIG_TTL_SEC,
+  getFinancialConfig,
+  type FinancialConfigPayload,
+} from "@/lib/financial/cache";
+
+function canManageFinancials(role?: string | null) {
+  return role === "OWNER";
+}
+
+function stripUndefined<T extends Record<string, unknown>>(input: T) {
+  const out: Record<string, unknown> = {};
+  for (const [key, value] of Object.entries(input)) {
+    if (value !== undefined) out[key] = value;
+  }
+  return out as T;
+}
+
+function normalizeCurrency(value?: string | null) {
+  if (!value) return null;
+  const trimmed = value.trim();
+  if (!trimmed) return null;
+  return trimmed.toUpperCase();
+}
+
+const numberField = z.preprocess(
+  (value) => {
+    if (value === "" || value === null || value === undefined) return null;
+    const n = Number(value);
+    return Number.isFinite(n) ? n : value;
+  },
+  z.number().finite().nullable()
+);
+
+const numericFields = {
+  machineCostPerMin: numberField.optional(),
+  operatorCostPerMin: numberField.optional(),
+  ratedRunningKw: numberField.optional(),
+  idleKw: numberField.optional(),
+  kwhRate: numberField.optional(),
+  energyMultiplier: numberField.optional(),
+  energyCostPerMin: numberField.optional(),
+  scrapCostPerUnit: numberField.optional(),
+  rawMaterialCostPerUnit: numberField.optional(),
+};
+
+const orgSchema = z
+  .object({
+    defaultCurrency: z.string().trim().min(1).max(8).optional(),
+    ...numericFields,
+  })
+  .strict();
+
+const locationSchema = z
+  .object({
+    location: z.string().trim().min(1).max(80),
+    currency: z.string().trim().min(1).max(8).optional().nullable(),
+    ...numericFields,
+  })
+  .strict();
+
+const machineSchema = z
+  .object({
+    machineId: z.string().uuid(),
+    currency: z.string().trim().min(1).max(8).optional().nullable(),
+    ...numericFields,
+  })
+  .strict();
+
+const productSchema = z
+  .object({
+    sku: z.string().trim().min(1).max(64),
+    currency: z.string().trim().min(1).max(8).optional().nullable(),
+    rawMaterialCostPerUnit: numberField.optional(),
+  })
+  .strict();
+
+const payloadSchema = z
+  .object({
+    org: orgSchema.optional(),
+    locations: z.array(locationSchema).optional(),
+    machines: z.array(machineSchema).optional(),
+    products: z.array(productSchema).optional(),
+  })
+  .strict();
+
+async function ensureOrgFinancialProfile(
+  tx: Prisma.TransactionClient,
+  orgId: string,
+  userId: string
+) {
+  const existing = await tx.orgFinancialProfile.findUnique({ where: { orgId } });
+  if (existing) return existing;
+  return tx.orgFinancialProfile.create({
+    data: {
+      orgId,
+      defaultCurrency: "USD",
+      energyMultiplier: 1.0,
+      updatedBy: userId,
+    },
+  });
+}
+
+function toMs(value?: Date | string | null) {
+  if (!value) return 0;
+  const date = typeof value === "string" ? new Date(value) : value;
+  const ms = date.getTime();
+  return Number.isNaN(ms) ? 0 : ms;
+}
+
+function maxUpdatedMs(rows: Array<{ updatedAt?: Date | string | null }>) {
+  let max = 0;
+  for (const row of rows) {
+    const ms = toMs(row.updatedAt);
+    if (ms > max) max = ms;
+  }
+  return max;
+}
+
+function buildConfigEtag(orgId: string, payload: FinancialConfigPayload) {
+  const parts = [
+    orgId,
+    toMs(payload.org?.updatedAt),
+    maxUpdatedMs(payload.locations ?? []),
+    maxUpdatedMs(payload.machines ?? []),
+    maxUpdatedMs(payload.products ?? []),
+    payload.locations?.length ?? 0,
+    payload.machines?.length ?? 0,
+    payload.products?.length ?? 0,
+  ];
+  return `W/"${createHash("sha1").update(parts.join("|")).digest("hex")}"`;
+}
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const membership = await prisma.orgUser.findUnique({
+    where: { orgId_userId: { orgId: session.orgId, userId: session.userId } },
+    select: { role: true },
+  });
+  if (!canManageFinancials(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const url = new URL(req.url);
+  const refresh = url.searchParams.get("refresh") === "1";
+
+  await prisma.$transaction((tx) => ensureOrgFinancialProfile(tx, session.orgId, session.userId));
+  const payload = await getFinancialConfig(session.orgId, { refresh });
+
+  const etag = buildConfigEtag(session.orgId, payload);
+  const responseHeaders = new Headers({
+    "Cache-Control": `private, max-age=${FINANCIAL_CONFIG_TTL_SEC}, stale-while-revalidate=${FINANCIAL_CONFIG_SWR_SEC}`,
+    ETag: etag,
+    Vary: "Cookie",
+  });
+
+  const ifNoneMatch = req.headers.get("if-none-match");
+  if (!refresh && ifNoneMatch && ifNoneMatch === etag) {
+    return new NextResponse(null, { status: 304, headers: responseHeaders });
+  }
+
+  return NextResponse.json({ ok: true, ...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 membership = await prisma.orgUser.findUnique({
+    where: { orgId_userId: { orgId: session.orgId, userId: session.userId } },
+    select: { role: true },
+  });
+  if (!canManageFinancials(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const body = await req.json().catch(() => ({}));
+  const parsed = payloadSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+  }
+
+  const data = parsed.data;
+
+  await prisma.$transaction(async (tx) => {
+    await ensureOrgFinancialProfile(tx, session.orgId, session.userId);
+
+    if (data.org) {
+      const updateData = stripUndefined({
+        defaultCurrency: data.org.defaultCurrency?.trim().toUpperCase(),
+        machineCostPerMin: data.org.machineCostPerMin,
+        operatorCostPerMin: data.org.operatorCostPerMin,
+        ratedRunningKw: data.org.ratedRunningKw,
+        idleKw: data.org.idleKw,
+        kwhRate: data.org.kwhRate,
+        energyMultiplier: data.org.energyMultiplier == null ? undefined : data.org.energyMultiplier,
+        energyCostPerMin: data.org.energyCostPerMin,
+        scrapCostPerUnit: data.org.scrapCostPerUnit,
+        rawMaterialCostPerUnit: data.org.rawMaterialCostPerUnit,
+        updatedBy: session.userId,
+      });
+
+      if (Object.keys(updateData).length > 0) {
+        await tx.orgFinancialProfile.update({
+          where: { orgId: session.orgId },
+          data: updateData,
+        });
+      }
+    }
+
+    const machineIds = new Set((data.machines ?? []).map((m) => m.machineId));
+    const validMachineIds = new Set<string>();
+    if (machineIds.size > 0) {
+      const rows = await tx.machine.findMany({
+        where: { orgId: session.orgId, id: { in: Array.from(machineIds) } },
+        select: { id: true },
+      });
+      rows.forEach((m) => validMachineIds.add(m.id));
+    }
+
+    for (const loc of data.locations ?? []) {
+      const updateData = stripUndefined({
+        currency: normalizeCurrency(loc.currency),
+        machineCostPerMin: loc.machineCostPerMin,
+        operatorCostPerMin: loc.operatorCostPerMin,
+        ratedRunningKw: loc.ratedRunningKw,
+        idleKw: loc.idleKw,
+        kwhRate: loc.kwhRate,
+        energyMultiplier: loc.energyMultiplier,
+        energyCostPerMin: loc.energyCostPerMin,
+        scrapCostPerUnit: loc.scrapCostPerUnit,
+        rawMaterialCostPerUnit: loc.rawMaterialCostPerUnit,
+        updatedBy: session.userId,
+      });
+
+      await tx.locationFinancialOverride.upsert({
+        where: { orgId_location: { orgId: session.orgId, location: loc.location } },
+        update: updateData,
+        create: {
+          orgId: session.orgId,
+          location: loc.location,
+          ...updateData,
+        },
+      });
+    }
+
+    for (const machine of data.machines ?? []) {
+      if (!validMachineIds.has(machine.machineId)) continue;
+      const updateData = stripUndefined({
+        currency: normalizeCurrency(machine.currency),
+        machineCostPerMin: machine.machineCostPerMin,
+        operatorCostPerMin: machine.operatorCostPerMin,
+        ratedRunningKw: machine.ratedRunningKw,
+        idleKw: machine.idleKw,
+        kwhRate: machine.kwhRate,
+        energyMultiplier: machine.energyMultiplier,
+        energyCostPerMin: machine.energyCostPerMin,
+        scrapCostPerUnit: machine.scrapCostPerUnit,
+        rawMaterialCostPerUnit: machine.rawMaterialCostPerUnit,
+        updatedBy: session.userId,
+      });
+
+      await tx.machineFinancialOverride.upsert({
+        where: { orgId_machineId: { orgId: session.orgId, machineId: machine.machineId } },
+        update: updateData,
+        create: {
+          orgId: session.orgId,
+          machineId: machine.machineId,
+          ...updateData,
+        },
+      });
+    }
+
+    for (const product of data.products ?? []) {
+      const updateData = stripUndefined({
+        currency: normalizeCurrency(product.currency),
+        rawMaterialCostPerUnit: product.rawMaterialCostPerUnit,
+        updatedBy: session.userId,
+      });
+
+      await tx.productCostOverride.upsert({
+        where: { orgId_sku: { orgId: session.orgId, sku: product.sku } },
+        update: updateData,
+        create: {
+          orgId: session.orgId,
+          sku: product.sku,
+          ...updateData,
+        },
+      });
+    }
+  });
+
+  revalidateTag(`financial-config:${session.orgId}`, { expire: 0 });
+  revalidateTag(`financial-impact:${session.orgId}`, { expire: 0 });
+
+  const payload = await getFinancialConfig(session.orgId, { refresh: true });
+  return NextResponse.json({ ok: true, ...payload });
+}

app/api/financial/export/excel/route.ts

@@ -0,0 +1,156 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { prisma } from "@/lib/prisma";
+import { computeFinancialImpact } from "@/lib/financial/impact";
+
+const RANGE_MS: Record<string, number> = {
+  "24h": 24 * 60 * 60 * 1000,
+  "7d": 7 * 24 * 60 * 60 * 1000,
+  "30d": 30 * 24 * 60 * 60 * 1000,
+};
+
+function canManageFinancials(role?: string | null) {
+  return role === "OWNER";
+}
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (!Number.isNaN(n)) return new Date(n);
+  const d = new Date(input);
+  return Number.isNaN(d.getTime()) ? null : d;
+}
+
+function pickRange(req: NextRequest) {
+  const url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "7d";
+  const now = new Date();
+
+  if (range === "custom") {
+    const start = parseDate(url.searchParams.get("start")) ?? new Date(now.getTime() - RANGE_MS["24h"]);
+    const end = parseDate(url.searchParams.get("end")) ?? now;
+    return { start, end };
+  }
+
+  const ms = RANGE_MS[range] ?? RANGE_MS["24h"];
+  return { start: new Date(now.getTime() - ms), end: now };
+}
+
+function csvValue(value: string | number | null | undefined) {
+  if (value === null || value === undefined) return "";
+  const text = String(value);
+  if (/[",\n]/.test(text)) {
+    return `"${text.replace(/"/g, "\"\"")}"`;
+  }
+  return text;
+}
+
+function formatNumber(value: number | null) {
+  if (value == null || !Number.isFinite(value)) return "";
+  return value.toFixed(4);
+}
+
+function slugify(value: string) {
+  return value
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "")
+    .slice(0, 60) || "report";
+}
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageFinancials(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const url = new URL(req.url);
+  const { start, end } = pickRange(req);
+  const machineId = url.searchParams.get("machineId") ?? undefined;
+  const location = url.searchParams.get("location") ?? undefined;
+  const sku = url.searchParams.get("sku") ?? undefined;
+  const currency = url.searchParams.get("currency") ?? undefined;
+
+  const [org, impact] = await Promise.all([
+    prisma.org.findUnique({ where: { id: session.orgId }, select: { name: true } }),
+    computeFinancialImpact({
+      orgId: session.orgId,
+      start,
+      end,
+      machineId,
+      location,
+      sku,
+      currency,
+      includeEvents: true,
+    }),
+  ]);
+
+  const orgName = org?.name ?? "Organization";
+  const header = [
+    "org_name",
+    "range_start",
+    "range_end",
+    "event_id",
+    "event_ts",
+    "event_type",
+    "status",
+    "severity",
+    "category",
+    "machine_id",
+    "machine_name",
+    "location",
+    "work_order_id",
+    "sku",
+    "duration_sec",
+    "cost_machine",
+    "cost_operator",
+    "cost_energy",
+    "cost_scrap",
+    "cost_raw_material",
+    "cost_total",
+    "currency",
+  ];
+
+  const rows = impact.events.map((event) => [
+    orgName,
+    start.toISOString(),
+    end.toISOString(),
+    event.id,
+    event.ts.toISOString(),
+    event.eventType,
+    event.status,
+    event.severity,
+    event.category,
+    event.machineId,
+    event.machineName ?? "",
+    event.location ?? "",
+    event.workOrderId ?? "",
+    event.sku ?? "",
+    formatNumber(event.durationSec),
+    formatNumber(event.costMachine),
+    formatNumber(event.costOperator),
+    formatNumber(event.costEnergy),
+    formatNumber(event.costScrap),
+    formatNumber(event.costRawMaterial),
+    formatNumber(event.costTotal),
+    event.currency,
+  ]);
+
+  const lines = [header, ...rows].map((row) => row.map(csvValue).join(","));
+  const csv = lines.join("\n");
+
+  const fileName = `financial_events_${slugify(orgName)}.csv`;
+  return new NextResponse(csv, {
+    headers: {
+      "Content-Type": "text/csv; charset=utf-8",
+      "Content-Disposition": `attachment; filename=\"${fileName}\"`,
+    },
+  });
+}

app/api/financial/export/pdf/route.ts

@@ -0,0 +1,246 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { prisma } from "@/lib/prisma";
+import { computeFinancialImpact } from "@/lib/financial/impact";
+
+const RANGE_MS: Record<string, number> = {
+  "24h": 24 * 60 * 60 * 1000,
+  "7d": 7 * 24 * 60 * 60 * 1000,
+  "30d": 30 * 24 * 60 * 60 * 1000,
+};
+
+function canManageFinancials(role?: string | null) {
+  return role === "OWNER";
+}
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (!Number.isNaN(n)) return new Date(n);
+  const d = new Date(input);
+  return Number.isNaN(d.getTime()) ? null : d;
+}
+
+function pickRange(req: NextRequest) {
+  const url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "7d";
+  const now = new Date();
+
+  if (range === "custom") {
+    const start = parseDate(url.searchParams.get("start")) ?? new Date(now.getTime() - RANGE_MS["24h"]);
+    const end = parseDate(url.searchParams.get("end")) ?? now;
+    return { start, end };
+  }
+
+  const ms = RANGE_MS[range] ?? RANGE_MS["24h"];
+  return { start: new Date(now.getTime() - ms), end: now };
+}
+
+function escapeHtml(value: string) {
+  return value
+    .replace(/&/g, "&amp;")
+    .replace(/</g, "&lt;")
+    .replace(/>/g, "&gt;")
+    .replace(/\"/g, "&quot;")
+    .replace(/'/g, "&#39;");
+}
+
+function formatMoney(value: number, currency: string) {
+  if (!Number.isFinite(value)) return "--";
+  try {
+    return new Intl.NumberFormat("en-US", { style: "currency", currency, maximumFractionDigits: 2 }).format(value);
+  } catch {
+    return `${value.toFixed(2)} ${currency}`;
+  }
+}
+
+function formatNumber(value: number | null, digits = 2) {
+  if (value == null || !Number.isFinite(value)) return "--";
+  return value.toFixed(digits);
+}
+
+function slugify(value: string) {
+  return value
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "")
+    .slice(0, 60) || "report";
+}
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageFinancials(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const url = new URL(req.url);
+  const { start, end } = pickRange(req);
+  const machineId = url.searchParams.get("machineId") ?? undefined;
+  const location = url.searchParams.get("location") ?? undefined;
+  const sku = url.searchParams.get("sku") ?? undefined;
+  const currency = url.searchParams.get("currency") ?? undefined;
+
+  const [org, impact] = await Promise.all([
+    prisma.org.findUnique({ where: { id: session.orgId }, select: { name: true } }),
+    computeFinancialImpact({
+      orgId: session.orgId,
+      start,
+      end,
+      machineId,
+      location,
+      sku,
+      currency,
+      includeEvents: true,
+    }),
+  ]);
+
+  const orgName = org?.name ?? "Organization";
+  const summaryBlocks = impact.currencySummaries
+    .map(
+      (summary) => `
+        <div class="card">
+          <div class="card-title">${escapeHtml(summary.currency)}</div>
+          <div class="card-value">${escapeHtml(formatMoney(summary.totals.total, summary.currency))}</div>
+          <div class="card-sub">Slow: ${escapeHtml(formatMoney(summary.totals.slowCycle, summary.currency))}</div>
+          <div class="card-sub">Micro: ${escapeHtml(formatMoney(summary.totals.microstop, summary.currency))}</div>
+          <div class="card-sub">Macro: ${escapeHtml(formatMoney(summary.totals.macrostop, summary.currency))}</div>
+          <div class="card-sub">Scrap: ${escapeHtml(formatMoney(summary.totals.scrap, summary.currency))}</div>
+        </div>
+      `
+    )
+    .join("");
+
+  const dailyTables = impact.currencySummaries
+    .map((summary) => {
+      const rows = summary.byDay
+        .map(
+          (row) => `
+          <tr>
+            <td>${escapeHtml(row.day)}</td>
+            <td>${escapeHtml(formatMoney(row.total, summary.currency))}</td>
+            <td>${escapeHtml(formatMoney(row.slowCycle, summary.currency))}</td>
+            <td>${escapeHtml(formatMoney(row.microstop, summary.currency))}</td>
+            <td>${escapeHtml(formatMoney(row.macrostop, summary.currency))}</td>
+            <td>${escapeHtml(formatMoney(row.scrap, summary.currency))}</td>
+          </tr>
+        `
+        )
+        .join("");
+
+      return `
+        <section class="section">
+          <h3>${escapeHtml(summary.currency)} Daily Breakdown</h3>
+          <table>
+            <thead>
+              <tr>
+                <th>Day</th>
+                <th>Total</th>
+                <th>Slow</th>
+                <th>Micro</th>
+                <th>Macro</th>
+                <th>Scrap</th>
+              </tr>
+            </thead>
+            <tbody>
+              ${rows || "<tr><td colspan=\"6\">No data</td></tr>"}
+            </tbody>
+          </table>
+        </section>
+      `;
+    })
+    .join("");
+
+  const eventRows = impact.events
+    .map(
+      (e) => `
+        <tr>
+          <td>${escapeHtml(e.ts.toISOString())}</td>
+          <td>${escapeHtml(e.eventType)}</td>
+          <td>${escapeHtml(e.category)}</td>
+          <td>${escapeHtml(e.machineName ?? "-")}</td>
+          <td>${escapeHtml(e.location ?? "-")}</td>
+          <td>${escapeHtml(e.sku ?? "-")}</td>
+          <td>${escapeHtml(e.workOrderId ?? "-")}</td>
+          <td>${escapeHtml(formatNumber(e.durationSec))}</td>
+          <td>${escapeHtml(formatMoney(e.costTotal, e.currency))}</td>
+          <td>${escapeHtml(e.currency)}</td>
+        </tr>
+      `
+    )
+    .join("");
+
+  const html = `<!doctype html>
+<html lang="en">
+<head>
+  <meta charset="utf-8" />
+  <title>Financial Impact Report</title>
+  <style>
+    body { font-family: Arial, sans-serif; color: #0f172a; margin: 32px; }
+    h1 { margin: 0 0 6px; }
+    .muted { color: #64748b; font-size: 12px; }
+    .cards { display: grid; grid-template-columns: repeat(auto-fit, minmax(220px, 1fr)); gap: 12px; margin: 20px 0; }
+    .card { border: 1px solid #e2e8f0; border-radius: 12px; padding: 12px; }
+    .card-title { font-size: 12px; text-transform: uppercase; color: #64748b; }
+    .card-value { font-size: 20px; font-weight: 700; margin: 8px 0; }
+    .card-sub { font-size: 12px; color: #475569; }
+    .section { margin-top: 24px; }
+    table { width: 100%; border-collapse: collapse; margin-top: 8px; }
+    th, td { border: 1px solid #e2e8f0; padding: 8px; font-size: 12px; text-align: left; }
+    th { background: #f8fafc; }
+    footer { margin-top: 32px; text-align: right; font-size: 11px; color: #94a3b8; }
+  </style>
+</head>
+<body>
+  <header>
+    <h1>Financial Impact Report</h1>
+    <div class="muted">${escapeHtml(orgName)} | ${escapeHtml(start.toISOString())} - ${escapeHtml(end.toISOString())}</div>
+  </header>
+
+  <section class="cards">
+    ${summaryBlocks || "<div class=\"muted\">No totals yet.</div>"}
+  </section>
+
+  ${dailyTables}
+
+  <section class="section">
+    <h3>Event Details</h3>
+    <table>
+      <thead>
+        <tr>
+          <th>Timestamp</th>
+          <th>Event</th>
+          <th>Category</th>
+          <th>Machine</th>
+          <th>Location</th>
+          <th>SKU</th>
+          <th>Work Order</th>
+          <th>Duration (sec)</th>
+          <th>Cost</th>
+          <th>Currency</th>
+        </tr>
+      </thead>
+      <tbody>
+        ${eventRows || "<tr><td colspan=\"10\">No events</td></tr>"}
+      </tbody>
+    </table>
+  </section>
+
+  <footer>Power by MaliounTech</footer>
+</body>
+</html>`;
+
+  const fileName = `financial_report_${slugify(orgName)}.html`;
+  return new NextResponse(html, {
+    headers: {
+      "Content-Type": "text/html; charset=utf-8",
+      "Content-Disposition": `attachment; filename=\"${fileName}\"`,
+    },
+  });
+}

app/api/financial/impact/route.ts

@@ -0,0 +1,84 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import {
+  FINANCIAL_IMPACT_SWR_SEC,
+  FINANCIAL_IMPACT_TTL_SEC,
+  getFinancialImpactCached,
+} from "@/lib/financial/cache";
+
+const RANGE_MS: Record<string, number> = {
+  "24h": 24 * 60 * 60 * 1000,
+  "7d": 7 * 24 * 60 * 60 * 1000,
+  "30d": 30 * 24 * 60 * 60 * 1000,
+};
+
+function canManageFinancials(role?: string | null) {
+  return role === "OWNER";
+}
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (!Number.isNaN(n)) return new Date(n);
+  const d = new Date(input);
+  return Number.isNaN(d.getTime()) ? null : d;
+}
+
+function pickRange(req: NextRequest) {
+  const url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "7d";
+  const now = new Date();
+
+  if (range === "custom") {
+    const start = parseDate(url.searchParams.get("start")) ?? new Date(now.getTime() - RANGE_MS["24h"]);
+    const end = parseDate(url.searchParams.get("end")) ?? now;
+    return { start, end };
+  }
+
+  const ms = RANGE_MS[range] ?? RANGE_MS["24h"];
+  return { start: new Date(now.getTime() - ms), end: now };
+}
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageFinancials(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const url = new URL(req.url);
+  const refresh = url.searchParams.get("refresh") === "1";
+  const { start, end } = pickRange(req);
+  const machineId = url.searchParams.get("machineId") ?? undefined;
+  const location = url.searchParams.get("location") ?? undefined;
+  const sku = url.searchParams.get("sku") ?? undefined;
+  const currency = url.searchParams.get("currency") ?? undefined;
+
+  const result = await getFinancialImpactCached(
+    {
+      orgId: session.orgId,
+      start,
+      end,
+      machineId,
+      location,
+      sku,
+      currency,
+      includeEvents: false,
+    },
+    { refresh }
+  );
+
+  const responseHeaders = new Headers({
+    "Cache-Control": `private, max-age=${FINANCIAL_IMPACT_TTL_SEC}, stale-while-revalidate=${FINANCIAL_IMPACT_SWR_SEC}`,
+    Vary: "Cookie",
+  });
+
+  return NextResponse.json({ ok: true, ...result }, { headers: responseHeaders });
+}

app/api/health/route.ts

@@ -0,0 +1,7 @@
+import { NextResponse } from "next/server";
+import { logLine } from "@/lib/logger";
+
+export async function GET() {
+  logLine("health.hit", { ok: true });
+  return NextResponse.json({ ok: true });
+}

app/api/ingest/cycle/route.ts

@@ -1,45 +1,206 @@
 import { NextResponse } from "next/server";
 import { prisma } from "@/lib/prisma";
+import { getMachineAuth } from "@/lib/machineAuthCache";
+import { z } from "zod";
+
+function asRecord(value: unknown): Record<string, unknown> | null {
+  if (!value || typeof value !== "object" || Array.isArray(value)) return null;
+  return value as Record<string, unknown>;
+}
+
+function unwrapEnvelope(raw: unknown) {
+  const record = asRecord(raw);
+  if (!record) return raw;
+  const payload = asRecord(record.payload);
+  if (!payload) return raw;
+
+  const hasMeta =
+    record.schemaVersion !== undefined ||
+    record.machineId !== undefined ||
+    record.tsMs !== undefined ||
+    record.tsDevice !== undefined ||
+    record.seq !== undefined ||
+    record.type !== undefined;
+  if (!hasMeta) return raw;
+
+  return {
+    ...payload,
+    machineId: record.machineId ?? payload.machineId,
+    tsMs: record.tsMs ?? payload.tsMs,
+    tsDevice: record.tsDevice ?? payload.tsDevice,
+    schemaVersion: record.schemaVersion ?? payload.schemaVersion,
+    seq: record.seq ?? payload.seq,
+  };
+}
+
+function asNumber(value: unknown) {
+  if (typeof value === "number" && Number.isFinite(value)) return value;
+  if (typeof value === "string" && value.trim() !== "") {
+    const parsed = Number(value);
+    return Number.isFinite(parsed) ? parsed : undefined;
+  }
+  return undefined;
+}
+
+function normalizeCycleInput(raw: unknown): Record<string, unknown> | null {
+  const row = asRecord(raw);
+  if (!row) return null;
+  const data = asRecord(row.data);
+
+  const fromRowOrData = (keys: string[]) => {
+    for (const key of keys) {
+      if (row[key] !== undefined) return row[key];
+      if (data && data[key] !== undefined) return data[key];
+    }
+    return undefined;
+  };
+
+  return {
+    ...row,
+    actual_cycle_time: fromRowOrData(["actual_cycle_time", "actualCycleTime", "actual_cycle", "actual"]),
+    theoretical_cycle_time: fromRowOrData([
+      "theoretical_cycle_time",
+      "theoreticalCycleTime",
+      "cycleTime",
+      "cycle_time",
+      "ideal",
+    ]),
+    cycle_count: fromRowOrData(["cycle_count", "cycleCount"]),
+    work_order_id: fromRowOrData(["work_order_id", "workOrderId"]),
+    good_delta: fromRowOrData(["good_delta", "goodDelta"]),
+    // `scrap_total` is cumulative and should not be persisted as per-cycle delta.
+    scrap_delta: fromRowOrData(["scrap_delta", "scrapDelta"]),
+    timestamp: fromRowOrData(["timestamp", "tsMs"]),
+    ts: fromRowOrData(["ts", "tsMs"]),
+    event_timestamp: fromRowOrData(["event_timestamp", "eventTimestamp"]),
+  };
+}
+
+const numberFromAny = z.preprocess((value) => {
+  if (typeof value === "number") return value;
+  if (typeof value === "string" && value.trim() !== "") return Number(value);
+  return value;
+}, z.number().finite());
+
+const intFromAny = z.preprocess((value) => {
+  if (typeof value === "number") return Math.trunc(value);
+  if (typeof value === "string" && value.trim() !== "") return Math.trunc(Number(value));
+  return value;
+}, z.number().int().finite());
+
+const machineIdSchema = z.string().uuid();
+
+const cycleSchema = z
+  .object({
+    actual_cycle_time: numberFromAny,
+    theoretical_cycle_time: numberFromAny.optional(),
+    cycle_count: intFromAny.optional(),
+    work_order_id: z.string().trim().max(64).optional(),
+    sku: z.string().trim().max(64).optional(),
+    cavities: intFromAny.optional(),
+    good_delta: intFromAny.optional(),
+    scrap_delta: intFromAny.optional(),
+    timestamp: numberFromAny.optional(),
+    ts: numberFromAny.optional(),
+    event_timestamp: numberFromAny.optional(),
+  })
+  .passthrough();
 
 export async function POST(req: Request) {
   const apiKey = req.headers.get("x-api-key");
   if (!apiKey) return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
 
-  const body = await req.json().catch(() => null);
-  if (!body?.machineId || !body?.cycle) {
+  let body: unknown = await req.json().catch(() => null);
+  body = unwrapEnvelope(body);
+  const bodyRecord = asRecord(body) ?? {};
+
+  const machineId =
+    bodyRecord.machineId ??
+    bodyRecord.machine_id ??
+    (asRecord(bodyRecord.machine)?.id ?? null);
+  if (!machineId || !machineIdSchema.safeParse(String(machineId)).success) {
     return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
   }
 
-  const machine = await prisma.machine.findFirst({
-    where: { id: String(body.machineId), apiKey },
-    select: { id: true, orgId: true },
-  });
+  const machine = await getMachineAuth(String(machineId), apiKey);
   if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
 
-  const c = body.cycle;
+  const cyclesRaw = bodyRecord.cycles ?? bodyRecord.cycle;
+  if (!cyclesRaw) {
+    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+  }
 
-  const tsMs =
-    (typeof c.timestamp === "number" && c.timestamp) ||
-    (typeof c.ts === "number" && c.ts) ||
-    (typeof c.event_timestamp === "number" && c.event_timestamp) ||
+  const cycleList = (Array.isArray(cyclesRaw) ? cyclesRaw : [cyclesRaw])
+    .map((row) => normalizeCycleInput(row))
+    .filter((row): row is Record<string, unknown> => !!row);
+
+  if (!cycleList.length) {
+    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+  }
+
+  const parsedCycles = z.array(cycleSchema).safeParse(cycleList);
+  if (!parsedCycles.success) {
+    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+  }
+
+  const fallbackTsMs =
+    asNumber(bodyRecord.tsMs) ||
+    asNumber(bodyRecord.tsDevice) ||
     undefined;
 
+  const rows = parsedCycles.data.map((data) => {
+    const tsMs =
+      (typeof data.timestamp === "number" && data.timestamp) ||
+      (typeof data.ts === "number" && data.ts) ||
+      (typeof data.event_timestamp === "number" && data.event_timestamp) ||
+      fallbackTsMs;
+
     const ts = tsMs ? new Date(tsMs) : new Date();
 
-  const row = await prisma.machineCycle.create({
-    data: {
+    return {
       orgId: machine.orgId,
       machineId: machine.id,
       ts,
-      cycleCount: typeof c.cycle_count === "number" ? c.cycle_count : null,
-      actualCycleTime: Number(c.actual_cycle_time),
-      theoreticalCycleTime: c.theoretical_cycle_time != null ? Number(c.theoretical_cycle_time) : null,
-      workOrderId: c.work_order_id ? String(c.work_order_id) : null,
-      sku: c.sku ? String(c.sku) : null,
-      cavities: typeof c.cavities === "number" ? c.cavities : null,
-      goodDelta: typeof c.good_delta === "number" ? c.good_delta : null,
-      scrapDelta: typeof c.scrap_delta === "number" ? c.scrap_delta : null,
-    },
+      cycleCount: typeof data.cycle_count === "number" ? data.cycle_count : null,
+      actualCycleTime: data.actual_cycle_time,
+      theoreticalCycleTime: typeof data.theoretical_cycle_time === "number" ? data.theoretical_cycle_time : null,
+      workOrderId: data.work_order_id ? String(data.work_order_id) : null,
+      sku: data.sku ? String(data.sku) : null,
+      cavities: typeof data.cavities === "number" ? data.cavities : null,
+      goodDelta: typeof data.good_delta === "number" ? data.good_delta : null,
+      scrapDelta: typeof data.scrap_delta === "number" ? data.scrap_delta : null,
+    };
+  });
+
+  const result = await prisma.machineCycle.createMany({
+    data: rows,
+    skipDuplicates: true,
+  });
+
+  if (rows.length === 1) {
+    const row = await prisma.machineCycle.findFirst({
+      where: {
+        orgId: machine.orgId,
+        machineId: machine.id,
+        ts: rows[0].ts,
+        cycleCount: rows[0].cycleCount ?? null,
+      },
+      orderBy: { createdAt: "asc" },
+      select: { id: true, ts: true },
+    });
+    return NextResponse.json({
+      ok: true,
+      id: row?.id,
+      ts: row?.ts,
+      inserted: result.count,
+      duplicate: result.count === 0,
+    });
+  }
+
+  return NextResponse.json({
+    ok: true,
+    inserted: result.count,
+    requested: rows.length,
+    count: result.count,
   });
-  return NextResponse.json({ ok: true, id: row.id, ts: row.ts });
 }

app/api/ingest/event/route.ts

@@ -1,12 +1,30 @@
 import { NextResponse } from "next/server";
 import { prisma } from "@/lib/prisma";
+import { getMachineAuth } from "@/lib/machineAuthCache";
+import { z } from "zod";
+import { evaluateAlertsForEvent } from "@/lib/alerts/engine";
+import { toJsonValue } from "@/lib/prismaJson";
+import {
+  detailEffectiveReasonCode,
+  findCatalogReason,
+  findCatalogReasonByReasonCode,
+  toReasonCode,
+  type ReasonCatalog,
+  type ReasonCatalogKind,
+} from "@/lib/reasonCatalog";
+import { effectiveReasonCatalogForOrg } from "@/lib/reasonCatalogDb";
 
-const normalizeType = (t: any) =>
+const normalizeType = (t: unknown) =>
   String(t ?? "")
     .trim()
     .toLowerCase()
     .replace(/_/g, "-");
 
+function asRecord(value: unknown): Record<string, unknown> | null {
+  if (!value || typeof value !== "object" || Array.isArray(value)) return null;
+  return value as Record<string, unknown>;
+}
+
 const CANON_TYPE: Record<string, string> = {
   // Node-RED
   "production-stopped": "stop",
@@ -21,82 +39,331 @@ const CANON_TYPE: Record<string, string> = {
   "microparo": "microstop",
   "micro-paro": "microstop",
   "down": "stop",
+  "downtime-acknowledged": "downtime-acknowledged",
+  "scrap-manual-entry": "scrap-manual-entry",
+  "mold-change": "mold-change",
 };
 
 const ALLOWED_TYPES = new Set([
   "slow-cycle",
   "microstop",
   "macrostop",
+  "offline",
+  "error",
   "oee-drop",
   "quality-spike",
   "performance-degradation",
   "predictive-oee-decline",
+  "downtime-acknowledged",
+  "scrap-manual-entry",
+  "mold-change",
 ]);
 
-// thresholds for stop classification (tune later / move to machine config)
-const MICROSTOP_SEC = 60;
-const MACROSTOP_SEC = 300;
+const machineIdSchema = z.string().uuid();
+const MAX_EVENTS = 100;
+
+//when no cycle time is configed
+const DEFAULT_MACROSTOP_SEC = 300;
+const NON_AUTHORITATIVE_REASON_CODES = new Set(["PENDIENTE", "UNCLASSIFIED"]);
+
+function isNonAuthoritativeReasonCode(code: unknown) {
+  const normalized = clampText(code, 64)?.toUpperCase();
+  return !!normalized && NON_AUTHORITATIVE_REASON_CODES.has(normalized);
+}
+
+function clampText(value: unknown, maxLen: number) {
+  if (value === null || value === undefined) return null;
+  const text = String(value).trim().replace(/[\u0000-\u001f\u007f]/g, "");
+  if (!text) return null;
+  return text.length > maxLen ? text.slice(0, maxLen) : text;
+}
+
+function numberFrom(value: unknown) {
+  if (typeof value === "number" && Number.isFinite(value)) return value;
+  if (typeof value === "string" && value.trim()) {
+    const parsed = Number(value);
+    if (Number.isFinite(parsed)) return parsed;
+  }
+  return null;
+}
+function parseSeqToBigInt(value: unknown): bigint | null {
+  if (value === null || value === undefined) return null;
+  if (typeof value === "number") {
+    if (!Number.isInteger(value) || value < 0) return null;
+    return BigInt(value);
+  }
+  if (typeof value === "string" && /^\d+$/.test(value)) return BigInt(value);
+  return null;
+}
+
+function canonicalText(value: unknown) {
+  return String(value ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+}
+
+function parseReasonPath(rawPath: unknown) {
+  let category: string | null = null;
+  let detail: string | null = null;
+
+  if (Array.isArray(rawPath)) {
+    const first = rawPath[0];
+    const second = rawPath[1];
+    if (typeof first === "string") category = first;
+    if (typeof second === "string") detail = second;
+    if (asRecord(first)) category = clampText(first.id ?? first.label ?? first.value, 120);
+    if (asRecord(second)) detail = clampText(second.id ?? second.label ?? second.value, 120);
+  } else if (typeof rawPath === "string") {
+    const pieces = rawPath
+      .split(/>|\/|\\|\|/g)
+      .map((p) => p.trim())
+      .filter(Boolean);
+    category = pieces[0] ?? null;
+    detail = pieces[1] ?? null;
+  }
+
+  return {
+    category: clampText(category, 120),
+    detail: clampText(detail, 120),
+  };
+}
+
+function parseReasonTextPath(reasonText: unknown) {
+  const text = clampText(reasonText, 240);
+  if (!text) return { category: null as string | null, detail: null as string | null };
+  const pieces = text
+    .split(/>|\/|\\|\|/g)
+    .map((p) => p.trim())
+    .filter(Boolean);
+  return {
+    category: clampText(pieces[0] ?? null, 120),
+    detail: clampText(pieces[1] ?? null, 120),
+  };
+}
+
+function findCatalogReasonFlexible(
+  catalog: ReasonCatalog | null,
+  kind: ReasonCatalogKind,
+  categoryIdOrLabel: unknown,
+  detailIdOrLabel: unknown
+) {
+  const direct = findCatalogReason(catalog, kind, categoryIdOrLabel, detailIdOrLabel);
+  if (direct) return direct;
+  if (!catalog) return null;
+
+  const catNeedle = canonicalText(categoryIdOrLabel);
+  const detNeedle = canonicalText(detailIdOrLabel);
+  if (!catNeedle || !detNeedle) return null;
+
+  for (const category of catalog[kind] ?? []) {
+    const catMatch =
+      canonicalText(category.id) === catNeedle || canonicalText(category.label) === catNeedle;
+    if (!catMatch) continue;
+    for (const detail of category.details) {
+      const detMatch = canonicalText(detail.id) === detNeedle || canonicalText(detail.label) === detNeedle;
+      if (!detMatch) continue;
+      return {
+        categoryId: category.id,
+        categoryLabel: category.label,
+        detailId: detail.id,
+        detailLabel: detail.label,
+        reasonCode: detailEffectiveReasonCode(category, detail),
+        reasonLabel: `${category.label} > ${detail.label}`,
+      };
+    }
+  }
+  return null;
+}
+
+function resolveReason(
+  raw: Record<string, unknown>,
+  kind: ReasonCatalogKind,
+  catalog: ReasonCatalog | null,
+  fallbackVersion: number
+) {
+  const reasonPath = parseReasonPath(raw.reasonPath);
+  const reasonTextPath = parseReasonTextPath(raw.reasonText);
+  const categoryIdRaw = clampText(raw.categoryId ?? reasonPath.category ?? reasonTextPath.category, 64);
+  const detailIdRaw = clampText(raw.detailId ?? reasonPath.detail ?? reasonTextPath.detail, 64);
+  const fromCatalogFlexible = findCatalogReasonFlexible(catalog, kind, categoryIdRaw, detailIdRaw);
+  const rawReasonCodeEarly = clampText(raw.reasonCode, 64);
+  const fromCatalogByCode =
+    !fromCatalogFlexible && rawReasonCodeEarly
+      ? findCatalogReasonByReasonCode(catalog, kind, rawReasonCodeEarly)
+      : null;
+  const fromCatalog = fromCatalogFlexible ?? fromCatalogByCode;
+
+  const categoryLabelRaw = clampText(raw.categoryLabel ?? reasonPath.category ?? reasonTextPath.category, 120);
+  const detailLabelRaw = clampText(raw.detailLabel ?? reasonPath.detail ?? reasonTextPath.detail, 120);
+
+  const reasonCode =
+    clampText(raw.reasonCode, 64)?.toUpperCase() ??
+    fromCatalog?.reasonCode ??
+    toReasonCode(categoryIdRaw ?? categoryLabelRaw, detailIdRaw ?? detailLabelRaw) ??
+    null;
+
+  const categoryId = fromCatalog?.categoryId ?? categoryIdRaw;
+  const detailId = fromCatalog?.detailId ?? detailIdRaw;
+  const categoryLabel = fromCatalog?.categoryLabel ?? categoryLabelRaw;
+  const detailLabel = fromCatalog?.detailLabel ?? detailLabelRaw;
+
+  const pathLabel =
+    clampText(raw.reasonText, 240) ??
+    fromCatalog?.reasonLabel ??
+    (categoryLabel && detailLabel ? `${categoryLabel} > ${detailLabel}` : null) ??
+    detailLabel ??
+    categoryLabel ??
+    reasonCode;
+
+  const catalogVersionRaw = numberFrom(raw.catalogVersion);
+  const catalogVersion = catalogVersionRaw != null ? Math.trunc(catalogVersionRaw) : fallbackVersion;
+
+  return {
+    type: kind,
+    categoryId,
+    categoryLabel,
+    detailId,
+    detailLabel,
+    reasonCode,
+    reasonLabel: pathLabel,
+    reasonText: pathLabel,
+    catalogVersion,
+  };
+}
 
 export async function POST(req: Request) {
   const apiKey = req.headers.get("x-api-key");
-  if (!apiKey) {
-    return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
+  if (!apiKey) return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
+
+  let body: unknown = await req.json().catch(() => null);
+
+  // ✅ if Node-RED sent an array as the whole body, unwrap it
+  if (Array.isArray(body)) body = body[0];
+  const bodyRecord = asRecord(body) ?? {};
+  const payloadRecord = asRecord(bodyRecord.payload) ?? {};
+
+  // ✅ accept multiple common keys
+  const machineId =
+    bodyRecord.machineId ??
+    bodyRecord.machine_id ??
+    (asRecord(bodyRecord.machine)?.id ?? null);
+  let rawEvent =
+    bodyRecord.event ??
+    bodyRecord.events ??
+    bodyRecord.anomalies ??
+    payloadRecord.event ??
+    payloadRecord.events ??
+    payloadRecord.anomalies ??
+    payloadRecord ??
+    bodyRecord.data; // sometimes "data"
+
+  const rawEventRecord = asRecord(rawEvent);
+  if (rawEventRecord?.event && typeof rawEventRecord.event === "object") rawEvent = rawEventRecord.event;
+  if (Array.isArray(rawEventRecord?.events)) rawEvent = rawEventRecord.events;
+
+  if (!machineId || !rawEvent) {
+    return NextResponse.json(
+      { ok: false, error: "Invalid payload", got: { hasMachineId: !!machineId, keys: Object.keys(bodyRecord) } },
+      { status: 400 }
+    );
   }
 
-  const body = await req.json().catch(() => null);
-  if (!body?.machineId || !body?.event) {
-    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+  if (!machineIdSchema.safeParse(String(machineId)).success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine id" }, { status: 400 });
   }
 
+  const machine = await getMachineAuth(String(machineId), apiKey);
+  if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
 
-  const machine = await prisma.machine.findFirst({
-    where: { id: String(body.machineId), apiKey },
-    select: { id: true, orgId: true },
+  const bodySeq = parseSeqToBigInt(bodyRecord.seq);
+  const bodySchemaVersion = clampText(bodyRecord.schemaVersion, 16);
+
+  const orgSettings = await prisma.orgSettings.findUnique({
+    where: { orgId: machine.orgId },
+    select: { stoppageMultiplier: true, macroStoppageMultiplier: true, defaultsJson: true, version: true },
   });
-  if (!machine) {
-    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
-  }
+  const reasonCatalog = await effectiveReasonCatalogForOrg(
+    machine.orgId,
+    orgSettings?.defaultsJson ?? null,
+    orgSettings?.version ?? 1
+  );
 
-  // Normalize to array (Node-RED sends array of anomalies)
-  const rawEvent = body.event;
+  const defaultMicroMultiplier = Number(orgSettings?.stoppageMultiplier ?? 1.5);
+  const defaultMacroMultiplier = Math.max(
+    defaultMicroMultiplier,
+    Number(orgSettings?.macroStoppageMultiplier ?? 5)
+  );
+
+
+  // ✅ normalize to array no matter what
   const events = Array.isArray(rawEvent) ? rawEvent : [rawEvent];
+  if (events.length > MAX_EVENTS) {
+    return NextResponse.json({ ok: false, error: "Too many events" }, { status: 400 });
+  }
 
   const created: { id: string; ts: Date; eventType: string }[] = [];
-  const skipped: any[] = [];
+  const skipped: Array<Record<string, unknown>> = [];
 
   for (const ev of events) {
-    if (!ev || typeof ev !== "object") {
+    const evRecord = asRecord(ev);
+    if (!evRecord) {
       skipped.push({ reason: "invalid_event_object" });
       continue;
     }
+    const evData = asRecord(evRecord.data) ?? {};
+    // We'll re-check reason again after parsing `data` (it may be a JSON string)
+    let evReason = asRecord(evRecord.reason) ?? asRecord(evData.reason);
+    const evDowntime = asRecord(evRecord.downtime) ?? asRecord(evData.downtime);
+    // Some producers nest the reason under `downtime.reason`
+    if (!evReason) evReason = asRecord(evDowntime?.reason);
 
-    const rawType = (ev as any).eventType ?? (ev as any).anomaly_type ?? (ev as any).topic ?? body.topic ?? "";
+    const rawType = evRecord.eventType ?? evRecord.anomaly_type ?? evRecord.topic ?? bodyRecord.topic ?? "";
     const typ0 = normalizeType(rawType);
     const typ = CANON_TYPE[typ0] ?? typ0;
 
     // Determine timestamp
     const tsMs =
-      (typeof (ev as any)?.timestamp === "number" && (ev as any).timestamp) ||
-      (typeof (ev as any)?.data?.timestamp === "number" && (ev as any).data.timestamp) ||
-      (typeof (ev as any)?.data?.event_timestamp === "number" && (ev as any).data.event_timestamp) ||
+      (typeof evRecord.timestamp === "number" && evRecord.timestamp) ||
+      (typeof evData.timestamp === "number" && evData.timestamp) ||
+      (typeof evData.event_timestamp === "number" && evData.event_timestamp) ||
       null;
 
     const ts = tsMs ? new Date(tsMs) : new Date();
 
     // Severity defaulting (do not skip on severity — store for audit)
-    let sev = String((ev as any).severity ?? "").trim().toLowerCase();
+    let sev = String(evRecord.severity ?? "").trim().toLowerCase();
     if (!sev) sev = "warning";
 
     // Stop classification -> microstop/macrostop
     let finalType = typ;
+    let stopSecForReason: number | null = null;
     if (typ === "stop") {
       const stopSec =
-        (typeof (ev as any)?.data?.stoppage_duration_seconds === "number" && (ev as any).data.stoppage_duration_seconds) ||
-        (typeof (ev as any)?.data?.stop_duration_seconds === "number" && (ev as any).data.stop_duration_seconds) ||
+        (typeof evData.stoppage_duration_seconds === "number" && evData.stoppage_duration_seconds) ||
+        (typeof evData.stop_duration_seconds === "number" && evData.stop_duration_seconds) ||
         null;
+      stopSecForReason = stopSec != null ? Number(stopSec) : null;
 
       if (stopSec != null) {
-        finalType = stopSec >= MACROSTOP_SEC ? "macrostop" : "microstop";
+        const theoretical = Number(evData.theoretical_cycle_time ?? evData.theoreticalCycleTime ?? 0) || 0;
+
+        const microMultiplier = Number(
+          evData.micro_threshold_multiplier ?? evData.threshold_multiplier ?? defaultMicroMultiplier
+        );
+        const macroMultiplier = Math.max(
+          microMultiplier,
+          Number(evData.macro_threshold_multiplier ?? defaultMacroMultiplier)
+        );
+
+        if (theoretical > 0) {
+          const macroThresholdSec = theoretical * macroMultiplier;
+          finalType = stopSec >= macroThresholdSec ? "macrostop" : "microstop";
+        } else {
+          finalType = stopSec >= DEFAULT_MACROSTOP_SEC ? "macrostop" : "microstop";
+        }
       } else {
         // missing duration -> conservative
         finalType = "microstop";
@@ -109,44 +376,378 @@ export async function POST(req: Request) {
     }
 
     const title =
-      String((ev as any).title ?? "").trim() ||
+      clampText(evRecord.title, 160) ||
       (finalType === "slow-cycle" ? "Slow Cycle Detected" :
        finalType === "macrostop" ? "Macrostop Detected" :
        finalType === "microstop" ? "Microstop Detected" :
        "Event");
 
-    const description = (ev as any).description ? String((ev as any).description) : null;
+    const description = clampText(evRecord.description, 1000);
 
     // store full blob, ensure object
-    const rawData = (ev as any).data ?? ev;
-    const dataObj = typeof rawData === "string" ? (() => {
-      try { return JSON.parse(rawData); } catch { return { raw: rawData }; }
-    })() : rawData;
+    const rawData = evRecord.data ?? evRecord;
+    const parsedData = typeof rawData === "string"
+      ? (() => {
+          try {
+            return JSON.parse(rawData);
+          } catch {
+            return { raw: rawData };
+          }
+        })()
+      : rawData;
+    const dataObj: Record<string, unknown> =
+      parsedData && typeof parsedData === "object" && !Array.isArray(parsedData)
+        ? { ...(parsedData as Record<string, unknown>) }
+        : { raw: parsedData };
+    if (evRecord.status != null && dataObj.status == null) dataObj.status = evRecord.status;
+    if (evRecord.alert_id != null && dataObj.alert_id == null) dataObj.alert_id = evRecord.alert_id;
+    if (evRecord.is_update != null && dataObj.is_update == null) dataObj.is_update = evRecord.is_update;
+    if (evRecord.is_auto_ack != null && dataObj.is_auto_ack == null) dataObj.is_auto_ack = evRecord.is_auto_ack;
+    if (evReason && dataObj.reason == null) dataObj.reason = evReason;
+    if (evDowntime && dataObj.downtime == null) dataObj.downtime = evDowntime;
 
-    const row = await prisma.machineEvent.create({
-      data: {
+    // If `data` was a JSON string, the earlier evReason lookup would miss it.
+    // Re-check here using the normalized object we will persist.
+    if (!evReason) evReason = asRecord(dataObj.reason);
+    if (!evReason) evReason = asRecord(asRecord(dataObj.downtime)?.reason);
+
+    // If we have a reasonText but missing ids, derive ids from the path-like string.
+    if (evReason) {
+      const hasCat = clampText((evReason as any).categoryId, 64) ?? clampText((evReason as any).categoryLabel, 120);
+      const hasDet = clampText((evReason as any).detailId, 64) ?? clampText((evReason as any).detailLabel, 120);
+      const rt = clampText((evReason as any).reasonText, 240);
+      if ((!hasCat || !hasDet) && rt) {
+        const parsed = parseReasonTextPath(rt);
+        const next = { ...evReason } as Record<string, unknown>;
+        // Preserve any explicit ids; only fill gaps.
+        if ((next as any).categoryId == null && parsed.category) next.categoryId = canonicalText(parsed.category);
+        if ((next as any).categoryLabel == null && parsed.category) next.categoryLabel = parsed.category;
+        if ((next as any).detailId == null && parsed.detail) next.detailId = canonicalText(parsed.detail);
+        if ((next as any).detailLabel == null && parsed.detail) next.detailLabel = parsed.detail;
+        evReason = next;
+      }
+    }
+
+    const activeWorkOrder = asRecord(evRecord.activeWorkOrder);
+    const dataActiveWorkOrder = asRecord(evData.activeWorkOrder);
+
+    // ✨ Cada evento puede traer su propio seq, o usar el del payload raíz
+    const evSeq = 
+      parseSeqToBigInt(evRecord.seq) ??
+      parseSeqToBigInt(evData.seq) ??
+      bodySeq;
+
+    const evSchemaVersion = 
+      clampText(evRecord.schemaVersion, 16) ??
+      bodySchemaVersion;
+
+    const eventData = {
+      orgId: machine.orgId,
+      machineId: machine.id,
+      schemaVersion: evSchemaVersion,
+      seq: evSeq,
+      ts,
+      topic: clampText(evRecord.topic ?? finalType, 64) ?? finalType,
+      eventType: finalType,
+      severity: sev,
+      requiresAck: !!evRecord.requires_ack,
+      title,
+      description,
+      data: toJsonValue(dataObj),
+      workOrderId:
+        clampText(evRecord.work_order_id, 64) ??
+        clampText(evData.work_order_id, 64) ??
+        clampText(activeWorkOrder?.id, 64) ??
+        clampText(dataActiveWorkOrder?.id, 64) ??
+        null,
+      sku:
+        clampText(evRecord.sku, 64) ??
+        clampText(evData.sku, 64) ??
+        clampText(activeWorkOrder?.sku, 64) ??
+        clampText(dataActiveWorkOrder?.sku, 64) ??
+        null,
+    };
+
+    // ✨ Idempotente: si ya existe (mismo orgId+machineId+seq), no inserta
+    const insertResult = await prisma.machineEvent.createMany({
+      data: [eventData],
+      skipDuplicates: true,
+    });
+
+    // ✨ Buscar la fila (la recién creada o la duplicada existente)
+    let row;
+    if (evSeq != null) {
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          seq: evSeq,
+        },
+        orderBy: { ts: "asc" },
+      });
+    } else {
+      // Sin seq, buscar por ts (fallback compatibilidad con eventos viejos)
+      row = await prisma.machineEvent.findFirst({
+        where: { 
           orgId: machine.orgId, 
           machineId: machine.id, 
           ts,
-        topic: String((ev as any).topic ?? finalType),
           eventType: finalType,
-        severity: sev,
-        requiresAck: !!(ev as any).requires_ack,
-        title,
-        description,
-        data: dataObj,
-        workOrderId:
-          (ev as any)?.work_order_id ? String((ev as any).work_order_id)
-          : (ev as any)?.data?.work_order_id ? String((ev as any).data.work_order_id)
-          : null,
-        sku:
-          (ev as any)?.sku ? String((ev as any).sku)
-          : (ev as any)?.data?.sku ? String((ev as any).data.sku)
-          : null,
         },
+        orderBy: { ts: "desc" },
       });
+    }
+
+    if (!row) {
+      skipped.push({ reason: "row_not_found_after_insert", seq: evSeq?.toString() });
+      continue;
+    }
+
+    const wasDuplicate = insertResult.count === 0;
+
+    // Si fue duplicado, no procesar reasonEntry ni alertas (ya se hicieron antes)
+    if (wasDuplicate) {
+      created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+      continue;  // ✨ saltar el resto del procesamiento
+    }
 
     created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+
+    
+
+    // If the payload carries a `reason`, create the corresponding ReasonEntry.
+    // If it doesn't, still create an "UNCLASSIFIED" downtime ReasonEntry for stop events so the dashboard can show coverage.
+    if (evRecord.is_update || evRecord.is_auto_ack || dataObj.is_update || dataObj.is_auto_ack){
+  // skip duplicate reasonEntry for refresh/ack 
+    } else if (evReason || finalType === "microstop" || finalType === "macrostop" || finalType === "downtime-acknowledged" || finalType === "mold-change"){
+      const fallbackIncidentKey =
+        clampText(
+          evData.incidentKey ??
+            dataObj.incidentKey ??
+            evDowntime?.incidentKey ??
+            evReason?.incidentKey,
+          128
+        ) ?? null;
+      const moldIncidentKey =
+        clampText(evData.incidentKey ?? dataObj.incidentKey, 128) ??
+        (numberFrom(evData.start_ms ?? dataObj.start_ms) != null
+          ? `mold-change:${Math.trunc(numberFrom(evData.start_ms ?? dataObj.start_ms) as number)}`
+          : null);
+      const reasonRaw: Record<string, unknown> =
+        evReason ??
+        (finalType === "mold-change"
+          ? ({
+              type: "downtime",
+              categoryId: "cambio-molde",
+              detailId: "cambio-molde",
+              categoryLabel: "Cambio molde",
+              detailLabel: "Cambio molde",
+              reasonCode: "MOLD_CHANGE",
+              reasonText: "Cambio molde",
+              incidentKey: moldIncidentKey ?? fallbackIncidentKey ?? row.id,
+            } as Record<string, unknown>)
+          :
+        ({
+          type: "downtime",
+          categoryId: "unclassified",
+          detailId: "unclassified",
+          categoryLabel: "Unclassified",
+          detailLabel: "Unclassified",
+          reasonCode: "UNCLASSIFIED",
+          reasonText: "Unclassified",
+          incidentKey: fallbackIncidentKey ?? row.id,
+        } as Record<string, unknown>));
+
+      const inferredKind: ReasonCatalogKind =
+        String(reasonRaw.type ?? "").toLowerCase() === "scrap" || finalType === "scrap-manual-entry"
+          ? "scrap"
+          : "downtime";
+      const resolved = resolveReason(reasonRaw, inferredKind, reasonCatalog, reasonCatalog.version);
+
+      if (resolved.reasonCode) {
+        const continuityIncidentKey =
+          inferredKind === "downtime"
+            ? clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey ?? fallbackIncidentKey, 128) ?? row.id
+            : null;
+        const reasonMetaIncidentKey =
+          inferredKind === "downtime"
+            ? continuityIncidentKey
+            : clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128);
+        const reasonId =
+          clampText(reasonRaw.reasonId, 128) ??
+          (inferredKind === "downtime"
+            ? `evt:${machine.id}:downtime:${continuityIncidentKey ?? row.id}`
+            : `evt:${machine.id}:scrap:${clampText(reasonRaw.scrapEntryId, 128) ?? row.id}`);
+
+        const workOrderId =
+          clampText(evRecord.work_order_id, 64) ??
+          clampText(evData.work_order_id, 64) ??
+          clampText(evRecord.workOrderId, 64) ??
+          null;
+
+        const commonWrite = {
+          reasonCode: resolved.reasonCode,
+          reasonLabel: resolved.reasonLabel ?? resolved.reasonCode,
+          reasonText: resolved.reasonText ?? null,
+          capturedAt: row.ts,
+          workOrderId,
+          schemaVersion: Math.max(1, Math.trunc(resolved.catalogVersion)),
+          meta: toJsonValue({
+            source: "ingest:event",
+            eventId: row.id,
+            eventType: row.eventType,
+            incidentKey: reasonMetaIncidentKey,
+            anomalyType:
+              clampText(evRecord.anomalyType, 64) ??
+              clampText(evDowntime?.anomalyType, 64) ??
+              clampText(evRecord.anomaly_type, 64),
+            reason: {
+              type: resolved.type,
+              categoryId: resolved.categoryId,
+              categoryLabel: resolved.categoryLabel,
+              detailId: resolved.detailId,
+              detailLabel: resolved.detailLabel,
+              reasonText: resolved.reasonText,
+              catalogVersion: resolved.catalogVersion,
+            },
+          }),
+        };
+
+        if (inferredKind === "downtime") {
+          const incidentKey = continuityIncidentKey ?? row.id;
+          const durationSeconds =
+            numberFrom(evDowntime?.durationSeconds) ??
+            numberFrom(evData.duration_sec) ??
+            numberFrom(evData.stoppage_duration_seconds) ??
+            numberFrom(evData.stop_duration_seconds) ??
+            (stopSecForReason != null ? stopSecForReason : null) ??
+            null;
+          const episodeEndTsMs =
+            numberFrom(evData.end_ms) ??
+            numberFrom(evDowntime?.episodeEndTsMs) ??
+            numberFrom(evDowntime?.acknowledgedAtMs) ??
+            null;
+
+          let guardedWrite = commonWrite;
+          const incomingIsNonAuthoritative = isNonAuthoritativeReasonCode(resolved.reasonCode);
+          const isManualAckEvent = finalType === "downtime-acknowledged";
+          if (!isManualAckEvent && incomingIsNonAuthoritative) {
+            const existingEpisode = await prisma.reasonEntry.findFirst({
+              where: {
+                orgId: machine.orgId,
+                kind: "downtime",
+                episodeId: incidentKey,
+              },
+              select: {
+                reasonCode: true,
+                reasonLabel: true,
+                reasonText: true,
+                meta: true,
+              },
+            });
+            if (existingEpisode && !isNonAuthoritativeReasonCode(existingEpisode.reasonCode)) {
+              const existingMeta = asRecord(existingEpisode.meta);
+              const existingMetaReason = asRecord(existingMeta?.reason);
+              guardedWrite = {
+                ...commonWrite,
+                reasonCode: existingEpisode.reasonCode,
+                reasonLabel: existingEpisode.reasonLabel ?? existingEpisode.reasonCode,
+                reasonText:
+                  existingEpisode.reasonText ??
+                  existingEpisode.reasonLabel ??
+                  existingEpisode.reasonCode,
+                meta: toJsonValue({
+                  source: "ingest:event",
+                  eventId: row.id,
+                  eventType: row.eventType,
+                  incidentKey: reasonMetaIncidentKey,
+                  anomalyType:
+                    clampText(evRecord.anomalyType, 64) ??
+                    clampText(evDowntime?.anomalyType, 64) ??
+                    clampText(evRecord.anomaly_type, 64),
+                  reason: existingMetaReason ?? {
+                    type: resolved.type,
+                    categoryId: resolved.categoryId,
+                    categoryLabel: resolved.categoryLabel,
+                    detailId: resolved.detailId,
+                    detailLabel: resolved.detailLabel,
+                    reasonText:
+                      existingEpisode.reasonText ??
+                      existingEpisode.reasonLabel ??
+                      existingEpisode.reasonCode,
+                    catalogVersion: resolved.catalogVersion,
+                  },
+                  reasonPreservedFromManual: true,
+                  incomingReasonCode: resolved.reasonCode,
+                }),
+              };
+            }
+          }
+
+          await prisma.reasonEntry.upsert({
+            where: { reasonId },
+            create: {
+              orgId: machine.orgId,
+              machineId: machine.id,
+              reasonId,
+              kind: "downtime",
+              episodeId: incidentKey,
+              durationSeconds: durationSeconds != null ? Math.max(0, Math.trunc(durationSeconds)) : null,
+              episodeEndTs: episodeEndTsMs != null ? new Date(episodeEndTsMs) : null,
+              ...guardedWrite,
+            },
+            update: {
+              kind: "downtime",
+              episodeId: incidentKey,
+              durationSeconds: durationSeconds != null ? Math.max(0, Math.trunc(durationSeconds)) : null,
+              episodeEndTs: episodeEndTsMs != null ? new Date(episodeEndTsMs) : null,
+              ...guardedWrite,
+            },
+          });
+        } else {
+          const scrapEntryId =
+            clampText((reasonRaw as any).scrapEntryId, 128) ??
+            clampText(evRecord.id, 128) ??
+            clampText(evRecord.eventId, 128) ??
+            row.id;
+          const scrapQtyRaw =
+            numberFrom(evRecord.scrapDelta) ??
+            numberFrom(evData.scrapDelta) ??
+            numberFrom(evData.scrap_delta) ??
+            0;
+          const scrapQty = Math.max(0, Math.trunc(scrapQtyRaw));
+
+          await prisma.reasonEntry.upsert({
+            where: { reasonId },
+            create: {
+              orgId: machine.orgId,
+              machineId: machine.id,
+              reasonId,
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText((reasonRaw as any).scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+            update: {
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText((reasonRaw as any).scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+          });
+        }
+      }
+    }
+
+    try {
+      if (row.eventType !== "downtime-acknowledged" && row.eventType !== "scrap-manual-entry") {
+        await evaluateAlertsForEvent(row.id);
+      }
+    } catch (err) {
+      console.error("[alerts] evaluation failed", err);
+    }
   }
 
   return NextResponse.json({ ok: true, createdCount: created.length, created, skippedCount: skipped.length, skipped });

app/api/ingest/event/route.ts.bak

@@ -0,0 +1,670 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { getMachineAuth } from "@/lib/machineAuthCache";
+import { z } from "zod";
+import { evaluateAlertsForEvent } from "@/lib/alerts/engine";
+import { toJsonValue } from "@/lib/prismaJson";
+import {
+  findCatalogReason,
+  loadFallbackReasonCatalog,
+  normalizeReasonCatalog,
+  toReasonCode,
+  type ReasonCatalog,
+  type ReasonCatalogKind,
+} from "@/lib/reasonCatalog";
+
+const normalizeType = (t: unknown) =>
+  String(t ?? "")
+    .trim()
+    .toLowerCase()
+    .replace(/_/g, "-");
+
+function asRecord(value: unknown): Record<string, unknown> | null {
+  if (!value || typeof value !== "object" || Array.isArray(value)) return null;
+  return value as Record<string, unknown>;
+}
+
+const CANON_TYPE: Record<string, string> = {
+  // Node-RED
+  "production-stopped": "stop",
+  "oee-drop": "oee-drop",
+  "quality-spike": "quality-spike",
+  "predictive-oee-decline": "predictive-oee-decline",
+  "performance-degradation": "performance-degradation",
+
+  // legacy / synonyms
+  "macroparo": "macrostop",
+  "macro-stop": "macrostop",
+  "microparo": "microstop",
+  "micro-paro": "microstop",
+  "down": "stop",
+  "downtime-acknowledged": "downtime-acknowledged",
+  "scrap-manual-entry": "scrap-manual-entry",
+  "mold-change": "mold-change",
+};
+
+const ALLOWED_TYPES = new Set([
+  "slow-cycle",
+  "microstop",
+  "macrostop",
+  "offline",
+  "error",
+  "oee-drop",
+  "quality-spike",
+  "performance-degradation",
+  "predictive-oee-decline",
+  "downtime-acknowledged",
+  "scrap-manual-entry",
+  "mold-change",
+]);
+
+const machineIdSchema = z.string().uuid();
+const MAX_EVENTS = 100;
+
+//when no cycle time is configed
+const DEFAULT_MACROSTOP_SEC = 300;
+
+
+function clampText(value: unknown, maxLen: number) {
+  if (value === null || value === undefined) return null;
+  const text = String(value).trim().replace(/[\u0000-\u001f\u007f]/g, "");
+  if (!text) return null;
+  return text.length > maxLen ? text.slice(0, maxLen) : text;
+}
+
+function numberFrom(value: unknown) {
+  if (typeof value === "number" && Number.isFinite(value)) return value;
+  if (typeof value === "string" && value.trim()) {
+    const parsed = Number(value);
+    if (Number.isFinite(parsed)) return parsed;
+  }
+  return null;
+}
+function parseSeqToBigInt(value: unknown): bigint | null {
+  if (value === null || value === undefined) return null;
+  if (typeof value === "number") {
+    if (!Number.isInteger(value) || value < 0) return null;
+    return BigInt(value);
+  }
+  if (typeof value === "string" && /^\d+$/.test(value)) return BigInt(value);
+  return null;
+}
+
+function canonicalText(value: unknown) {
+  return String(value ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+}
+
+function parseReasonPath(rawPath: unknown) {
+  let category: string | null = null;
+  let detail: string | null = null;
+
+  if (Array.isArray(rawPath)) {
+    const first = rawPath[0];
+    const second = rawPath[1];
+    if (typeof first === "string") category = first;
+    if (typeof second === "string") detail = second;
+    if (asRecord(first)) category = clampText(first.id ?? first.label ?? first.value, 120);
+    if (asRecord(second)) detail = clampText(second.id ?? second.label ?? second.value, 120);
+  } else if (typeof rawPath === "string") {
+    const pieces = rawPath
+      .split(/>|\/|\\|\|/g)
+      .map((p) => p.trim())
+      .filter(Boolean);
+    category = pieces[0] ?? null;
+    detail = pieces[1] ?? null;
+  }
+
+  return {
+    category: clampText(category, 120),
+    detail: clampText(detail, 120),
+  };
+}
+
+function parseReasonTextPath(reasonText: unknown) {
+  const text = clampText(reasonText, 240);
+  if (!text) return { category: null as string | null, detail: null as string | null };
+  const pieces = text
+    .split(/>|\/|\\|\|/g)
+    .map((p) => p.trim())
+    .filter(Boolean);
+  return {
+    category: clampText(pieces[0] ?? null, 120),
+    detail: clampText(pieces[1] ?? null, 120),
+  };
+}
+
+function findCatalogReasonFlexible(
+  catalog: ReasonCatalog | null,
+  kind: ReasonCatalogKind,
+  categoryIdOrLabel: unknown,
+  detailIdOrLabel: unknown
+) {
+  const direct = findCatalogReason(catalog, kind, categoryIdOrLabel, detailIdOrLabel);
+  if (direct) return direct;
+  if (!catalog) return null;
+
+  const catNeedle = canonicalText(categoryIdOrLabel);
+  const detNeedle = canonicalText(detailIdOrLabel);
+  if (!catNeedle || !detNeedle) return null;
+
+  for (const category of catalog[kind] ?? []) {
+    const catMatch =
+      canonicalText(category.id) === catNeedle || canonicalText(category.label) === catNeedle;
+    if (!catMatch) continue;
+    for (const detail of category.details) {
+      const detMatch = canonicalText(detail.id) === detNeedle || canonicalText(detail.label) === detNeedle;
+      if (!detMatch) continue;
+      return {
+        categoryId: category.id,
+        categoryLabel: category.label,
+        detailId: detail.id,
+        detailLabel: detail.label,
+        reasonCode: toReasonCode(category.id, detail.id),
+        reasonLabel: `${category.label} > ${detail.label}`,
+      };
+    }
+  }
+  return null;
+}
+
+function getCatalogFromDefaults(defaultsJson: unknown) {
+  const defaults = asRecord(defaultsJson);
+  if (!defaults) return null;
+  return normalizeReasonCatalog(defaults.reasonCatalog ?? defaults.reasonCatalogData);
+}
+
+function resolveReason(
+  raw: Record<string, unknown>,
+  kind: ReasonCatalogKind,
+  catalog: ReasonCatalog | null,
+  fallbackVersion: number
+) {
+  const reasonPath = parseReasonPath(raw.reasonPath);
+  const reasonTextPath = parseReasonTextPath(raw.reasonText);
+  const categoryIdRaw = clampText(raw.categoryId ?? reasonPath.category ?? reasonTextPath.category, 64);
+  const detailIdRaw = clampText(raw.detailId ?? reasonPath.detail ?? reasonTextPath.detail, 64);
+  const fromCatalog = findCatalogReasonFlexible(catalog, kind, categoryIdRaw, detailIdRaw);
+
+  const categoryLabelRaw = clampText(raw.categoryLabel ?? reasonPath.category ?? reasonTextPath.category, 120);
+  const detailLabelRaw = clampText(raw.detailLabel ?? reasonPath.detail ?? reasonTextPath.detail, 120);
+
+  const reasonCode =
+    clampText(raw.reasonCode, 64)?.toUpperCase() ??
+    fromCatalog?.reasonCode ??
+    toReasonCode(categoryIdRaw ?? categoryLabelRaw, detailIdRaw ?? detailLabelRaw) ??
+    null;
+
+  const categoryId = fromCatalog?.categoryId ?? categoryIdRaw;
+  const detailId = fromCatalog?.detailId ?? detailIdRaw;
+  const categoryLabel = fromCatalog?.categoryLabel ?? categoryLabelRaw;
+  const detailLabel = fromCatalog?.detailLabel ?? detailLabelRaw;
+
+  const pathLabel =
+    clampText(raw.reasonText, 240) ??
+    fromCatalog?.reasonLabel ??
+    (categoryLabel && detailLabel ? `${categoryLabel} > ${detailLabel}` : null) ??
+    detailLabel ??
+    categoryLabel ??
+    reasonCode;
+
+  const catalogVersionRaw = numberFrom(raw.catalogVersion);
+  const catalogVersion = catalogVersionRaw != null ? Math.trunc(catalogVersionRaw) : fallbackVersion;
+
+  return {
+    type: kind,
+    categoryId,
+    categoryLabel,
+    detailId,
+    detailLabel,
+    reasonCode,
+    reasonLabel: pathLabel,
+    reasonText: pathLabel,
+    catalogVersion,
+  };
+}
+
+export async function POST(req: Request) {
+  const apiKey = req.headers.get("x-api-key");
+  if (!apiKey) return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
+
+  let body: unknown = await req.json().catch(() => null);
+
+  // ✅ if Node-RED sent an array as the whole body, unwrap it
+  if (Array.isArray(body)) body = body[0];
+  const bodyRecord = asRecord(body) ?? {};
+  const payloadRecord = asRecord(bodyRecord.payload) ?? {};
+
+  // ✅ accept multiple common keys
+  const machineId =
+    bodyRecord.machineId ??
+    bodyRecord.machine_id ??
+    (asRecord(bodyRecord.machine)?.id ?? null);
+  let rawEvent =
+    bodyRecord.event ??
+    bodyRecord.events ??
+    bodyRecord.anomalies ??
+    payloadRecord.event ??
+    payloadRecord.events ??
+    payloadRecord.anomalies ??
+    payloadRecord ??
+    bodyRecord.data; // sometimes "data"
+
+  const rawEventRecord = asRecord(rawEvent);
+  if (rawEventRecord?.event && typeof rawEventRecord.event === "object") rawEvent = rawEventRecord.event;
+  if (Array.isArray(rawEventRecord?.events)) rawEvent = rawEventRecord.events;
+
+  if (!machineId || !rawEvent) {
+    return NextResponse.json(
+      { ok: false, error: "Invalid payload", got: { hasMachineId: !!machineId, keys: Object.keys(bodyRecord) } },
+      { status: 400 }
+    );
+  }
+
+  if (!machineIdSchema.safeParse(String(machineId)).success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine id" }, { status: 400 });
+  }
+
+  const machine = await getMachineAuth(String(machineId), apiKey);
+  if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  const orgSettings = await prisma.orgSettings.findUnique({
+    where: { orgId: machine.orgId },
+    select: { stoppageMultiplier: true, macroStoppageMultiplier: true, defaultsJson: true },
+  });
+  const fallbackCatalog = await loadFallbackReasonCatalog();
+  const settingsCatalog = getCatalogFromDefaults(orgSettings?.defaultsJson);
+  const reasonCatalog = settingsCatalog ?? fallbackCatalog;
+
+  const defaultMicroMultiplier = Number(orgSettings?.stoppageMultiplier ?? 1.5);
+  const defaultMacroMultiplier = Math.max(
+    defaultMicroMultiplier,
+    Number(orgSettings?.macroStoppageMultiplier ?? 5)
+  );
+
+
+  // ✅ normalize to array no matter what
+  const events = Array.isArray(rawEvent) ? rawEvent : [rawEvent];
+  if (events.length > MAX_EVENTS) {
+    return NextResponse.json({ ok: false, error: "Too many events" }, { status: 400 });
+  }
+
+  const created: { id: string; ts: Date; eventType: string }[] = [];
+  const skipped: Array<Record<string, unknown>> = [];
+
+  for (const ev of events) {
+    const evRecord = asRecord(ev);
+    if (!evRecord) {
+      skipped.push({ reason: "invalid_event_object" });
+      continue;
+    }
+    const evData = asRecord(evRecord.data) ?? {};
+    // We'll re-check reason again after parsing `data` (it may be a JSON string)
+    let evReason = asRecord(evRecord.reason) ?? asRecord(evData.reason);
+    const evDowntime = asRecord(evRecord.downtime) ?? asRecord(evData.downtime);
+    // Some producers nest the reason under `downtime.reason`
+    if (!evReason) evReason = asRecord(evDowntime?.reason);
+
+    const rawType = evRecord.eventType ?? evRecord.anomaly_type ?? evRecord.topic ?? bodyRecord.topic ?? "";
+    const typ0 = normalizeType(rawType);
+    const typ = CANON_TYPE[typ0] ?? typ0;
+
+    // Determine timestamp
+    const tsMs =
+      (typeof evRecord.timestamp === "number" && evRecord.timestamp) ||
+      (typeof evData.timestamp === "number" && evData.timestamp) ||
+      (typeof evData.event_timestamp === "number" && evData.event_timestamp) ||
+      null;
+
+    const ts = tsMs ? new Date(tsMs) : new Date();
+
+    // Severity defaulting (do not skip on severity — store for audit)
+    let sev = String(evRecord.severity ?? "").trim().toLowerCase();
+    if (!sev) sev = "warning";
+
+    // Stop classification -> microstop/macrostop
+    let finalType = typ;
+    let stopSecForReason: number | null = null;
+    if (typ === "stop") {
+      const stopSec =
+        (typeof evData.stoppage_duration_seconds === "number" && evData.stoppage_duration_seconds) ||
+        (typeof evData.stop_duration_seconds === "number" && evData.stop_duration_seconds) ||
+        null;
+      stopSecForReason = stopSec != null ? Number(stopSec) : null;
+
+      if (stopSec != null) {
+        const theoretical = Number(evData.theoretical_cycle_time ?? evData.theoreticalCycleTime ?? 0) || 0;
+
+        const microMultiplier = Number(
+          evData.micro_threshold_multiplier ?? evData.threshold_multiplier ?? defaultMicroMultiplier
+        );
+        const macroMultiplier = Math.max(
+          microMultiplier,
+          Number(evData.macro_threshold_multiplier ?? defaultMacroMultiplier)
+        );
+
+        if (theoretical > 0) {
+          const macroThresholdSec = theoretical * macroMultiplier;
+          finalType = stopSec >= macroThresholdSec ? "macrostop" : "microstop";
+        } else {
+          finalType = stopSec >= DEFAULT_MACROSTOP_SEC ? "macrostop" : "microstop";
+        }
+      } else {
+        // missing duration -> conservative
+        finalType = "microstop";
+      }
+    }
+
+    if (!ALLOWED_TYPES.has(finalType)) {
+      skipped.push({ reason: "type_not_allowed", typ: finalType, sev });
+      continue;
+    }
+
+    const title =
+      clampText(evRecord.title, 160) ||
+      (finalType === "slow-cycle" ? "Slow Cycle Detected" :
+       finalType === "macrostop" ? "Macrostop Detected" :
+       finalType === "microstop" ? "Microstop Detected" :
+       "Event");
+
+    const description = clampText(evRecord.description, 1000);
+
+    // store full blob, ensure object
+    const rawData = evRecord.data ?? evRecord;
+    const parsedData = typeof rawData === "string"
+      ? (() => {
+          try {
+            return JSON.parse(rawData);
+          } catch {
+            return { raw: rawData };
+          }
+        })()
+      : rawData;
+    const dataObj: Record<string, unknown> =
+      parsedData && typeof parsedData === "object" && !Array.isArray(parsedData)
+        ? { ...(parsedData as Record<string, unknown>) }
+        : { raw: parsedData };
+    if (evRecord.status != null && dataObj.status == null) dataObj.status = evRecord.status;
+    if (evRecord.alert_id != null && dataObj.alert_id == null) dataObj.alert_id = evRecord.alert_id;
+    if (evRecord.is_update != null && dataObj.is_update == null) dataObj.is_update = evRecord.is_update;
+    if (evRecord.is_auto_ack != null && dataObj.is_auto_ack == null) dataObj.is_auto_ack = evRecord.is_auto_ack;
+    if (evReason && dataObj.reason == null) dataObj.reason = evReason;
+    if (evDowntime && dataObj.downtime == null) dataObj.downtime = evDowntime;
+
+    // If `data` was a JSON string, the earlier evReason lookup would miss it.
+    // Re-check here using the normalized object we will persist.
+    if (!evReason) evReason = asRecord(dataObj.reason);
+    if (!evReason) evReason = asRecord(asRecord(dataObj.downtime)?.reason);
+
+    // If we have a reasonText but missing ids, derive ids from the path-like string.
+    if (evReason) {
+      const hasCat = clampText((evReason as any).categoryId, 64) ?? clampText((evReason as any).categoryLabel, 120);
+      const hasDet = clampText((evReason as any).detailId, 64) ?? clampText((evReason as any).detailLabel, 120);
+      const rt = clampText((evReason as any).reasonText, 240);
+      if ((!hasCat || !hasDet) && rt) {
+        const parsed = parseReasonTextPath(rt);
+        const next = { ...evReason } as Record<string, unknown>;
+        // Preserve any explicit ids; only fill gaps.
+        if ((next as any).categoryId == null && parsed.category) next.categoryId = canonicalText(parsed.category);
+        if ((next as any).categoryLabel == null && parsed.category) next.categoryLabel = parsed.category;
+        if ((next as any).detailId == null && parsed.detail) next.detailId = canonicalText(parsed.detail);
+        if ((next as any).detailLabel == null && parsed.detail) next.detailLabel = parsed.detail;
+        evReason = next;
+      }
+    }
+
+    const activeWorkOrder = asRecord(evRecord.activeWorkOrder);
+    const dataActiveWorkOrder = asRecord(evData.activeWorkOrder);
+
+    // ✨ Cada evento puede traer su propio seq, o usar el del payload raíz
+    const evSeq = 
+      parseSeqToBigInt(evRecord.seq) ??
+      parseSeqToBigInt(evData.seq) ??
+      bodySeq;
+
+    const evSchemaVersion = 
+      clampText(evRecord.schemaVersion, 16) ??
+      bodySchemaVersion;
+
+    const eventData = {
+      orgId: machine.orgId,
+      machineId: machine.id,
+      schemaVersion: evSchemaVersion,
+      seq: evSeq,
+      ts,
+      topic: clampText(evRecord.topic ?? finalType, 64) ?? finalType,
+      eventType: finalType,
+      severity: sev,
+      requiresAck: !!evRecord.requires_ack,
+      title,
+      description,
+      data: toJsonValue(dataObj),
+      workOrderId:
+        clampText(evRecord.work_order_id, 64) ??
+        clampText(evData.work_order_id, 64) ??
+        clampText(activeWorkOrder?.id, 64) ??
+        clampText(dataActiveWorkOrder?.id, 64) ??
+        null,
+      sku:
+        clampText(evRecord.sku, 64) ??
+        clampText(evData.sku, 64) ??
+        clampText(activeWorkOrder?.sku, 64) ??
+        clampText(dataActiveWorkOrder?.sku, 64) ??
+        null,
+    };
+
+    // ✨ Idempotente: si ya existe (mismo orgId+machineId+seq), no inserta
+    const insertResult = await prisma.machineEvent.createMany({
+      data: [eventData],
+      skipDuplicates: true,
+    });
+
+    // ✨ Buscar la fila (la recién creada o la duplicada existente)
+    let row;
+    if (evSeq != null) {
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          seq: evSeq,
+        },
+        orderBy: { ts_server: "asc" },
+      });
+    } else {
+      // Sin seq, buscar por ts (fallback compatibilidad con eventos viejos)
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          ts,
+          eventType: finalType,
+        },
+        orderBy: { ts_server: "desc" },
+      });
+    }
+
+    if (!row) {
+      skipped.push({ reason: "row_not_found_after_insert", seq: evSeq?.toString() });
+      continue;
+    }
+
+    const wasDuplicate = insertResult.count === 0;
+
+    // Si fue duplicado, no procesar reasonEntry ni alertas (ya se hicieron antes)
+    if (wasDuplicate) {
+      created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+      continue;  // ✨ saltar el resto del procesamiento
+    }
+
+    created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+
+    
+
+    // If the payload carries a `reason`, create the corresponding ReasonEntry.
+    // If it doesn't, still create an "UNCLASSIFIED" downtime ReasonEntry for stop events so the dashboard can show coverage.
+    if (evRecord.is_update || evRecord.is_auto_ack || dataObj.is_update || dataObj.is_auto_ack){
+  // skip duplicate reasonEntry for refresh/ack 
+    } else if (evReason || finalType === "microstop" || finalType === "macrostop" || finalType === "downtime-acknowledged" || finalType === "mold-change"){
+      const moldIncidentKey =
+        clampText(evData.incidentKey ?? dataObj.incidentKey, 128) ??
+        (numberFrom(evData.start_ms ?? dataObj.start_ms) != null
+          ? `mold-change:${Math.trunc(numberFrom(evData.start_ms ?? dataObj.start_ms) as number)}`
+          : null);
+      const reasonRaw: Record<string, unknown> =
+        evReason ??
+        (finalType === "mold-change"
+          ? ({
+              type: "downtime",
+              categoryId: "cambio-molde",
+              detailId: "cambio-molde",
+              categoryLabel: "Cambio molde",
+              detailLabel: "Cambio molde",
+              reasonCode: "MOLD_CHANGE",
+              reasonText: "Cambio molde",
+              incidentKey: moldIncidentKey ?? row.id,
+            } as Record<string, unknown>)
+          :
+        ({
+          type: "downtime",
+          categoryId: "unclassified",
+          detailId: "unclassified",
+          categoryLabel: "Unclassified",
+          detailLabel: "Unclassified",
+          reasonCode: "UNCLASSIFIED",
+          reasonText: "Unclassified",
+          incidentKey: row.id,
+        } as Record<string, unknown>));
+
+      const inferredKind: ReasonCatalogKind =
+        String(reasonRaw.type ?? "").toLowerCase() === "scrap" || finalType === "scrap-manual-entry"
+          ? "scrap"
+          : "downtime";
+      const resolved = resolveReason(reasonRaw, inferredKind, reasonCatalog, reasonCatalog.version);
+
+      if (resolved.reasonCode) {
+        const reasonId =
+          clampText(reasonRaw.reasonId, 128) ??
+          (inferredKind === "downtime"
+            ? `evt:${machine.id}:downtime:${clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id}`
+            : `evt:${machine.id}:scrap:${clampText(reasonRaw.scrapEntryId, 128) ?? row.id}`);
+
+        const workOrderId =
+          clampText(evRecord.work_order_id, 64) ??
+          clampText(evData.work_order_id, 64) ??
+          clampText(evRecord.workOrderId, 64) ??
+          null;
+
+        const commonWrite = {
+          reasonCode: resolved.reasonCode,
+          reasonLabel: resolved.reasonLabel ?? resolved.reasonCode,
+          reasonText: resolved.reasonText ?? null,
+          capturedAt: row.ts,
+          workOrderId,
+          schemaVersion: Math.max(1, Math.trunc(resolved.catalogVersion)),
+          meta: toJsonValue({
+            source: "ingest:event",
+            eventId: row.id,
+            eventType: row.eventType,
+            incidentKey: clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128),
+            anomalyType:
+              clampText(evRecord.anomalyType, 64) ??
+              clampText(evDowntime?.anomalyType, 64) ??
+              clampText(evRecord.anomaly_type, 64),
+            reason: {
+              type: resolved.type,
+              categoryId: resolved.categoryId,
+              categoryLabel: resolved.categoryLabel,
+              detailId: resolved.detailId,
+              detailLabel: resolved.detailLabel,
+              reasonText: resolved.reasonText,
+              catalogVersion: resolved.catalogVersion,
+            },
+          }),
+        };
+
+        if (inferredKind === "downtime") {
+          const incidentKey = clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id;
+          const durationSeconds =
+            numberFrom(evDowntime?.durationSeconds) ??
+            numberFrom(evData.duration_sec) ??
+            numberFrom(evData.stoppage_duration_seconds) ??
+            numberFrom(evData.stop_duration_seconds) ??
+            (stopSecForReason != null ? stopSecForReason : null) ??
+            null;
+          const episodeEndTsMs =
+            numberFrom(evData.end_ms) ??
+            numberFrom(evDowntime?.episodeEndTsMs) ??
+            numberFrom(evDowntime?.acknowledgedAtMs) ??
+            null;
+
+          await prisma.reasonEntry.upsert({
+            where: { reasonId },
+            create: {
+              orgId: machine.orgId,
+              machineId: machine.id,
+              reasonId,
+              kind: "downtime",
+              episodeId: incidentKey,
+              durationSeconds: durationSeconds != null ? Math.max(0, Math.trunc(durationSeconds)) : null,
+              episodeEndTs: episodeEndTsMs != null ? new Date(episodeEndTsMs) : null,
+              ...commonWrite,
+            },
+            update: {
+              kind: "downtime",
+              episodeId: incidentKey,
+              durationSeconds: durationSeconds != null ? Math.max(0, Math.trunc(durationSeconds)) : null,
+              episodeEndTs: episodeEndTsMs != null ? new Date(episodeEndTsMs) : null,
+              ...commonWrite,
+            },
+          });
+        } else {
+          const scrapEntryId =
+            clampText((reasonRaw as any).scrapEntryId, 128) ??
+            clampText(evRecord.id, 128) ??
+            clampText(evRecord.eventId, 128) ??
+            row.id;
+          const scrapQtyRaw =
+            numberFrom(evRecord.scrapDelta) ??
+            numberFrom(evData.scrapDelta) ??
+            numberFrom(evData.scrap_delta) ??
+            0;
+          const scrapQty = Math.max(0, Math.trunc(scrapQtyRaw));
+
+          await prisma.reasonEntry.upsert({
+            where: { reasonId },
+            create: {
+              orgId: machine.orgId,
+              machineId: machine.id,
+              reasonId,
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText((reasonRaw as any).scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+            update: {
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText((reasonRaw as any).scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+          });
+        }
+      }
+    }
+
+    try {
+      if (row.eventType !== "downtime-acknowledged" && row.eventType !== "scrap-manual-entry") {
+        await evaluateAlertsForEvent(row.id);
+      }
+    } catch (err) {
+      console.error("[alerts] evaluation failed", err);
+    }
+  }
+
+  return NextResponse.json({ ok: true, createdCount: created.length, created, skippedCount: skipped.length, skipped });
+}

app/api/ingest/heartbeat/route.ts

@@ -1,32 +1,174 @@
 import { NextResponse } from "next/server";
 import { prisma } from "@/lib/prisma";
+import { getMachineAuth } from "@/lib/machineAuthCache";
+import { normalizeHeartbeatV1 } from "@/lib/contracts/v1";
+import { toJsonValue } from "@/lib/prismaJson";
 
-export async function POST(req: Request) {
-  const apiKey = req.headers.get("x-api-key");
-  if (!apiKey) return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
-
-  const body = await req.json().catch(() => null);
-  if (!body?.machineId || !body?.status) {
-    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+function getClientIp(req: Request) {
+  const xf = req.headers.get("x-forwarded-for");
+  if (xf) return xf.split(",")[0]?.trim() || null;
+  return req.headers.get("x-real-ip") || null;
 }
 
-  const machine = await prisma.machine.findFirst({
-    where: { id: String(body.machineId), apiKey },
-    select: { id: true, orgId: true },
+function parseSeqToBigInt(seq: unknown): bigint | null {
+  if (seq === null || seq === undefined) return null;
+  if (typeof seq === "number") {
+    if (!Number.isInteger(seq) || seq < 0) return null;
+    return BigInt(seq);
+  }
+  if (typeof seq === "string" && /^\d+$/.test(seq)) return BigInt(seq);
+  return null;
+}
+
+export async function POST(req: Request) {
+  const endpoint = "/api/ingest/heartbeat";
+  const ip = getClientIp(req);
+  const userAgent = req.headers.get("user-agent");
+
+  let rawBody: unknown = null;
+  let orgId: string | null = null;
+  let machineId: string | null = null;
+  let seq: bigint | null = null;
+  let schemaVersion: string | null = null;
+  let tsDeviceDate: Date | null = null;
+
+  try {
+    // 1) Auth header exists
+    const apiKey = req.headers.get("x-api-key");
+    if (!apiKey) {
+      await prisma.ingestLog.create({
+        data: { endpoint, ok: false, status: 401, errorCode: "MISSING_API_KEY", errorMsg: "Missing api key", ip, userAgent },
       });
+      return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
+    }
 
-  if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    // 2) Parse JSON
+    rawBody = await req.json().catch(() => null);
 
-  const hb = await prisma.machineHeartbeat.create({
+    // 3) Normalize to v1 (legacy tolerated)
+    const normalized = normalizeHeartbeatV1(rawBody);
+    if (!normalized.ok) {
+      await prisma.ingestLog.create({
         data: {
-      orgId: machine.orgId,
+          endpoint,
+          ok: false,
+          status: 400,
+          errorCode: "INVALID_PAYLOAD",
+          errorMsg: normalized.error,
+          body: toJsonValue(rawBody),
+          ip,
+          userAgent,
+        },
+      });
+      return NextResponse.json({ ok: false, error: "Invalid payload", detail: normalized.error }, { status: 400 });
+    }
+
+    const body = normalized.value;
+    schemaVersion = body.schemaVersion;
+    machineId = body.machineId;
+    seq = parseSeqToBigInt(body.seq);
+    tsDeviceDate = new Date(body.tsDevice);
+
+    // 4) Authorize machineId + apiKey
+    const machine = await getMachineAuth(machineId, apiKey);
+
+    if (!machine) {
+      await prisma.ingestLog.create({
+        data: {
+          endpoint,
+          ok: false,
+          status: 401,
+          errorCode: "UNAUTHORIZED",
+          errorMsg: "Unauthorized (machineId/apiKey mismatch)",
+          body: toJsonValue(rawBody),
+          machineId,
+          schemaVersion,
+          seq,
+          tsDevice: tsDeviceDate,
+          ip,
+          userAgent,
+        },
+      });
+      return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    }
+
+    orgId = machine.orgId;
+
+    // 5) Store heartbeat
+    // Keep your legacy fields, but store meta fields too.
+    const tsServerNow = new Date();
+    const hbRow = {
+      orgId,
       machineId: machine.id,
-      status: String(body.status),
+      schemaVersion,
+      seq,
+      ts: tsDeviceDate,
+      tsServer: tsServerNow,
+      status: body.status ? String(body.status) : (body.online ? "RUN" : "STOP"),
       message: body.message ? String(body.message) : null,
       ip: body.ip ? String(body.ip) : null,
       fwVersion: body.fwVersion ? String(body.fwVersion) : null,
+    };
+
+    const insertHb = await prisma.machineHeartbeat.createMany({
+      data: [hbRow],
+      skipDuplicates: true,
+    });
+
+    const hb = await prisma.machineHeartbeat.findFirst({
+      where: {
+        orgId,
+        machineId: machine.id,
+        ts: tsDeviceDate,
+      },
+      orderBy: { tsServer: "asc" },
+    });
+
+    if (!hb) {
+      return NextResponse.json({ ok: false, error: "Server error", detail: "Heartbeat row missing" }, { status: 500 });
+    }
+
+    // Optional: update machine last seen (same as KPI) — also on duplicate HB so lastSeen is fresh
+    await prisma.machine.update({
+      where: { id: machine.id },
+      data: {
+        schemaVersion,
+        seq,
+        tsDevice: tsDeviceDate,
+        tsServer: tsServerNow,
       },
     });
 
-  return NextResponse.json({ ok: true, id: hb.id, ts: hb.ts });
+    return NextResponse.json({
+      ok: true,
+      id: hb.id,
+      tsDevice: hb.ts,
+      tsServer: hb.tsServer,
+      duplicate: insertHb.count === 0,
+    });
+  } catch (err: unknown) {
+    const msg = err instanceof Error ? err.message : "Unknown error";
+
+    try {
+      await prisma.ingestLog.create({
+        data: {
+          orgId,
+          machineId,
+          endpoint,
+          ok: false,
+          status: 500,
+          errorCode: "SERVER_ERROR",
+          errorMsg: msg,
+          schemaVersion,
+          seq,
+          tsDevice: tsDeviceDate ?? undefined,
+          body: toJsonValue(rawBody),
+          ip,
+          userAgent,
+        },
+      });
+    } catch {}
+
+    return NextResponse.json({ ok: false, error: "Server error", detail: msg }, { status: 500 });
+  }
 }

app/api/ingest/kpi/route.ts

@@ -1,50 +1,363 @@
+// mis-control-tower/app/api/ingest/kpi/route.ts
 import { NextResponse } from "next/server";
 import { prisma } from "@/lib/prisma";
+import { getMachineAuth } from "@/lib/machineAuthCache";
+import { normalizeSnapshotV1 } from "@/lib/contracts/v1";
+import { toJsonValue } from "@/lib/prismaJson";
+import { logLine } from "@/lib/logger";
 
-export async function POST(req: Request) {
-  const apiKey = req.headers.get("x-api-key");
-  if (!apiKey) return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
-
-  const body = await req.json().catch(() => null);
-  if (!body?.machineId || !body?.kpis) {
-    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+function getClientIp(req: Request) {
+  const xf = req.headers.get("x-forwarded-for");
+  if (xf) return xf.split(",")[0]?.trim() || null;
+  return req.headers.get("x-real-ip") || null;
 }
 
-  const machine = await prisma.machine.findFirst({
-    where: { id: String(body.machineId), apiKey },
-    select: { id: true, orgId: true },
-  });
-  if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+function parseSeqToBigInt(seq: unknown): bigint | null {
+  if (seq === null || seq === undefined) return null;
+  if (typeof seq === "number") {
+    if (!Number.isInteger(seq) || seq < 0) return null;
+    return BigInt(seq);
+  }
+  if (typeof seq === "string" && /^\d+$/.test(seq)) return BigInt(seq);
+  return null;
+}
 
-  const wo = body.activeWorkOrder ?? {};
-  const k = body.kpis ?? {};
+function asRecord(value: unknown): Record<string, unknown> | null {
+  if (!value || typeof value !== "object" || Array.isArray(value)) return null;
+  return value as Record<string, unknown>;
+}
 
-  const row = await prisma.machineKpiSnapshot.create({
+function toFiniteNumber(value: unknown): number | null {
+  if (typeof value === "number" && Number.isFinite(value)) return value;
+  if (typeof value === "string") {
+    const parsed = Number(value);
+    if (Number.isFinite(parsed)) return parsed;
+  }
+  return null;
+}
+
+function toFiniteInt(value: unknown): number | null {
+  const parsed = toFiniteNumber(value);
+  if (parsed == null) return null;
+  return Math.trunc(parsed);
+}
+
+function pickFirstNumber(...values: unknown[]) {
+  for (const value of values) {
+    const parsed = toFiniteNumber(value);
+    if (parsed != null) return parsed;
+  }
+  return null;
+}
+
+function readPath(root: unknown, path: string[]): unknown {
+  let current = root;
+  for (const key of path) {
+    const record = asRecord(current);
+    if (!record) return undefined;
+    current = record[key];
+  }
+  return current;
+}
+
+function collectQualityTrace(params: {
+  rawBody: unknown;
+  normalizedKpis: Record<string, unknown> | null;
+  persistedQuality: number | null;
+  machineId: string;
+  rowId: string;
+}) {
+  const { rawBody, normalizedKpis, persistedQuality, machineId, rowId } = params;
+  const candidates = [
+    "kpis.quality",
+    "payload.kpis.quality",
+    "kpi_snapshot.quality",
+    "quality",
+    "payload.quality",
+  ] as const;
+
+  const rawQualityCandidates: Record<string, { type: string; value: unknown }> = {};
+  for (const path of candidates) {
+    const value = readPath(rawBody, path.split("."));
+    rawQualityCandidates[path] = {
+      type: value === null ? "null" : typeof value,
+      value,
+    };
+  }
+
+  const normalizedQuality = normalizedKpis?.quality;
+  return {
+    machineId,
+    rowId,
+    rawQualityCandidates,
+    normalizedQuality: {
+      type: normalizedQuality === null ? "null" : typeof normalizedQuality,
+      value: normalizedQuality ?? null,
+    },
+    persistedQuality: {
+      type: persistedQuality === null ? "null" : typeof persistedQuality,
+      value: persistedQuality,
+    },
+  };
+}
+
+export async function POST(req: Request) {
+  const endpoint = "/api/ingest/kpi";
+  const startedAt = Date.now();
+  const ip = getClientIp(req);
+  const userAgent = req.headers.get("user-agent");
+  const traceEnabled = process.env.TRACE_KPI_INGEST === "1" || req.headers.get("x-debug-ingest") === "1";
+
+  let rawBody: unknown = null;
+  let orgId: string | null = null;
+  let machineId: string | null = null;
+  let seq: bigint | null = null;
+  let schemaVersion: string | null = null;
+  let tsDeviceDate: Date | null = null;
+
+  try {
+    const apiKey = req.headers.get("x-api-key");
+    if (!apiKey) {
+      await prisma.ingestLog.create({
         data: {
-      orgId: machine.orgId,
+          endpoint,
+          ok: false,
+          status: 401,
+          errorCode: "MISSING_API_KEY",
+          errorMsg: "Missing api key",
+          ip,
+          userAgent,
+        },
+      });
+      return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
+    }
+
+    rawBody = await req.json().catch(() => null);
+    const normalized = normalizeSnapshotV1(rawBody);
+    if (!normalized.ok) {
+      await prisma.ingestLog.create({
+        data: {
+          endpoint,
+          ok: false,
+          status: 400,
+          errorCode: "INVALID_PAYLOAD",
+          errorMsg: normalized.error,
+          body: toJsonValue(rawBody),
+          ip,
+          userAgent,
+        },
+      });
+      return NextResponse.json({ ok: false, error: "Invalid payload", detail: normalized.error }, { status: 400 });
+    }
+
+    const body = normalized.value;
+
+    schemaVersion = body.schemaVersion;
+    machineId = body.machineId;
+    seq = parseSeqToBigInt(body.seq);
+    tsDeviceDate = new Date(body.tsDevice);
+
+    // Auth: machineId + apiKey must match
+    const machine = await getMachineAuth(machineId, apiKey);
+
+    if (!machine) {
+      await prisma.ingestLog.create({
+        data: {
+          endpoint,
+          ok: false,
+          status: 401,
+          errorCode: "UNAUTHORIZED",
+          errorMsg: "Unauthorized (machineId/apiKey mismatch)",
+          body: toJsonValue(rawBody),
+          machineId,
+          schemaVersion,
+          seq,
+          tsDevice: tsDeviceDate,
+          ip,
+          userAgent,
+        },
+      });
+      return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    }
+
+    orgId = machine.orgId;
+
+    const woRecord = (body.activeWorkOrder ?? {}) as Record<string, unknown>;
+    const activeWorkOrderId = woRecord.id != null ? String(woRecord.id).trim() : "";
+    const activeSku = woRecord.sku != null ? String(woRecord.sku).trim() : "";
+    const activeStatus = woRecord.status != null ? String(woRecord.status).trim() : "";
+    const activeTargetQty = toFiniteInt(woRecord.target);
+    const activeCycleTime = toFiniteNumber(woRecord.cycleTime);
+    const good = pickFirstNumber(woRecord.good, woRecord.goodParts, woRecord.good_parts);
+    const scrap = pickFirstNumber(woRecord.scrap, woRecord.scrapParts, woRecord.scrap_parts);
+    const activeGoodParts = Math.max(0, Math.trunc(good ?? 0));
+    const activeScrapParts = Math.max(0, Math.trunc(scrap ?? 0));
+    const activeCycleCount = Math.max(
+      0,
+      toFiniteInt(woRecord.cycleCount ?? woRecord.cycle_count ?? body.cycle_count) ?? 0
+    );
+    const snapshotCycleCount =
+      toFiniteInt(body.cycle_count) ??
+      toFiniteInt(woRecord.cycle_count) ??
+      toFiniteInt(woRecord.cycleCount);
+    const snapshotGoodParts =
+      toFiniteInt(body.good_parts) ??
+      toFiniteInt(woRecord.good_parts) ??
+      toFiniteInt(woRecord.goodParts);
+    const snapshotScrapParts =
+      toFiniteInt(body.scrap_parts) ??
+      toFiniteInt(woRecord.scrap_parts) ??
+      toFiniteInt(woRecord.scrapParts);
+    const k = body.kpis ?? {};
+    const safeCycleTime =
+      typeof body.cycleTime === "number" && body.cycleTime > 0
+        ? body.cycleTime
+        : activeCycleTime != null && activeCycleTime > 0
+          ? activeCycleTime
+          : null;
+
+    const safeCavities =
+      typeof body.cavities === "number" && body.cavities > 0
+        ? body.cavities
+        : typeof woRecord.cavities === "number" && woRecord.cavities > 0
+          ? woRecord.cavities
+          : null;
+    // Write snapshot (ts = tsDevice; tsServer auto). Idempotent on (org, machine, ts) to absorb retries.
+    const kpiData = {
+      orgId,
       machineId: machine.id,
-
-      workOrderId: wo.id ? String(wo.id) : null,
-      sku: wo.sku ? String(wo.sku) : null,
-
-      target: typeof wo.target === "number" ? wo.target : null,
-      good: typeof wo.good === "number" ? wo.good : null,
-      scrap: typeof wo.scrap === "number" ? wo.scrap : null,
-
-      cycleCount: typeof body.cycle_count === "number" ? body.cycle_count : null,
-      goodParts: typeof body.good_parts === "number" ? body.good_parts : null,
-
-      cycleTime: typeof body.cycleTime === "number" ? body.cycleTime : null,
-
+      schemaVersion,
+      seq,
+      ts: tsDeviceDate,
+      workOrderId: activeWorkOrderId || null,
+      sku: activeSku || null,
+      target: activeTargetQty,
+      good: good != null ? Math.trunc(good) : null,
+      scrap: scrap != null ? Math.trunc(scrap) : null,
+      cycleCount: snapshotCycleCount,
+      goodParts: snapshotGoodParts,
+      scrapParts: snapshotScrapParts,
+      cavities: safeCavities,
+      cycleTime: safeCycleTime,
+      actualCycle: typeof body.actualCycleTime === "number" ? body.actualCycleTime : null,
       availability: typeof k.availability === "number" ? k.availability : null,
       performance: typeof k.performance === "number" ? k.performance : null,
       quality: typeof k.quality === "number" ? k.quality : null,
       oee: typeof k.oee === "number" ? k.oee : null,
-
       trackingEnabled: typeof body.trackingEnabled === "boolean" ? body.trackingEnabled : null,
       productionStarted: typeof body.productionStarted === "boolean" ? body.productionStarted : null,
+    };
+    const insertKpi = await prisma.machineKpiSnapshot.createMany({
+      data: [kpiData],
+      skipDuplicates: true,
+    });
+    const row = await prisma.machineKpiSnapshot.findFirst({
+      where: { orgId, machineId: machine.id, ts: tsDeviceDate },
+      orderBy: { tsServer: "asc" },
+    });
+    if (!row) {
+      return NextResponse.json({ ok: false, error: "Server error", detail: "KPI snapshot row missing" }, { status: 500 });
+    }
+
+    if (activeWorkOrderId) {
+      await prisma.machineWorkOrder.upsert({
+        where: {
+          machineId_workOrderId: {
+            machineId: machine.id,
+            workOrderId: activeWorkOrderId,
+          },
+        },
+        create: {
+          orgId: machine.orgId,
+          machineId: machine.id,
+          workOrderId: activeWorkOrderId,
+          sku: activeSku || null,
+          targetQty: activeTargetQty,
+          cycleTime: activeCycleTime,
+          status: activeStatus || "RUNNING",
+          goodParts: activeGoodParts,
+          scrapParts: activeScrapParts,
+          cycleCount: activeCycleCount,
+        },
+        update: {
+          sku: activeSku || undefined,
+          targetQty: activeTargetQty ?? undefined,
+          cycleTime: activeCycleTime ?? undefined,
+          status: activeStatus || undefined,
+          goodParts: activeGoodParts,
+          scrapParts: activeScrapParts,
+          cycleCount: activeCycleCount,
+        },
+      });
+    }
+
+    // Optional but useful: update machine "last seen" meta fields
+    await prisma.machine.update({
+      where: { id: machine.id },
+      data: {
+        schemaVersion,
+        seq,
+        tsDevice: tsDeviceDate,
+        tsServer: new Date(),
       },
     });
 
-  return NextResponse.json({ ok: true, id: row.id, ts: row.ts });
+    const trace = collectQualityTrace({
+      rawBody,
+      normalizedKpis: asRecord(k),
+      persistedQuality: row.quality ?? null,
+      machineId: machine.id,
+      rowId: row.id,
+    });
+    if (traceEnabled) {
+      logLine("ingest.kpi.trace", {
+        endpoint,
+        machineId: machine.id,
+        orgId,
+        schemaVersion,
+        seq: seq != null ? seq.toString() : null,
+        ip,
+        userAgent,
+        trace,
+        rawBody: toJsonValue(rawBody),
+      });
+    }
+
+    return NextResponse.json({
+      ok: true,
+      id: row.id,
+      tsDevice: row.ts,
+      tsServer: row.tsServer,
+      duplicate: insertKpi.count === 0,
+      trace: traceEnabled ? trace : undefined,
+    });
+  } catch (err: unknown) {
+    const msg = err instanceof Error ? err.message : "Unknown error";
+
+    // Never fail the request because logging failed
+    try {
+      await prisma.ingestLog.create({
+        data: {
+          orgId,
+          machineId,
+          endpoint,
+          ok: false,
+          status: 500,
+          errorCode: "SERVER_ERROR",
+          errorMsg: msg,
+          schemaVersion,
+          seq,
+          tsDevice: tsDeviceDate ?? undefined,
+          body: toJsonValue(rawBody),
+          ip,
+          userAgent,
+        },
+      });
+    } catch {}
+
+    return NextResponse.json({ ok: false, error: "Server error", detail: msg }, { status: 500 });
+  } finally {
+    // (If later you add latency_ms to IngestLog, you can store Date.now() - startedAt here.)
+    void startedAt;
+  }
 }

app/api/ingest/reason/route.ts

@@ -0,0 +1,150 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+
+const bad = (status: number, error: string) =>
+  NextResponse.json({ ok: false, error }, { status });
+
+const asTrimmedString = (v: any) => {
+  if (v == null) return "";
+  return String(v).trim();
+};
+
+export async function POST(req: Request) {
+  const apiKey = req.headers.get("x-api-key");
+  if (!apiKey) return bad(401, "Missing api key");
+
+  const body = await req.json().catch(() => null);
+  if (!body?.machineId || !body?.reason) return bad(400, "Invalid payload");
+
+  const machine = await prisma.machine.findFirst({
+    where: { id: String(body.machineId), apiKey },
+    select: { id: true, orgId: true },
+  });
+  if (!machine) return bad(401, "Unauthorized");
+
+  const r = body.reason;
+
+  const reasonId = asTrimmedString(r.reasonId);
+  if (!reasonId) return bad(400, "Missing reason.reasonId");
+
+  const kind = asTrimmedString(r.kind).toLowerCase();
+  if (kind !== "downtime" && kind !== "scrap")
+    return bad(400, "Invalid reason.kind");
+
+  const capturedAtMs = r.capturedAtMs;
+  if (typeof capturedAtMs !== "number" || !Number.isFinite(capturedAtMs)) {
+    return bad(400, "Invalid reason.capturedAtMs");
+  }
+  const capturedAt = new Date(capturedAtMs);
+
+  const reasonCodeRaw = asTrimmedString(r.reasonCode);
+  if (!reasonCodeRaw) return bad(400, "Missing reason.reasonCode");
+  const reasonCode = reasonCodeRaw.toUpperCase(); // normalize for grouping/pareto
+
+  const reasonLabel = r.reasonLabel != null ? String(r.reasonLabel) : null;
+
+  let reasonText = r.reasonText != null ? String(r.reasonText).trim() : null;
+  if (reasonCode === "OTHER") {
+    if (!reasonText || reasonText.length < 2)
+      return bad(400, "reason.reasonText required when reasonCode=OTHER");
+  } else {
+    // Non-OTHER must not store free text
+    reasonText = null;
+  }
+
+  // Optional shared fields
+  const workOrderId =
+    r.workOrderId != null && String(r.workOrderId).trim()
+      ? String(r.workOrderId).trim()
+      : null;
+
+  const schemaVersion =
+    typeof r.schemaVersion === "number" && Number.isFinite(r.schemaVersion)
+      ? Math.trunc(r.schemaVersion)
+      : 1;
+
+  const meta = r.meta != null ? r.meta : null;
+
+  // Kind-specific fields
+  let episodeId: string | null = null;
+  let durationSeconds: number | null = null;
+  let episodeEndTs: Date | null = null;
+
+  let scrapEntryId: string | null = null;
+  let scrapQty: number | null = null;
+  let scrapUnit: string | null = null;
+
+  if (kind === "downtime") {
+    episodeId = asTrimmedString(r.episodeId) || null;
+    if (!episodeId) return bad(400, "Missing reason.episodeId for downtime");
+
+    if (typeof r.durationSeconds !== "number" || !Number.isFinite(r.durationSeconds)) {
+      return bad(400, "Invalid reason.durationSeconds for downtime");
+    }
+    durationSeconds = Math.max(0, Math.trunc(r.durationSeconds));
+
+    const episodeEndTsMs = r.episodeEndTsMs;
+    if (episodeEndTsMs != null) {
+      if (typeof episodeEndTsMs !== "number" || !Number.isFinite(episodeEndTsMs)) {
+        return bad(400, "Invalid reason.episodeEndTsMs");
+      }
+      episodeEndTs = new Date(episodeEndTsMs);
+    }
+  } else {
+    scrapEntryId = asTrimmedString(r.scrapEntryId) || null;
+    if (!scrapEntryId) return bad(400, "Missing reason.scrapEntryId for scrap");
+
+    if (typeof r.scrapQty !== "number" || !Number.isFinite(r.scrapQty)) {
+      return bad(400, "Invalid reason.scrapQty for scrap");
+    }
+    scrapQty = Math.max(0, Math.trunc(r.scrapQty));
+
+    scrapUnit =
+      r.scrapUnit != null && String(r.scrapUnit).trim()
+        ? String(r.scrapUnit).trim()
+        : null;
+  }
+
+  // Idempotent upsert keyed by reasonId
+  const row = await prisma.reasonEntry.upsert({
+    where: { reasonId },
+    create: {
+      orgId: machine.orgId,
+      machineId: machine.id,
+      reasonId,
+      kind,
+      episodeId,
+      durationSeconds,
+      episodeEndTs,
+      scrapEntryId,
+      scrapQty,
+      scrapUnit,
+      reasonCode,
+      reasonLabel,
+      reasonText,
+      capturedAt,
+      workOrderId,
+      meta,
+      schemaVersion,
+    },
+    update: {
+      kind,
+      episodeId,
+      durationSeconds,
+      episodeEndTs,
+      scrapEntryId,
+      scrapQty,
+      scrapUnit,
+      reasonCode,
+      reasonLabel,
+      reasonText,
+      capturedAt,
+      workOrderId,
+      meta,
+      schemaVersion,
+    },
+    select: { id: true, reasonId: true },
+  });
+
+  return NextResponse.json({ ok: true, id: row.id, reasonId: row.reasonId });
+}

app/api/invites/[token]/route.ts

@@ -0,0 +1,153 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import bcrypt from "bcrypt";
+import { prisma } from "@/lib/prisma";
+import { buildSessionCookieOptions, COOKIE_NAME, SESSION_DAYS } from "@/lib/auth/sessionCookie";
+import { z } from "zod";
+
+const tokenSchema = z.string().regex(/^[a-f0-9]{48}$/i);
+const acceptSchema = z.object({
+  name: z.string().trim().min(1).max(80).optional(),
+  password: z.string().min(8).max(256),
+});
+
+async function loadInvite(token: string) {
+  return prisma.orgInvite.findFirst({
+    where: {
+      token,
+      revokedAt: null,
+      acceptedAt: null,
+      expiresAt: { gt: new Date() },
+    },
+    include: {
+      org: { select: { id: true, name: true, slug: true } },
+    },
+  });
+}
+
+export async function GET(
+  _req: NextRequest,
+  { params }: { params: Promise<{ token: string }> }
+) {
+  const { token } = await params;
+  if (!tokenSchema.safeParse(token).success) {
+    return NextResponse.json({ ok: false, error: "Invalid invite token" }, { status: 400 });
+  }
+  const invite = await loadInvite(token);
+  if (!invite) {
+    return NextResponse.json({ ok: false, error: "Invite not found" }, { status: 404 });
+  }
+
+  return NextResponse.json({
+    ok: true,
+    invite: {
+      email: invite.email,
+      role: invite.role,
+      org: invite.org,
+      expiresAt: invite.expiresAt,
+    },
+  });
+}
+
+export async function POST(
+  req: NextRequest,
+  { params }: { params: Promise<{ token: string }> }
+) {
+  const { token } = await params;
+  if (!tokenSchema.safeParse(token).success) {
+    return NextResponse.json({ ok: false, error: "Invalid invite token" }, { status: 400 });
+  }
+  const invite = await loadInvite(token);
+  if (!invite) {
+    return NextResponse.json({ ok: false, error: "Invite not found" }, { status: 404 });
+  }
+
+  const body = await req.json().catch(() => ({}));
+  const parsed = acceptSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid invite payload" }, { status: 400 });
+  }
+  const name = String(parsed.data.name || "").trim();
+  const password = parsed.data.password;
+
+  const existingUser = await prisma.user.findUnique({
+    where: { email: invite.email },
+  });
+
+  if (!existingUser && !name) {
+    return NextResponse.json({ ok: false, error: "Name is required" }, { status: 400 });
+  }
+
+  let userId = existingUser?.id ?? null;
+  if (existingUser) {
+    if (!existingUser.isActive) {
+      return NextResponse.json({ ok: false, error: "User is inactive" }, { status: 403 });
+    }
+    const ok = await bcrypt.compare(password, existingUser.passwordHash);
+    if (!ok) {
+      return NextResponse.json({ ok: false, error: "Invalid credentials" }, { status: 401 });
+    }
+    userId = existingUser.id;
+  } else {
+    const passwordHash = await bcrypt.hash(password, 10);
+    const created = await prisma.user.create({
+      data: {
+        email: invite.email,
+        name,
+        passwordHash,
+        emailVerifiedAt: new Date(),
+      },
+    });
+    userId = created.id;
+  }
+
+  const expiresAt = new Date(Date.now() + SESSION_DAYS * 24 * 60 * 60 * 1000);
+
+  const session = await prisma.$transaction(async (tx) => {
+    if (existingUser && !existingUser.emailVerifiedAt) {
+      await tx.user.update({
+        where: { id: existingUser.id },
+        data: {
+          emailVerifiedAt: new Date(),
+          emailVerificationToken: null,
+          emailVerificationExpiresAt: null,
+        },
+      });
+    }
+
+    await tx.orgUser.upsert({
+      where: {
+        orgId_userId: {
+          orgId: invite.orgId,
+          userId,
+        },
+      },
+      update: {
+        role: invite.role,
+      },
+      create: {
+        orgId: invite.orgId,
+        userId,
+        role: invite.role,
+      },
+    });
+
+    await tx.orgInvite.update({
+      where: { id: invite.id },
+      data: { acceptedAt: new Date() },
+    });
+
+    return tx.session.create({
+      data: {
+        userId,
+        orgId: invite.orgId,
+        expiresAt,
+      },
+    });
+  });
+
+  const res = NextResponse.json({ ok: true, next: "/machines" });
+  res.cookies.set(COOKIE_NAME, session.id, buildSessionCookieOptions(req));
+
+  return res;
+}

app/api/login copy/route.ts

@@ -0,0 +1,74 @@
+import { NextResponse } from "next/server";
+import bcrypt from "bcrypt";
+import { prisma } from "@/lib/prisma";
+import { z } from "zod";
+
+const COOKIE_NAME = "mis_session";
+const SESSION_DAYS = 7;
+
+const loginSchema = z.object({
+  email: z.string().trim().min(1).max(254).email(),
+  password: z.string().min(1).max(256),
+  next: z.string().optional(),
+});
+
+function safeNextPath(value: unknown) {
+  const raw = String(value ?? "").trim();
+  if (!raw) return "/machines";
+  if (!raw.startsWith("/") || raw.startsWith("//")) return "/machines";
+  return raw;
+}
+
+export async function POST(req: Request) {
+  const body = await req.json().catch(() => ({}));
+  const parsed = loginSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid login payload" }, { status: 400 });
+  }
+  const email = parsed.data.email.toLowerCase();
+  const password = parsed.data.password;
+  const next = safeNextPath(parsed.data.next);
+
+  const user = await prisma.user.findUnique({ where: { email } });
+  if (!user || !user.isActive) {
+    return NextResponse.json({ ok: false, error: "Invalid credentials" }, { status: 401 });
+  }
+
+  const ok = await bcrypt.compare(password, user.passwordHash);
+  if (!ok) {
+    return NextResponse.json({ ok: false, error: "Invalid credentials" }, { status: 401 });
+  }
+
+  // Multiple orgs per user: pick the oldest membership for now
+  const membership = await prisma.orgUser.findFirst({
+    where: { userId: user.id },
+    orderBy: { createdAt: "asc" },
+  });
+
+  if (!membership) {
+    return NextResponse.json({ ok: false, error: "User has no organization" }, { status: 403 });
+  }
+
+  const expiresAt = new Date(Date.now() + SESSION_DAYS * 24 * 60 * 60 * 1000);
+
+  const session = await prisma.session.create({
+    data: {
+      userId: user.id,
+      orgId: membership.orgId,
+      expiresAt,
+      // optional fields you can add later: ip/userAgent
+    },
+  });
+
+  const res = NextResponse.json({ ok: true, next });
+
+  res.cookies.set(COOKIE_NAME, session.id, {
+    httpOnly: true,
+    sameSite: "lax",
+    secure: false, // set true once HTTPS only
+    path: "/",
+    maxAge: SESSION_DAYS * 24 * 60 * 60,
+  });
+
+  return res;
+}

app/api/login/route.ts

@@ -1,25 +1,41 @@
 import { NextResponse } from "next/server";
 import bcrypt from "bcrypt";
 import { prisma } from "@/lib/prisma";
+import { buildSessionCookieOptions, COOKIE_NAME, SESSION_DAYS } from "@/lib/auth/sessionCookie";
+import { z } from "zod";
 
-const COOKIE_NAME = "mis_session";
-const SESSION_DAYS = 7;
+const loginSchema = z.object({
+  email: z.string().trim().min(1).max(254).email(),
+  password: z.string().min(1).max(256),
+  next: z.string().optional(),
+});
+
+function safeNextPath(value: unknown) {
+  const raw = String(value ?? "").trim();
+  if (!raw) return "/machines";
+  if (!raw.startsWith("/") || raw.startsWith("//")) return "/machines";
+  return raw;
+}
 
 export async function POST(req: Request) {
   const body = await req.json().catch(() => ({}));
-  const email = String(body.email || "").trim().toLowerCase();
-  const password = String(body.password || "");
-  const next = String(body.next || "/machines");
-
-  if (!email || !password) {
-    return NextResponse.json({ ok: false, error: "Missing email/password" }, { status: 400 });
+  const parsed = loginSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid login payload" }, { status: 400 });
   }
+  const email = parsed.data.email.toLowerCase();
+  const password = parsed.data.password;
+  const next = safeNextPath(parsed.data.next);
 
   const user = await prisma.user.findUnique({ where: { email } });
   if (!user || !user.isActive) {
     return NextResponse.json({ ok: false, error: "Invalid credentials" }, { status: 401 });
   }
 
+  if (!user.emailVerifiedAt) {
+    return NextResponse.json({ ok: false, error: "Email not verified" }, { status: 403 });
+  }
+
   const ok = await bcrypt.compare(password, user.passwordHash);
   if (!ok) {
     return NextResponse.json({ ok: false, error: "Invalid credentials" }, { status: 401 });
@@ -47,14 +63,7 @@ export async function POST(req: Request) {
   });
 
   const res = NextResponse.json({ ok: true, next });
-
-  res.cookies.set(COOKIE_NAME, session.id, {
-    httpOnly: true,
-    sameSite: "lax",
-    secure: false, // set true once HTTPS only
-    path: "/",
-    maxAge: SESSION_DAYS * 24 * 60 * 60,
-  });
+  res.cookies.set(COOKIE_NAME, session.id, buildSessionCookieOptions(req));
 
   return res;
 }

app/api/logout copy/route.ts

@@ -0,0 +1,21 @@
+import { NextResponse } from "next/server";
+import { cookies } from "next/headers";
+import { prisma } from "@/lib/prisma";
+
+const COOKIE_NAME = "mis_session";
+
+export async function POST() {
+  const jar = await cookies();
+  const sessionId = jar.get(COOKIE_NAME)?.value;
+
+  if (sessionId) {
+    await prisma.session.updateMany({
+      where: { id: sessionId, revokedAt: null },
+      data: { revokedAt: new Date() },
+    }).catch(() => {});
+  }
+
+  const res = NextResponse.json({ ok: true });
+  res.cookies.set(COOKIE_NAME, "", { path: "/", maxAge: 0 });
+  return res;
+}

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

@@ -1,183 +1,124 @@
 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";
 
-function normalizeEvent(row: any) {
-  // -----------------------------
-  // 1) Parse row.data safely
-  // data may be:
-  //   - object
-  //   - array of objects
-  //   - JSON string of either
-  // -----------------------------
-  const raw = row.data;
+const machineIdSchema = z.string().uuid();
 
-  let parsed: any = raw;
-  if (typeof raw === "string") {
-    try {
-      parsed = JSON.parse(raw);
-    } catch {
-      parsed = raw; // keep as string if not JSON
-    }
+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";
 }
 
-  // data can be object OR [object]
-  const blob = Array.isArray(parsed) ? parsed[0] : parsed;
+function isPlainObject(value: unknown): value is Record<string, unknown> {
+  return !!value && typeof value === "object" && !Array.isArray(value);
+}
 
-  // some payloads nest details under blob.data
-  const inner = blob?.data ?? blob ?? {};
+function parseNumber(value: string | null, fallback: number) {
+  if (value == null || value === "") return fallback;
+  const parsed = Number(value);
+  return Number.isFinite(parsed) ? parsed : fallback;
+}
 
-  const normalizeType = (t: any) =>
-    String(t ?? "")
-      .trim()
-      .toLowerCase()
-      .replace(/_/g, "-");
-
-  // -----------------------------
-  // 2) Alias mapping (canonical types)
-  // -----------------------------
-  const ALIAS: Record<string, string> = {
-    // Spanish / synonyms
-    macroparo: "macrostop",
-    "macro-stop": "macrostop",
-    macro_stop: "macrostop",
-
-    microparo: "microstop",
-    "micro-paro": "microstop",
-    micro_stop: "microstop",
-
-    // Node-RED types
-    "production-stopped": "stop", // we'll classify to micro/macro below
-
-    // legacy / generic
-    down: "stop",
+type MachineFkReference = {
+  tableName: string;
+  columnName: string;
+  deleteRule: string;
 };
 
-  // -----------------------------
-  // 3) Determine event type from DB or blob
-  // -----------------------------
-  const fromDbType =
-    row.eventType && row.eventType !== "unknown" ? row.eventType : null;
-
-  const fromBlobType =
-    blob?.anomaly_type ??
-    blob?.eventType ??
-    blob?.topic ??
-    inner?.anomaly_type ??
-    inner?.eventType ??
-    null;
-
-  // infer slow-cycle if signature exists
-  const inferredType =
-    fromDbType ??
-    fromBlobType ??
-    ((inner?.actual_cycle_time && inner?.theoretical_cycle_time) ||
-    (blob?.actual_cycle_time && blob?.theoretical_cycle_time)
-      ? "slow-cycle"
-      : "unknown");
-
-  const eventTypeRaw = normalizeType(inferredType);
-  let eventType = ALIAS[eventTypeRaw] ?? eventTypeRaw;
-
-  // -----------------------------
-  // 4) Optional: classify "stop" into micro/macro based on duration if present
-  // (keeps old rows usable even if they stored production-stopped)
-  // -----------------------------
-  if (eventType === "stop") {
-    const stopSec =
-      (typeof inner?.stoppage_duration_seconds === "number" && inner.stoppage_duration_seconds) ||
-      (typeof blob?.stoppage_duration_seconds === "number" && blob.stoppage_duration_seconds) ||
-      (typeof inner?.stop_duration_seconds === "number" && inner.stop_duration_seconds) ||
-      null;
-
-    // tune these thresholds to match your MES spec
-    const MACROSTOP_SEC = 300; // 5 min
-    eventType = stopSec != null && stopSec >= MACROSTOP_SEC ? "macrostop" : "microstop";
+function quoteIdent(identifier: string) {
+  return `"${identifier.replace(/"/g, "\"\"")}"`;
 }
 
-  // -----------------------------
-  // 5) Severity, title, description, timestamp
-  // -----------------------------
-  const severity =
-    String(
-      (row.severity && row.severity !== "info" ? row.severity : null) ??
-        blob?.severity ??
-        inner?.severity ??
-        "info"
+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')
       )
-      .trim()
-      .toLowerCase();
+  `;
 
-  const title =
-    String(
-      (row.title && row.title !== "Event" ? row.title : null) ??
-        blob?.title ??
-        inner?.title ??
-        (eventType === "slow-cycle" ? "Slow Cycle Detected" : "Event")
-    ).trim();
+  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();
 
-  const description =
-    row.description ??
-    blob?.description ??
-    inner?.description ??
-    (eventType === "slow-cycle" &&
-    (inner?.actual_cycle_time ?? blob?.actual_cycle_time) &&
-    (inner?.theoretical_cycle_time ?? blob?.theoretical_cycle_time) &&
-    (inner?.delta_percent ?? blob?.delta_percent) != null
-      ? `Cycle took ${Number(inner?.actual_cycle_time ?? blob?.actual_cycle_time).toFixed(1)}s (+${Number(inner?.delta_percent ?? blob?.delta_percent)}% vs ${Number(inner?.theoretical_cycle_time ?? blob?.theoretical_cycle_time).toFixed(1)}s objetivo)`
-      : null);
+    if (rule === "CASCADE") continue;
 
-  const ts =
-    row.ts ??
-    (typeof blob?.timestamp === "number" ? new Date(blob.timestamp) : null) ??
-    (typeof inner?.timestamp === "number" ? new Date(inner.timestamp) : null) ??
-    null;
-
-  const workOrderId =
-    row.workOrderId ??
-    blob?.work_order_id ??
-    inner?.work_order_id ??
-    null;
-
-  return {
-    id: row.id,
-    ts,
-    topic: String(row.topic ?? blob?.topic ?? eventType),
-    eventType,
-    severity,
-    title,
-    description,
-    requiresAck: !!row.requiresAck,
-    workOrderId,
-  };
+    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 }> }
-) {
+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 machine = await prisma.machine.findFirst({
+  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: { ts: "desc" },
+          orderBy: { tsServer: "desc" },
           take: 1,
-        select: { ts: true, status: true, message: true, ip: true, fwVersion: true },
+          select: { ts: true, tsServer: true, status: true, message: true, ip: true, fwVersion: true },
         },
         kpiSnapshots: {
           orderBy: { ts: "desc" },
@@ -197,19 +138,92 @@ export async function GET(
           },
         },
       },
-  });
+    }),
+    prisma.orgSettings.findUnique({
+      where: { orgId: session.orgId },
+      select: { stoppageMultiplier: true, macroStoppageMultiplier: true },
+    }),
+    prisma.machineSettings.findUnique({
+      where: { machineId },
+      select: { overridesJson: true },
+    }),
+  ]);
 
-  if (!machine) {
-    return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+  if (!machineRow) {
+    return NextResponse.json({ ok: false, error: "Machine not found" }, { status: 404 });
   }
 
-  const rawEvents = await prisma.machineEvent.findMany({
+  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: 100, // pull more, we'll filter after normalization
+      take: eventsOnly ? 300 : 120,
       select: {
         id: true,
         ts: true,
@@ -222,104 +236,308 @@ export async function GET(
         data: true,
         workOrderId: true,
       },
-  });
-
-  const normalized = rawEvents.map(normalizeEvent);
-
-const ALLOWED_TYPES = new Set([
-  "slow-cycle",
-  "microstop",
-  "macrostop",
-  "oee-drop",
-  "quality-spike",
-  "performance-degradation",
-  "predictive-oee-decline",
+    }),
+    prisma.machineEvent.count({ where: eventWhereBase }),
   ]);
 
-const events = normalized
-  .filter((e) => ALLOWED_TYPES.has(e.eventType))
-  // keep slow-cycle even if severity is info, otherwise require warning/critical/error
-  .filter((e) =>
-    ["slow-cycle", "microstop", "macrostop"].includes(e.eventType) ||
-    ["warning", "critical", "error"].includes(e.severity)
-  )
-  .slice(0, 30);
+  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;
 
-// ---- cycles window ----
-const url = new URL(_req.url);
-const windowSec = Number(url.searchParams.get("windowSec") ?? "10800"); // default 3h
+  // 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 });
+  }
 
-const latestKpi = machine.kpiSnapshots[0] ?? null;
-
-// If KPI cycleTime missing, fallback to DB cycles (we fetch 1 first)
-const latestCycleForIdeal = await prisma.machineCycle.findFirst({
-  where: { orgId: session.orgId, machineId },
-  orderBy: { ts: "desc" },
-  select: { theoreticalCycleTime: true },
+  // Drop pure auto-ack refresh pings.
+  const filteredNoAutoAck = filtered.filter((event) => {
+    const meta = rawMetaById.get(event.id);
+    return !meta?.isAutoAck;
   });
 
-const effectiveCycleTime =
-  latestKpi?.cycleTime ??
-  latestCycleForIdeal?.theoreticalCycleTime ??
-  null;
+  // 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 = [];
 
-// Estimate how many cycles we need to cover the window.
-// Add buffer so the chart doesn’t look “tight”.
-const estCycleSec = Math.max(1, Number(effectiveCycleTime ?? 14));
-const needed = Math.ceil(windowSec / estCycleSec) + 50;
+  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);
+  }
 
-// Safety cap to avoid crazy payloads
-const takeCycles = Math.min(5000, Math.max(200, needed));
-
-const rawCycles = await prisma.machineCycle.findMany({
-  where: { orgId: session.orgId, machineId },
-  orderBy: { ts: "desc" },
-  take: takeCycles,
-  select: {
-    ts: true,
-    cycleCount: true,
-    actualCycleTime: true,
-    theoreticalCycleTime: true,
-    workOrderId: true,
-    sku: true,
-  },
+  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;
+    return bt - at;
   });
 
-// chart-friendly: oldest -> newest + numeric timestamps
-const cycles = rawCycles
-  .slice()
-  .reverse()
-  .map((c) => ({
-    ts: c.ts,
-    t: c.ts.getTime(),
-    cycleCount: c.cycleCount ?? null,
-    actual: c.actualCycleTime,
-    ideal: c.theoreticalCycleTime ?? null,
-    workOrderId: c.workOrderId ?? null,
-    sku: c.sku ?? null,
-  }));
-
-
-
-
   return NextResponse.json({
     ok: true,
-    machine: {
-      id: machine.id,
-      name: machine.name,
-      code: machine.code,
-      location: machine.location,
-      latestHeartbeat: machine.heartbeats[0] ?? null,
-      latestKpi: machine.kpiSnapshots[0] ?? null,
-      effectiveCycleTime
-      
-    },
-    events,
-    cycles
+    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/[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/pair/route.ts

@@ -0,0 +1,64 @@
+import { NextResponse } from "next/server";
+import { randomBytes } from "crypto";
+import { prisma } from "@/lib/prisma";
+import { getBaseUrl } from "@/lib/appUrl";
+import { normalizePairingCode } from "@/lib/pairingCode";
+import { z } from "zod";
+
+const pairSchema = z.object({
+  code: z.string().trim().max(16).optional(),
+  pairingCode: z.string().trim().max(16).optional(),
+});
+
+export async function POST(req: Request) {
+  const body = await req.json().catch(() => ({}));
+  const parsed = pairSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid pairing payload" }, { status: 400 });
+  }
+  const rawCode = String(parsed.data.code || parsed.data.pairingCode || "").trim();
+  const code = normalizePairingCode(rawCode);
+
+  if (!code || code.length !== 5) {
+    return NextResponse.json({ ok: false, error: "Invalid pairing code" }, { status: 400 });
+  }
+
+  const now = new Date();
+
+  const machine = await prisma.machine.findFirst({
+    where: {
+      pairingCode: code,
+      pairingCodeUsedAt: null,
+      pairingCodeExpiresAt: { gt: now },
+    },
+    select: { id: true, orgId: true, apiKey: true },
+  });
+
+  if (!machine) {
+    return NextResponse.json({ ok: false, error: "Pairing code not found or expired" }, { status: 404 });
+  }
+
+  let apiKey = machine.apiKey;
+  if (!apiKey) {
+    apiKey = randomBytes(24).toString("hex");
+  }
+
+  await prisma.machine.update({
+    where: { id: machine.id },
+    data: {
+      apiKey,
+      pairingCode: null,
+      pairingCodeExpiresAt: null,
+      pairingCodeUsedAt: now,
+    },
+  });
+
+  return NextResponse.json({
+    ok: true,
+    config: {
+      cloudBaseUrl: getBaseUrl(req),
+      machineId: machine.id,
+      apiKey,
+    },
+  });
+}

app/api/machines/route.ts

@@ -1,47 +1,167 @@
 import { NextResponse } from "next/server";
+import { randomBytes } from "crypto";
 import { prisma } from "@/lib/prisma";
-import { cookies } from "next/headers";
+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,
+  fetchLatestMacrostops,
+  fetchMachineBase,
+  mergeMachineOverviewRows,
+} from "@/lib/machines/withLatest";
 
-const COOKIE_NAME = "mis_session";
+let machinesColdStart = true;
 
-async function requireSession() {
-  const sessionId = (await cookies()).get(COOKIE_NAME)?.value;
-  if (!sessionId) return null;
+function getColdStartInfo() {
+  const coldStart = machinesColdStart;
+  machinesColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
 
-  return prisma.session.findFirst({
-    where: { id: sessionId, revokedAt: null, expiresAt: { gt: new Date() } },
-    include: { org: true, user: true },
+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 macrostopStart = nowMs();
+  const macrostops = await fetchLatestMacrostops(session.orgId, machineIds);
+  if (perfEnabled) timings.macrostopsQuery = elapsedMs(macrostopStart);
+
+  const postQueryStart = nowMs();
+
+  // flatten latest heartbeat for UI convenience
+  const out = mergeMachineOverviewRows({
+    machines,
+    heartbeats,
+    kpis,
+    macrostops,
+    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,
     });
   }
 
-export async function GET() {
+  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 machines = await prisma.machine.findMany({
-    where: { orgId: session.orgId },
-    orderBy: { createdAt: "desc" },
+  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,
-      createdAt: true,
-      updatedAt: true,
-      heartbeats: {
-        orderBy: { ts: "desc" },
-        take: 1,
-        select: { ts: true, status: true, message: true, ip: true, fwVersion: true },
-      },
+          pairingCode: true,
+          pairingCodeExpiresAt: true,
         },
       });
-
-  // flatten latest heartbeat for UI convenience
-  const out = machines.map((m) => ({
-    ...m,
-    latestHeartbeat: m.heartbeats[0] ?? null,
-    heartbeats: undefined,
-  }));
-
-  return NextResponse.json({ ok: true, machines: out });
+      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/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/me/route.ts

@@ -2,13 +2,19 @@ import { NextResponse } from "next/server";
 import { requireSession } from "@/lib/auth/requireSession";
 import { prisma } from "@/lib/prisma";
 
+
+
 export async function GET() {
   try {
-    const { userId, orgId } = await requireSession();
+    const session = await requireSession();
+    if (!session) {
+      return NextResponse.json({ ok: false }, { status: 401 });
+    }
+    const { userId, orgId } = session;
 
     const user = await prisma.user.findUnique({
       where: { id: userId },
-      select: { id: true, email: true, name: true },
+      select: { id: true, email: true, name: true, phone: true },
     });
 
     const org = await prisma.org.findUnique({
@@ -16,7 +22,12 @@ export async function GET() {
       select: { id: true, name: true, slug: true },
     });
 
-    return NextResponse.json({ ok: true, user, org });
+    const membership = await prisma.orgUser.findUnique({
+      where: { orgId_userId: { orgId, userId } },
+      select: { role: true },
+    });
+
+    return NextResponse.json({ ok: true, user, org, membership });
   } catch {
     return NextResponse.json({ ok: false }, { status: 401 });
   }

app/api/org/invites/[inviteId]/route.ts

@@ -0,0 +1,57 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { z } from "zod";
+
+function canManageMembers(role?: string | null) {
+  return role === "OWNER" || role === "ADMIN";
+}
+
+const inviteIdSchema = z.string().uuid();
+
+export async function DELETE(
+  _req: NextRequest,
+  { params }: { params: Promise<{ inviteId: string }> }
+) {
+  try {
+    const session = await requireSession();
+    if (!session) {
+      return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    }
+    const { inviteId } = await params;
+    if (!inviteIdSchema.safeParse(inviteId).success) {
+      return NextResponse.json({ ok: false, error: "Invalid invite id" }, { status: 400 });
+    }
+
+    const membership = await prisma.orgUser.findUnique({
+      where: {
+        orgId_userId: {
+          orgId: session.orgId,
+          userId: session.userId,
+        },
+      },
+      select: { role: true },
+    });
+
+    if (!canManageMembers(membership?.role)) {
+      return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+    }
+
+    await prisma.orgInvite.updateMany({
+      where: {
+        id: inviteId,
+        orgId: session.orgId,
+        acceptedAt: null,
+        revokedAt: null,
+      },
+      data: {
+        revokedAt: new Date(),
+      },
+    });
+
+    return NextResponse.json({ ok: true });
+  } catch {
+    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  }
+}

app/api/org/members/route.ts

@@ -0,0 +1,197 @@
+import { NextResponse } from "next/server";
+import { randomBytes } from "crypto";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { buildInviteEmail, sendEmail } from "@/lib/email";
+import { getBaseUrl } from "@/lib/appUrl";
+import { z } from "zod";
+
+const INVITE_DAYS = 7;
+const ROLES = new Set(["OWNER", "ADMIN", "MEMBER"]);
+const inviteSchema = z.object({
+  email: z.string().trim().min(1).max(254).email(),
+  role: z.string().trim().toUpperCase().optional(),
+});
+
+function canManageMembers(role?: string | null) {
+  return role === "OWNER" || role === "ADMIN";
+}
+
+export async function GET() {
+  try {
+    
+    const session = await requireSession();
+    if (!session) {
+      return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    }
+
+    const [org, members, invites] = await prisma.$transaction([
+      prisma.org.findUnique({
+        where: { id: session.orgId },
+        select: { id: true, name: true, slug: true },
+      }),
+      prisma.orgUser.findMany({
+        where: { orgId: session.orgId },
+        orderBy: { createdAt: "asc" },
+        include: {
+          user: { select: { id: true, email: true, name: true, isActive: true, createdAt: true } },
+        },
+      }),
+      prisma.orgInvite.findMany({
+        where: {
+          orgId: session.orgId,
+          revokedAt: null,
+          acceptedAt: null,
+          expiresAt: { gt: new Date() },
+        },
+        orderBy: { createdAt: "desc" },
+        select: {
+          id: true,
+          email: true,
+          role: true,
+          token: true,
+          createdAt: true,
+          expiresAt: true,
+        },
+      }),
+    ]);
+
+    const mappedMembers = members.map((m) => ({
+      id: m.user.id,
+      membershipId: m.id,
+      email: m.user.email,
+      name: m.user.name,
+      role: m.role,
+      isActive: m.user.isActive,
+      joinedAt: m.createdAt,
+    }));
+
+    return NextResponse.json({
+      ok: true,
+      org,
+      members: mappedMembers,
+      invites,
+    });
+  } catch {
+    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  }
+}
+
+export async function POST(req: Request) {
+  try {
+    const session = await requireSession();
+    if (!session) {
+      return 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 (!canManageMembers(membership?.role)) {
+      return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+    }
+
+    const body = await req.json().catch(() => ({}));
+    const parsed = inviteSchema.safeParse(body);
+    if (!parsed.success) {
+      return NextResponse.json({ ok: false, error: "Invalid invite payload" }, { status: 400 });
+    }
+    const email = parsed.data.email.toLowerCase();
+    const role = String(parsed.data.role || "MEMBER").toUpperCase();
+
+    if (!ROLES.has(role)) {
+      return NextResponse.json({ ok: false, error: "Invalid role" }, { status: 400 });
+    }
+
+    const existingUser = await prisma.user.findUnique({ where: { email } });
+    if (existingUser) {
+      const existingMembership = await prisma.orgUser.findUnique({
+        where: {
+          orgId_userId: {
+            orgId: session.orgId,
+            userId: existingUser.id,
+          },
+        },
+      });
+      if (existingMembership) {
+        return NextResponse.json({ ok: false, error: "User already in org" }, { status: 409 });
+      }
+    }
+
+    const existingInvite = await prisma.orgInvite.findFirst({
+      where: {
+        orgId: session.orgId,
+        email,
+        acceptedAt: null,
+        revokedAt: null,
+        expiresAt: { gt: new Date() },
+      },
+      orderBy: { createdAt: "desc" },
+    });
+
+    if (existingInvite) {
+      return NextResponse.json({ ok: true, invite: existingInvite });
+    }
+
+    let invite = null;
+    for (let i = 0; i < 3; i += 1) {
+      const token = randomBytes(24).toString("hex");
+      try {
+        invite = await prisma.orgInvite.create({
+          data: {
+            orgId: session.orgId,
+            email,
+            role,
+            token,
+            invitedBy: session.userId,
+            expiresAt: new Date(Date.now() + INVITE_DAYS * 24 * 60 * 60 * 1000),
+          },
+        });
+        break;
+      } catch (err: unknown) {
+        const code = typeof err === "object" && err !== null ? (err as { code?: string }).code : undefined;
+        if (code !== "P2002") throw err;
+      }
+    }
+
+    if (!invite) {
+      return NextResponse.json({ ok: false, error: "Failed to create invite" }, { status: 500 });
+    }
+
+    let emailSent = true;
+    let emailError: string | null = null;
+    try {
+      const org = await prisma.org.findUnique({
+        where: { id: session.orgId },
+        select: { name: true },
+      });
+      const baseUrl = getBaseUrl(req);
+      const inviteUrl = `${baseUrl}/invite/${invite.token}`;
+      const appName = "MIS Control Tower";
+      const content = buildInviteEmail({
+        appName,
+        orgName: org?.name || "your organization",
+        inviteUrl,
+      });
+      await sendEmail({
+        to: invite.email,
+        subject: content.subject,
+        text: content.text,
+        html: content.html,
+      });
+    } catch (err: unknown) {
+      emailSent = false;
+      emailError = err instanceof Error ? err.message : "Failed to send invite email";
+    }
+
+    return NextResponse.json({ ok: true, invite, emailSent, emailError });
+  } catch {
+    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  }
+}

app/api/overview/route.ts

@@ -0,0 +1,172 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { createHash } from "crypto";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getOverviewData } from "@/lib/overview/getOverviewData";
+import { getOverviewSummary } from "@/lib/overview/getOverviewSummary";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, formatServerTiming, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+
+let overviewColdStart = true;
+
+function getColdStartInfo() {
+  const coldStart = overviewColdStart;
+  overviewColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
+
+function toMs(value?: Date | null) {
+  return value ? value.getTime() : 0;
+}
+
+export async function GET(req: NextRequest) {
+  const perfEnabled = PERF_LOGS_ENABLED;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+  const { coldStart, uptimeMs } = getColdStartInfo();
+
+  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 url = new URL(req.url);
+  const detail = url.searchParams.get("detail") === "1";
+
+  if (!detail) {
+    const summaryStart = nowMs();
+    const { machines: machineRows } = await getOverviewSummary({ orgId: session.orgId });
+    if (perfEnabled) timings.summary = elapsedMs(summaryStart);
+
+    const payload = { ok: true, machines: machineRows, events: [] };
+    const responseHeaders = new Headers();
+    if (perfEnabled) {
+      timings.total = elapsedMs(totalStart);
+      responseHeaders.set("Server-Timing", formatServerTiming(timings));
+      const payloadBytes = Buffer.byteLength(JSON.stringify(payload));
+      logLine("perf.overview.api", {
+        orgId: session.orgId,
+        detail: false,
+        coldStart,
+        uptimeMs,
+        timings,
+        counts: { machines: machineRows.length, events: 0 },
+        payloadBytes,
+      });
+    }
+
+    return NextResponse.json(payload, { headers: responseHeaders });
+  }
+
+  const preQueryStart = nowMs();
+  const eventsMode = url.searchParams.get("events") ?? "critical";
+  const eventsWindowSecRaw = Number(url.searchParams.get("eventsWindowSec") ?? "21600");
+  const eventsWindowSec = Number.isFinite(eventsWindowSecRaw) ? eventsWindowSecRaw : 21600;
+  const eventMachinesRaw = Number(url.searchParams.get("eventMachines") ?? "6");
+  const eventMachines = Number.isFinite(eventMachinesRaw) ? Math.max(1, eventMachinesRaw) : 6;
+  if (perfEnabled) timings.preQuery = elapsedMs(preQueryStart);
+
+  const aggStart = nowMs();
+  const [machineAgg, heartbeatAgg, kpiAgg, eventAgg, orgSettings] = await Promise.all([
+    prisma.machine.aggregate({
+      where: { orgId: session.orgId },
+      _max: { updatedAt: true },
+    }),
+    prisma.machineHeartbeat.aggregate({
+      where: { orgId: session.orgId },
+      _max: { tsServer: true },
+    }),
+    prisma.machineKpiSnapshot.aggregate({
+      where: { orgId: session.orgId },
+      _max: { tsServer: true },
+    }),
+    prisma.machineEvent.aggregate({
+      where: { orgId: session.orgId },
+      _max: { tsServer: true },
+    }),
+    prisma.orgSettings.findUnique({
+      where: { orgId: session.orgId },
+      select: { updatedAt: true, stoppageMultiplier: true, macroStoppageMultiplier: true },
+    }),
+  ]);
+  if (perfEnabled) timings.agg = elapsedMs(aggStart);
+
+  const lastModifiedMs = Math.max(
+    toMs(machineAgg._max.updatedAt),
+    toMs(heartbeatAgg._max.tsServer),
+    toMs(kpiAgg._max.tsServer),
+    toMs(eventAgg._max.tsServer),
+    toMs(orgSettings?.updatedAt)
+  );
+
+  const versionParts = [
+    session.orgId,
+    eventsMode,
+    eventsWindowSec,
+    eventMachines,
+    toMs(machineAgg._max.updatedAt),
+    toMs(heartbeatAgg._max.tsServer),
+    toMs(kpiAgg._max.tsServer),
+    toMs(eventAgg._max.tsServer),
+    toMs(orgSettings?.updatedAt),
+  ];
+
+  const etag = `W/"${createHash("sha1").update(versionParts.join("|")).digest("hex")}"`;
+  const lastModified = new Date(lastModifiedMs || 0).toUTCString();
+  const responseHeaders = new Headers({
+    "Cache-Control": "private, no-cache, max-age=0, must-revalidate",
+    ETag: etag,
+    "Last-Modified": lastModified,
+    Vary: "Cookie",
+  });
+
+  const ifNoneMatch = req.headers.get("if-none-match");
+  if (ifNoneMatch && ifNoneMatch === etag) {
+    return new NextResponse(null, { status: 304, headers: responseHeaders });
+  }
+
+  const ifModifiedSince = req.headers.get("if-modified-since");
+  if (!ifNoneMatch && ifModifiedSince) {
+    const since = Date.parse(ifModifiedSince);
+    if (!Number.isNaN(since) && lastModifiedMs <= since) {
+      return new NextResponse(null, { status: 304, headers: responseHeaders });
+    }
+  }
+
+  const dataStart = nowMs();
+  const { machines: machineRows, events } = await getOverviewData({
+    orgId: session.orgId,
+    eventsMode,
+    eventsWindowSec,
+    eventMachines,
+    orgSettings,
+  });
+  if (perfEnabled) timings.data = elapsedMs(dataStart);
+
+  const postQueryStart = nowMs();
+
+  const payload = { ok: true, machines: machineRows, events };
+  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.overview.api", {
+      orgId: session.orgId,
+      detail: true,
+      coldStart,
+      uptimeMs,
+      eventsMode,
+      eventsWindowSec,
+      eventMachines,
+      timings,
+      counts: { machines: machineRows.length, events: events.length },
+      payloadBytes,
+    });
+  }
+
+  return NextResponse.json(payload, { headers: responseHeaders });
+}

app/api/reasons/catalog/route.ts

@@ -0,0 +1,54 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+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();
+  if (kind === "downtime" || kind === "scrap") return kind;
+  return null;
+}
+
+export async function GET(req: Request) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  const url = new URL(req.url);
+  const kind = asKind(url.searchParams.get("kind"));
+  if (!kind) {
+    return NextResponse.json({ ok: false, error: "Invalid kind (downtime|scrap)" }, { status: 400 });
+  }
+
+  const orgSettings = await prisma.orgSettings.findUnique({
+    where: { orgId: session.orgId },
+    select: { defaultsJson: true, version: true },
+  });
+  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 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,
+    kind,
+    catalogVersion: catalog.version,
+    categories: catalog[kind],
+    rows,
+  });
+}

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

@@ -0,0 +1,37 @@
+import type { NextRequest } from "next/server";
+import { NextResponse } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getRecapMachineDetailCached, parseRecapDetailRangeInput } from "@/lib/recap/redesign";
+
+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 (!machineId) {
+    return NextResponse.json({ ok: false, error: "machineId is required" }, { status: 400 });
+  }
+
+  const url = new URL(req.url);
+  const input = parseRecapDetailRangeInput(url.searchParams);
+  const detail = await getRecapMachineDetailCached({
+    orgId: session.orgId,
+    machineId,
+    input,
+  });
+
+  if (!detail) {
+    return NextResponse.json({ ok: false, error: "Machine not found" }, { status: 404 });
+  }
+
+  return NextResponse.json(detail, {
+    headers: {
+      "Cache-Control": "private, max-age=60, stale-while-revalidate=60",
+    },
+  });
+}

app/api/recap/[machineId]/timeline/route.ts

@@ -0,0 +1,42 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { prisma } from "@/lib/prisma";
+import { getRecapTimelineForMachine, parseRecapTimelineRange } from "@/lib/recap/timelineApi";
+
+function bad(status: number, error: string) {
+  return NextResponse.json({ ok: false, error }, { status });
+}
+
+export async function GET(
+  req: NextRequest,
+  { params }: { params: Promise<{ machineId: string }> }
+) {
+  const session = await requireSession();
+  if (!session) return bad(401, "Unauthorized");
+
+  const { machineId } = await params;
+  if (!machineId) return bad(400, "machineId is required");
+
+  const machine = await prisma.machine.findFirst({
+    where: { id: machineId, orgId: session.orgId },
+    select: { id: true },
+  });
+  if (!machine) return bad(404, "Machine not found");
+
+  const url = new URL(req.url);
+  const { start, end, maxSegments } = parseRecapTimelineRange(url.searchParams);
+  const response = await getRecapTimelineForMachine({
+    orgId: session.orgId,
+    machineId,
+    start,
+    end,
+    maxSegments,
+  });
+
+  return NextResponse.json(response, {
+    headers: {
+      "Cache-Control": "private, max-age=60, stale-while-revalidate=60",
+    },
+  });
+}

app/api/recap/route.ts

@@ -0,0 +1,29 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getRecapDataCached, parseRecapQuery } from "@/lib/recap/getRecapData";
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) {
+    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  }
+
+  const url = new URL(req.url);
+  const query = parseRecapQuery({
+    machineId: url.searchParams.get("machineId"),
+    start: url.searchParams.get("start"),
+    end: url.searchParams.get("end"),
+    shift: url.searchParams.get("shift"),
+  });
+
+  const recap = await getRecapDataCached({
+    orgId: session.orgId,
+    machineId: query.machineId,
+    start: query.start ?? undefined,
+    end: query.end ?? undefined,
+    shift: query.shift ?? undefined,
+  });
+
+  return NextResponse.json(recap);
+}

app/api/recap/summary/route.ts

@@ -0,0 +1,21 @@
+import type { NextRequest } from "next/server";
+import { NextResponse } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { getRecapSummaryCached, parseRecapSummaryHours } from "@/lib/recap/redesign";
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) {
+    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  }
+
+  const url = new URL(req.url);
+  const hours = parseRecapSummaryHours(url.searchParams.get("hours"));
+  const summary = await getRecapSummaryCached({ orgId: session.orgId, hours });
+
+  return NextResponse.json(summary, {
+    headers: {
+      "Cache-Control": "private, max-age=60, stale-while-revalidate=60",
+    },
+  });
+}

app/api/recap/timeline/route.ts

@@ -0,0 +1,39 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { requireSession } from "@/lib/auth/requireSession";
+import { prisma } from "@/lib/prisma";
+import { getRecapTimelineForMachine, parseRecapTimelineRange } from "@/lib/recap/timelineApi";
+
+function bad(status: number, error: string) {
+  return NextResponse.json({ ok: false, error }, { status });
+}
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return bad(401, "Unauthorized");
+
+  const url = new URL(req.url);
+  const machineId = url.searchParams.get("machineId");
+  if (!machineId) return bad(400, "machineId is required");
+
+  const machine = await prisma.machine.findFirst({
+    where: { id: machineId, orgId: session.orgId },
+    select: { id: true },
+  });
+  if (!machine) return bad(404, "Machine not found");
+
+  const { start, end, maxSegments } = parseRecapTimelineRange(url.searchParams);
+  const response = await getRecapTimelineForMachine({
+    orgId: session.orgId,
+    machineId,
+    start,
+    end,
+    maxSegments,
+  });
+
+  return NextResponse.json(response, {
+    headers: {
+      "Cache-Control": "private, max-age=60, stale-while-revalidate=60",
+    },
+  });
+}

app/api/reports/filters/route.ts

@@ -0,0 +1,145 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { createHash } from "crypto";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, formatServerTiming, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+
+let reportsFiltersColdStart = true;
+
+function getColdStartInfo() {
+  const coldStart = reportsFiltersColdStart;
+  reportsFiltersColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
+
+const RANGE_MS: Record<string, number> = {
+  "24h": 24 * 60 * 60 * 1000,
+  "7d": 7 * 24 * 60 * 60 * 1000,
+  "30d": 30 * 24 * 60 * 60 * 1000,
+};
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (!Number.isNaN(n)) return new Date(n);
+  const d = new Date(input);
+  return Number.isNaN(d.getTime()) ? null : d;
+}
+
+function pickRange(req: NextRequest) {
+  const url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "24h";
+  const now = new Date();
+
+  if (range === "custom") {
+    const start = parseDate(url.searchParams.get("start")) ?? new Date(now.getTime() - RANGE_MS["24h"]);
+    const end = parseDate(url.searchParams.get("end")) ?? now;
+    return { start, end };
+  }
+
+  const ms = RANGE_MS[range] ?? RANGE_MS["24h"];
+  return { start: new Date(now.getTime() - ms), end: now };
+}
+
+function toMs(value?: Date | null) {
+  return value ? value.getTime() : 0;
+}
+
+export async function GET(req: NextRequest) {
+  const perfEnabled = PERF_LOGS_ENABLED;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+  const { coldStart, uptimeMs } = getColdStartInfo();
+
+  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 url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "24h";
+  const machineId = url.searchParams.get("machineId") ?? undefined;
+  const { start, end } = pickRange(req);
+
+  const baseWhere = {
+    orgId: session.orgId,
+    ...(machineId ? { machineId } : {}),
+    ts: { gte: start, lte: end },
+  };
+
+  if (perfEnabled) timings.preQuery = elapsedMs(preQueryStart);
+
+  const versionStart = nowMs();
+  const cycleMax = await prisma.machineCycle.aggregate({
+    where: baseWhere,
+    _max: { tsServer: true },
+  });
+  if (perfEnabled) timings.version = elapsedMs(versionStart);
+
+  const versionParts = [
+    session.orgId,
+    range,
+    machineId ?? "",
+    toMs(cycleMax._max.tsServer),
+  ];
+  const etag = `W/"${createHash("sha1").update(versionParts.join("|")).digest("hex")}"`;
+  const responseHeaders = new Headers({
+    "Cache-Control": "private, no-cache, max-age=0, must-revalidate",
+    ETag: etag,
+    "Last-Modified": new Date(toMs(cycleMax._max.tsServer) || 0).toUTCString(),
+    Vary: "Cookie",
+  });
+
+  const ifNoneMatch = req.headers.get("if-none-match");
+  if (ifNoneMatch && ifNoneMatch === etag) {
+    return new NextResponse(null, { status: 304, headers: responseHeaders });
+  }
+
+  const workOrdersStart = nowMs();
+  const workOrderRows = await prisma.machineCycle.findMany({
+    where: { ...baseWhere, workOrderId: { not: null } },
+    distinct: ["workOrderId"],
+    select: { workOrderId: true },
+  });
+  if (perfEnabled) timings.workOrders = elapsedMs(workOrdersStart);
+
+  const skuStart = nowMs();
+  const skuRows = await prisma.machineCycle.findMany({
+    where: { ...baseWhere, sku: { not: null } },
+    distinct: ["sku"],
+    select: { sku: true },
+  });
+  if (perfEnabled) timings.skus = elapsedMs(skuStart);
+
+  const postQueryStart = nowMs();
+
+  const workOrders = workOrderRows.map((r) => r.workOrderId).filter(Boolean) as string[];
+  const skus = skuRows.map((r) => r.sku).filter(Boolean) as string[];
+
+  const payload = { ok: true, workOrders, skus };
+
+  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.reports.filters", {
+      orgId: session.orgId,
+      coldStart,
+      uptimeMs,
+      range,
+      machineId,
+      timings,
+      rowCounts: {
+        workOrderRows: workOrderRows.length,
+        skuRows: skuRows.length,
+      },
+      payloadBytes,
+    });
+  }
+
+  return NextResponse.json(payload, { headers: responseHeaders });
+}

app/api/reports/route.ts

@@ -0,0 +1,544 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { createHash } from "crypto";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { logLine } from "@/lib/logger";
+import { elapsedMs, formatServerTiming, nowMs, PERF_LOGS_ENABLED } from "@/lib/perf/serverTiming";
+
+let reportsColdStart = true;
+
+function getColdStartInfo() {
+  const coldStart = reportsColdStart;
+  reportsColdStart = false;
+  return { coldStart, uptimeMs: Math.round(process.uptime() * 1000) };
+}
+
+const RANGE_MS: Record<string, number> = {
+  "24h": 24 * 60 * 60 * 1000,
+  "7d": 7 * 24 * 60 * 60 * 1000,
+  "30d": 30 * 24 * 60 * 60 * 1000,
+};
+
+function parseDate(input?: string | null) {
+  if (!input) return null;
+  const n = Number(input);
+  if (!Number.isNaN(n)) return new Date(n);
+  const d = new Date(input);
+  return Number.isNaN(d.getTime()) ? null : d;
+}
+
+function pickRange(req: NextRequest) {
+  const url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "24h";
+  const now = new Date();
+
+  if (range === "custom") {
+    const start = parseDate(url.searchParams.get("start")) ?? new Date(now.getTime() - RANGE_MS["24h"]);
+    const end = parseDate(url.searchParams.get("end")) ?? now;
+    return { start, end };
+  }
+
+  const ms = RANGE_MS[range] ?? RANGE_MS["24h"];
+  return { start: new Date(now.getTime() - ms), end: now };
+}
+
+function safeNum(v: unknown) {
+  return typeof v === "number" && Number.isFinite(v) ? v : null;
+}
+
+function isProductionSnapshot(trackingEnabled: unknown, productionStarted: unknown) {
+  return trackingEnabled === true && productionStarted === true;
+}
+
+function toMs(value?: Date | null) {
+  return value ? value.getTime() : 0;
+}
+
+export async function GET(req: NextRequest) {
+  const perfEnabled = PERF_LOGS_ENABLED;
+  const totalStart = nowMs();
+  const timings: Record<string, number> = {};
+  const { coldStart, uptimeMs } = getColdStartInfo();
+
+  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 url = new URL(req.url);
+  const range = url.searchParams.get("range") ?? "24h";
+  const machineId = url.searchParams.get("machineId") ?? undefined;
+  const { start, end } = pickRange(req);
+  const workOrderId = url.searchParams.get("workOrderId") ?? undefined;
+  const sku = url.searchParams.get("sku") ?? undefined;
+  const baseWhere = {
+    orgId: session.orgId,
+    ...(machineId ? { machineId } : {}),
+    ...(workOrderId ? { workOrderId } : {}),
+    ...(sku ? { sku } : {}),
+  };
+
+  if (perfEnabled) timings.preQuery = elapsedMs(preQueryStart);
+
+  const versionStart = nowMs();
+  const [kpiMax, cycleMax, eventMax] = await Promise.all([
+    prisma.machineKpiSnapshot.aggregate({
+      where: { ...baseWhere, ts: { gte: start, lte: end } },
+      _max: { tsServer: true },
+    }),
+    prisma.machineCycle.aggregate({
+      where: { ...baseWhere, ts: { gte: start, lte: end } },
+      _max: { tsServer: true },
+    }),
+    prisma.machineEvent.aggregate({
+      where: { ...baseWhere, ts: { gte: start, lte: end } },
+      _max: { tsServer: true },
+    }),
+  ]);
+  if (perfEnabled) timings.version = elapsedMs(versionStart);
+
+  const lastModifiedMs = Math.max(
+    toMs(kpiMax._max.tsServer),
+    toMs(cycleMax._max.tsServer),
+    toMs(eventMax._max.tsServer)
+  );
+
+  const versionParts = [
+    session.orgId,
+    range,
+    machineId ?? "",
+    workOrderId ?? "",
+    sku ?? "",
+    toMs(kpiMax._max.tsServer),
+    toMs(cycleMax._max.tsServer),
+    toMs(eventMax._max.tsServer),
+  ];
+  const etag = `W/"${createHash("sha1").update(versionParts.join("|")).digest("hex")}"`;
+  const responseHeaders = new Headers({
+    "Cache-Control": "private, no-cache, max-age=0, must-revalidate",
+    ETag: etag,
+    "Last-Modified": new Date(lastModifiedMs || 0).toUTCString(),
+    Vary: "Cookie",
+  });
+
+  const ifNoneMatch = req.headers.get("if-none-match");
+  if (ifNoneMatch && ifNoneMatch === etag) {
+    return new NextResponse(null, { status: 304, headers: responseHeaders });
+  }
+
+  const kpiStart = nowMs();
+  const kpiRows = await prisma.machineKpiSnapshot.findMany({
+    where: { ...baseWhere, ts: { gte: start, lte: end } },
+    orderBy: { ts: "asc" },
+    select: {
+      ts: true,
+      oee: true,
+      availability: true,
+      performance: true,
+      quality: true,
+      good: true,
+      scrap: true,
+      target: true,
+      trackingEnabled: true,
+      productionStarted: true,
+      machineId: true,
+    },
+  });
+  if (perfEnabled) timings.kpiRows = elapsedMs(kpiStart);
+
+  let oeeSum = 0;
+  let oeeCount = 0;
+  let availSum = 0;
+  let availCount = 0;
+  let perfSum = 0;
+  let perfCount = 0;
+  let qualSum = 0;
+  let qualCount = 0;
+
+  // OEE-family summaries are production-only to avoid mixing downtime/off windows.
+  for (const k of kpiRows) {
+    if (!isProductionSnapshot(k.trackingEnabled, k.productionStarted)) continue;
+    if (safeNum(k.oee) != null) {
+      oeeSum += Number(k.oee);
+      oeeCount += 1;
+    }
+    if (safeNum(k.availability) != null) {
+      availSum += Number(k.availability);
+      availCount += 1;
+    }
+    if (safeNum(k.performance) != null) {
+      perfSum += Number(k.performance);
+      perfCount += 1;
+    }
+    if (safeNum(k.quality) != null) {
+      qualSum += Number(k.quality);
+      qualCount += 1;
+    }
+  }
+
+  const cyclesStart = nowMs();
+  const cycles = await prisma.machineCycle.findMany({
+    where: { ...baseWhere, ts: { gte: start, lte: end } },
+    select: { goodDelta: true, scrapDelta: true },
+  });
+  if (perfEnabled) timings.cycles = elapsedMs(cyclesStart);
+
+  let goodTotal = 0;
+  let scrapTotal = 0;
+
+  for (const c of cycles) {
+    if (safeNum(c.goodDelta) != null) goodTotal += Number(c.goodDelta);
+    if (safeNum(c.scrapDelta) != null) scrapTotal += Number(c.scrapDelta);
+  }
+
+  const kpiAggStart = nowMs();
+  const kpiAgg = await prisma.machineKpiSnapshot.groupBy({
+    by: ["machineId"],
+    where: { ...baseWhere, ts: { gte: start, lte: end } },
+    _max: { good: true, scrap: true, target: true },
+    _min: { good: true, scrap: true },
+    _count: { _all: true },
+  });
+  if (perfEnabled) timings.kpiAgg = elapsedMs(kpiAggStart);
+
+  let targetTotal = 0;
+  if (goodTotal === 0 && scrapTotal === 0) {
+    let goodFallback = 0;
+    let scrapFallback = 0;
+
+    for (const row of kpiAgg) {
+      const count = row._count._all ?? 0;
+      const maxGood = safeNum(row._max.good);
+      const minGood = safeNum(row._min.good);
+      const maxScrap = safeNum(row._max.scrap);
+      const minScrap = safeNum(row._min.scrap);
+
+      if (count > 1 && maxGood != null && minGood != null) {
+        goodFallback += Math.max(0, maxGood - minGood);
+      } else if (maxGood != null) {
+        goodFallback += maxGood;
+      }
+
+      if (count > 1 && maxScrap != null && minScrap != null) {
+        scrapFallback += Math.max(0, maxScrap - minScrap);
+      } else if (maxScrap != null) {
+        scrapFallback += maxScrap;
+      }
+    }
+
+    goodTotal = goodFallback;
+    scrapTotal = scrapFallback;
+  }
+
+  for (const row of kpiAgg) {
+    const maxTarget = safeNum(row._max.target);
+    if (maxTarget != null) targetTotal += maxTarget;
+  }
+
+  const eventsStart = nowMs();
+  const events = await prisma.machineEvent.findMany({
+    where: { ...baseWhere, ts: { gte: start, lte: end } },
+    select: { eventType: true, data: true },
+  });
+  if (perfEnabled) timings.events = elapsedMs(eventsStart);
+
+  let macrostopSec = 0;
+  let microstopSec = 0;
+  let slowCycleCount = 0;
+  let qualitySpikeCount = 0;
+  let performanceDegradationCount = 0;
+  let oeeDropCount = 0;
+
+  for (const e of events) {
+    const type = String(e.eventType ?? "").toLowerCase();
+    let blob: unknown = e.data;
+
+    if (typeof blob === "string") {
+      try {
+        blob = JSON.parse(blob);
+      } catch {
+        blob = null;
+      }
+    }
+
+    const blobRecord = typeof blob === "object" && blob !== null ? (blob as Record<string, unknown>) : null;
+    const innerCandidate = blobRecord?.data ?? blobRecord ?? {};
+    const inner =
+      typeof innerCandidate === "object" && innerCandidate !== null
+        ? (innerCandidate as Record<string, unknown>)
+        : {};
+    const stopSec =
+      (typeof inner?.stoppage_duration_seconds === "number" && inner.stoppage_duration_seconds) ||
+      (typeof inner?.stop_duration_seconds === "number" && inner.stop_duration_seconds) ||
+      0;
+
+    if (type === "macrostop") macrostopSec += Number(stopSec) || 0;
+    else if (type === "microstop") microstopSec += Number(stopSec) || 0;
+    else if (type === "slow-cycle") slowCycleCount += 1;
+    else if (type === "quality-spike") qualitySpikeCount += 1;
+    else if (type === "performance-degradation") performanceDegradationCount += 1;
+    else if (type === "oee-drop") oeeDropCount += 1;
+  }
+
+  type TrendPoint = { t: string; v: number | null };
+
+  const trend: {
+    oee: TrendPoint[];
+    availability: TrendPoint[];
+    performance: TrendPoint[];
+    quality: TrendPoint[];
+    scrapRate: TrendPoint[];
+  } = {
+    oee: [],
+    availability: [],
+    performance: [],
+    quality: [],
+    scrapRate: [],
+  };
+
+   type TsBucket = {
+    oeeSum: number; oeeCount: number;
+    availSum: number; availCount: number;
+    perfSum: number; perfCount: number;
+    qualSum: number; qualCount: number;
+    goodSum: number; scrapSum: number;
+    anyProduction: boolean;
+  };
+  const tsBuckets = new Map<string, TsBucket>();
+
+  for (const k of kpiRows) {
+    const t = k.ts.toISOString();
+    let b = tsBuckets.get(t);
+    if (!b) {
+      b = {
+        oeeSum: 0, oeeCount: 0,
+        availSum: 0, availCount: 0,
+        perfSum: 0, perfCount: 0,
+        qualSum: 0, qualCount: 0,
+        goodSum: 0, scrapSum: 0,
+        anyProduction: false,
+      };
+      tsBuckets.set(t, b);
+    }
+
+    const isProd = isProductionSnapshot(k.trackingEnabled, k.productionStarted);
+    if (isProd) {
+      b.anyProduction = true;
+      const oee = safeNum(k.oee);
+      if (oee != null) { b.oeeSum += Number(oee); b.oeeCount += 1; }
+      const avail = safeNum(k.availability);
+      if (avail != null) { b.availSum += Number(avail); b.availCount += 1; }
+      const perf = safeNum(k.performance);
+      if (perf != null) { b.perfSum += Number(perf); b.perfCount += 1; }
+      const qual = safeNum(k.quality);
+      if (qual != null) { b.qualSum += Number(qual); b.qualCount += 1; }
+    }
+
+    const good = safeNum(k.good);
+    const scrap = safeNum(k.scrap);
+    if (good != null) b.goodSum += Number(good);
+    if (scrap != null) b.scrapSum += Number(scrap);
+  }
+
+  // Iterate sorted ts. kpiRows already orderBy ts asc, but Map insertion
+  // order matches that, so spreading keys preserves order.
+  for (const [t, b] of tsBuckets) {
+    if (!b.anyProduction) {
+      // No machine producing at this ts -> gap, same as before.
+      trend.oee.push({ t, v: null });
+      trend.availability.push({ t, v: null });
+      trend.performance.push({ t, v: null });
+      trend.quality.push({ t, v: null });
+    } else {
+      trend.oee.push({ t, v: b.oeeCount ? b.oeeSum / b.oeeCount : null });
+      trend.availability.push({ t, v: b.availCount ? b.availSum / b.availCount : null });
+      trend.performance.push({ t, v: b.perfCount ? b.perfSum / b.perfCount : null });
+      trend.quality.push({ t, v: b.qualCount ? b.qualSum / b.qualCount : null });
+    }
+    const total = b.goodSum + b.scrapSum;
+    if (total > 0) {
+      trend.scrapRate.push({ t, v: (b.scrapSum / total) * 100 });
+    }
+  }
+  const cycleRowsStart = nowMs();
+  const cycleRows = await prisma.machineCycle.findMany({
+    where: { ...baseWhere, ts: { gte: start, lte: end } },
+    select: { actualCycleTime: true },
+  });
+  if (perfEnabled) timings.cycleRows = elapsedMs(cycleRowsStart);
+
+  const values = cycleRows
+    .map((c) => Number(c.actualCycleTime))
+    .filter((v) => Number.isFinite(v) && v > 0)
+    .sort((a, b) => a - b);
+
+  let cycleTimeBins: {
+    label: string;
+    count: number;
+    rangeStart?: number;
+    rangeEnd?: number;
+    overflow?: "low" | "high";
+    minValue?: number;
+    maxValue?: number;
+  }[] = [];
+
+  if (values.length) {
+    const pct = (p: number) => {
+      const idx = Math.max(0, Math.min(values.length - 1, Math.floor(p * (values.length - 1))));
+      return values[idx];
+    };
+
+    const p5 = pct(0.05);
+    const p95 = pct(0.95);
+
+    const inRange = values.filter((v) => v >= p5 && v <= p95);
+    const low = values.filter((v) => v < p5);
+    const high = values.filter((v) => v > p95);
+
+    const binCount = 10;
+    const span = Math.max(0.1, p95 - p5);
+    const step = span / binCount;
+
+    const counts = new Array(binCount).fill(0);
+    for (const v of inRange) {
+      const idx = Math.min(binCount - 1, Math.floor((v - p5) / step));
+      counts[idx] += 1;
+    }
+    const decimals = step < 0.1 ? 2 : step < 1 ? 1 : 0;
+
+    cycleTimeBins = counts.map((count, i) => {
+      const a = p5 + step * i;
+      const b = p5 + step * (i + 1);
+      return {
+        label: `${a.toFixed(decimals)}-${b.toFixed(decimals)}s`,
+        count,
+        rangeStart: a,
+        rangeEnd: b,
+      };
+    });
+    
+
+    if (low.length) {
+      cycleTimeBins.unshift({
+        label: `< ${p5.toFixed(1)}s`,
+        count: low.length,
+        rangeEnd: p5,
+        overflow: "low",
+        minValue: low[0],
+        maxValue: low[low.length - 1],
+      });
+    }
+
+    if (high.length) {
+      cycleTimeBins.push({
+        label: `> ${p95.toFixed(1)}s`,
+        count: high.length,
+        rangeStart: p95,
+        overflow: "high",
+        minValue: high[0],
+        maxValue: high[high.length - 1],
+      });
+    }
+  }
+  const scrapRate =
+    goodTotal + scrapTotal > 0 ? (scrapTotal / (goodTotal + scrapTotal)) * 100 : null;
+
+
+
+  // top scrap SKU / work order (from cycles)
+  const scrapBySku = new Map<string, number>();
+  const scrapByWo = new Map<string, number>();
+
+  const scrapRowsStart = nowMs();
+  const scrapRows = await prisma.machineCycle.findMany({
+    where: { ...baseWhere, ts: { gte: start, lte: end } },
+    select: { sku: true, workOrderId: true, scrapDelta: true },
+  });
+  if (perfEnabled) timings.scrapRows = elapsedMs(scrapRowsStart);
+
+  const postQueryStart = nowMs();
+
+  for (const row of scrapRows) {
+    const scrap = safeNum(row.scrapDelta);
+    if (scrap == null || scrap <= 0) continue;
+    if (row.sku) scrapBySku.set(row.sku, (scrapBySku.get(row.sku) ?? 0) + scrap);
+    if (row.workOrderId) scrapByWo.set(row.workOrderId, (scrapByWo.get(row.workOrderId) ?? 0) + scrap);
+  }
+
+  const topScrapSku = [...scrapBySku.entries()].sort((a, b) => b[1] - a[1])[0]?.[0] ?? null;
+  const topScrapWorkOrder = [...scrapByWo.entries()].sort((a, b) => b[1] - a[1])[0]?.[0] ?? null;
+
+  const oeeAvg = oeeCount ? oeeSum / oeeCount : null;
+  const availabilityAvg = availCount ? availSum / availCount : null;
+  const performanceAvg = perfCount ? perfSum / perfCount : null;
+  const qualityAvg = qualCount ? qualSum / qualCount : null;
+
+  // insights
+  const insights: string[] = [];
+  if (scrapRate != null && scrapRate > 5) insights.push(`Scrap rate is ${scrapRate.toFixed(1)}% (above 5%).`);
+  if (performanceAvg != null && performanceAvg < 85) insights.push("Performance below 85%.");
+  if (availabilityAvg != null && availabilityAvg < 85) insights.push("Availability below 85%.");
+  if (oeeAvg != null && oeeAvg < 85) insights.push("OEE below 85%.");
+  if (macrostopSec > 1800) insights.push("Macrostop time exceeds 30 minutes in this range.");
+
+
+
+  const payload = {
+    ok: true,
+    summary: {
+      oeeAvg,
+      availabilityAvg,
+      performanceAvg,
+      qualityAvg,
+      goodTotal,
+      scrapTotal,
+      targetTotal,
+      scrapRate,
+      topScrapSku,
+      topScrapWorkOrder,
+    },
+
+    downtime: {
+      macrostopSec,
+      microstopSec,
+      slowCycleCount,
+      qualitySpikeCount,
+      performanceDegradationCount,
+      oeeDropCount,
+    },
+    trend,
+    insights,
+    distribution: {
+      cycleTime: cycleTimeBins,
+    },
+  };
+
+  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.reports.api", {
+      orgId: session.orgId,
+      coldStart,
+      uptimeMs,
+      range,
+      machineId,
+      workOrderId,
+      sku,
+      timings,
+      rowCounts: {
+        kpiRows: kpiRows.length,
+        cycles: cycles.length,
+        events: events.length,
+        cycleRows: cycleRows.length,
+        scrapRows: scrapRows.length,
+      },
+      payloadBytes,
+    });
+  }
+
+  return NextResponse.json(payload, { headers: responseHeaders });
+}

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

@@ -0,0 +1,450 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { Prisma } from "@prisma/client";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { toJsonValue } from "@/lib/prismaJson";
+import {
+  DEFAULT_ALERTS,
+  DEFAULT_DEFAULTS,
+  DEFAULT_SHIFT,
+  applyOverridePatch,
+  buildSettingsPayload,
+  deepMerge,
+  validateDefaults,
+  validateShiftFields,
+  validateShiftSchedule,
+  validateShiftOverrides,
+  validateThresholds,
+} from "@/lib/settings";
+import { effectiveReasonCatalogForOrg } from "@/lib/reasonCatalogDb";
+import { publishSettingsUpdate } from "@/lib/mqtt";
+import { z } from "zod";
+
+function isPlainObject(value: unknown): value is Record<string, unknown> {
+  return !!value && typeof value === "object" && !Array.isArray(value);
+}
+
+function canManageSettings(role?: string | null) {
+  return role === "OWNER" || role === "ADMIN";
+}
+
+const machineIdSchema = z.string().uuid();
+const machineSettingsSchema = z
+  .object({
+    source: z.string().trim().max(40).optional(),
+    overrides: z.any().optional(),
+  })
+  .passthrough();
+
+function pickAllowedOverrides(raw: unknown) {
+  if (!isPlainObject(raw)) return {};
+  const out: Record<string, unknown> = {};
+  for (const key of ["shiftSchedule", "thresholds", "alerts", "defaults"]) {
+    if (raw[key] !== undefined) out[key] = raw[key];
+  }
+  return out;
+}
+
+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: catalog,
+    reasonCatalogData: catalog,
+    reasonCatalogVersion: Number(catalog.version || 1),
+  };
+}
+
+async function ensureOrgSettings(
+  tx: Prisma.TransactionClient,
+  orgId: string,
+  userId?: string | null
+) {
+  let settings = await tx.orgSettings.findUnique({
+    where: { orgId },
+  });
+
+  if (settings) {
+    let shifts = await tx.orgShift.findMany({
+      where: { orgId },
+      orderBy: { sortOrder: "asc" },
+    });
+    if (!shifts.length) {
+      await tx.orgShift.create({
+        data: {
+          orgId,
+          name: DEFAULT_SHIFT.name,
+          startTime: DEFAULT_SHIFT.start,
+          endTime: DEFAULT_SHIFT.end,
+          sortOrder: 1,
+          enabled: true,
+        },
+      });
+      shifts = await tx.orgShift.findMany({
+        where: { orgId },
+        orderBy: { sortOrder: "asc" },
+      });
+    }
+    return { settings, shifts };
+  }
+
+  settings = await tx.orgSettings.create({
+    data: {
+      orgId,
+      timezone: "UTC",
+      shiftChangeCompMin: 10,
+      lunchBreakMin: 30,
+      stoppageMultiplier: 1.5,
+      macroStoppageMultiplier: 5,
+      oeeAlertThresholdPct: 90,
+      performanceThresholdPct: 85,
+      qualitySpikeDeltaPct: 5,
+      alertsJson: DEFAULT_ALERTS,
+      defaultsJson: DEFAULT_DEFAULTS,
+      updatedBy: userId ?? null,
+    },
+  });
+
+  await tx.orgShift.create({
+    data: {
+      orgId,
+      name: DEFAULT_SHIFT.name,
+      startTime: DEFAULT_SHIFT.start,
+      endTime: DEFAULT_SHIFT.end,
+      sortOrder: 1,
+      enabled: true,
+    },
+  });
+
+  const shifts = await tx.orgShift.findMany({
+    where: { orgId },
+    orderBy: { sortOrder: "asc" },
+  });
+  return { settings, shifts };
+}
+
+export async function GET(
+  req: NextRequest,
+  { params }: { params: Promise<{ machineId: string }> }
+) {
+  const { machineId } = await params;
+  if (!machineIdSchema.safeParse(machineId).success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine id" }, { status: 400 });
+  }
+
+  const session = await requireSession();
+  let orgId: string | null = null;
+  let userId: string | null = null;
+  let machine: { id: string; orgId: string } | null = null;
+
+  if (session) {
+    machine = await prisma.machine.findFirst({
+      where: { id: machineId, orgId: session.orgId },
+      select: { id: true, orgId: true },
+    });
+    if (!machine) return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+    orgId = machine.orgId;
+    userId = session.userId;
+  } else {
+    const apiKey = req.headers.get("x-api-key");
+    if (!apiKey) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    machine = await prisma.machine.findFirst({
+      where: { id: machineId, apiKey },
+      select: { id: true, orgId: true },
+    });
+    if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    orgId = machine.orgId;
+  }
+  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");
+
+    const machineSettings = await tx.machineSettings.findUnique({
+      where: { machineId },
+      select: { overridesJson: true },
+    });
+
+    const rawOverrides = pickAllowedOverrides(machineSettings?.overridesJson ?? {});
+    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: orgPayload,
+    effectiveSettings: effective,
+    overrides: rawOverrides,
+  });
+}
+
+export async function PUT(
+  req: NextRequest,
+  { params }: { params: Promise<{ machineId: string }> }
+) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageSettings(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const { machineId } = await params;
+  if (!machineIdSchema.safeParse(machineId).success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine id" }, { status: 400 });
+  }
+
+  const machine = await prisma.machine.findFirst({
+    where: { id: machineId, orgId: session.orgId },
+    select: { id: true },
+  });
+
+  if (!machine) return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+
+  const body = await req.json().catch(() => ({}));
+  const parsed = machineSettingsSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid settings payload" }, { status: 400 });
+  }
+  const source = String(parsed.data.source ?? "control_tower");
+
+  let patch = parsed.data.overrides ?? parsed.data;
+  if (patch === null) {
+    patch = null;
+  }
+
+  if (patch && !isPlainObject(patch)) {
+    return NextResponse.json({ ok: false, error: "overrides must be an object or null" }, { status: 400 });
+  }
+
+  if (patch && Object.keys(patch).length === 0) {
+    return NextResponse.json({ ok: false, error: "No overrides provided" }, { status: 400 });
+  }
+
+  if (patch && Object.keys(pickAllowedOverrides(patch)).length !== Object.keys(patch).length) {
+    return NextResponse.json({ ok: false, error: "overrides contain unsupported keys" }, { status: 400 });
+  }
+
+  if (patch?.shiftSchedule && !isPlainObject(patch.shiftSchedule)) {
+    return NextResponse.json({ ok: false, error: "shiftSchedule must be an object" }, { status: 400 });
+  }
+  if (patch?.thresholds !== undefined && patch.thresholds !== null && !isPlainObject(patch.thresholds)) {
+    return NextResponse.json({ ok: false, error: "thresholds must be an object" }, { status: 400 });
+  }
+  if (patch?.alerts !== undefined && patch.alerts !== null && !isPlainObject(patch.alerts)) {
+    return NextResponse.json({ ok: false, error: "alerts must be an object" }, { status: 400 });
+  }
+  if (patch?.defaults !== undefined && patch.defaults !== null && !isPlainObject(patch.defaults)) {
+    return NextResponse.json({ ok: false, error: "defaults must be an object" }, { status: 400 });
+  }
+
+  const shiftValidation = validateShiftFields(
+    patch?.shiftSchedule?.shiftChangeCompensationMin,
+    patch?.shiftSchedule?.lunchBreakMin
+  );
+  if (!shiftValidation.ok) {
+    return NextResponse.json({ ok: false, error: shiftValidation.error }, { status: 400 });
+  }
+
+  const overridesResult =
+    patch?.shiftSchedule?.overrides !== undefined
+      ? validateShiftOverrides(patch.shiftSchedule.overrides)
+      : ({ ok: true, overrides: undefined } as const);
+  if (!overridesResult.ok) {
+    return NextResponse.json({ ok: false, error: overridesResult.error }, { status: 400 });
+  }
+
+  const thresholdsValidation = validateThresholds(patch?.thresholds);
+  if (!thresholdsValidation.ok) {
+    return NextResponse.json({ ok: false, error: thresholdsValidation.error }, { status: 400 });
+  }
+
+  const defaultsValidation = validateDefaults(patch?.defaults);
+  if (!defaultsValidation.ok) {
+    return NextResponse.json({ ok: false, error: defaultsValidation.error }, { status: 400 });
+  }
+
+  if (patch?.shiftSchedule?.shifts !== undefined) {
+    const shiftResult = validateShiftSchedule(patch.shiftSchedule.shifts);
+    if (!shiftResult.ok) {
+      return NextResponse.json({ ok: false, error: shiftResult.error }, { status: 400 });
+    }
+    patch = {
+      ...patch,
+      shiftSchedule: {
+        ...patch.shiftSchedule,
+        shifts: shiftResult.shifts?.map((s) => ({
+          name: s.name,
+          start: s.startTime,
+          end: s.endTime,
+          enabled: s.enabled !== false,
+        })),
+      },
+    };
+  }
+  if (patch?.shiftSchedule) {
+    patch = {
+      ...patch,
+      shiftSchedule: {
+        ...patch.shiftSchedule,
+        overrides:
+          patch.shiftSchedule.overrides !== undefined
+            ? overridesResult.overrides === null
+              ? null
+              : overridesResult.overrides
+            : patch.shiftSchedule.overrides,
+        shiftChangeCompensationMin:
+          patch.shiftSchedule.shiftChangeCompensationMin !== undefined
+            ? Number(patch.shiftSchedule.shiftChangeCompensationMin)
+            : patch.shiftSchedule.shiftChangeCompensationMin,
+        lunchBreakMin:
+          patch.shiftSchedule.lunchBreakMin !== undefined
+            ? Number(patch.shiftSchedule.lunchBreakMin)
+            : patch.shiftSchedule.lunchBreakMin,
+      },
+    };
+  }
+
+  if (patch?.thresholds) {
+    patch = {
+      ...patch,
+        thresholds: {
+          ...patch.thresholds,
+          stoppageMultiplier:
+            patch.thresholds.stoppageMultiplier !== undefined
+              ? Number(patch.thresholds.stoppageMultiplier)
+              : patch.thresholds.stoppageMultiplier,
+          macroStoppageMultiplier:
+            patch.thresholds.macroStoppageMultiplier !== undefined
+              ? Number(patch.thresholds.macroStoppageMultiplier)
+              : patch.thresholds.macroStoppageMultiplier,
+          oeeAlertThresholdPct:
+            patch.thresholds.oeeAlertThresholdPct !== undefined
+              ? Number(patch.thresholds.oeeAlertThresholdPct)
+              : patch.thresholds.oeeAlertThresholdPct,
+        performanceThresholdPct:
+          patch.thresholds.performanceThresholdPct !== undefined
+            ? Number(patch.thresholds.performanceThresholdPct)
+            : patch.thresholds.performanceThresholdPct,
+        qualitySpikeDeltaPct:
+          patch.thresholds.qualitySpikeDeltaPct !== undefined
+            ? Number(patch.thresholds.qualitySpikeDeltaPct)
+            : patch.thresholds.qualitySpikeDeltaPct,
+      },
+    };
+  }
+
+  if (patch?.defaults) {
+    patch = {
+      ...patch,
+      defaults: {
+        ...patch.defaults,
+        moldTotal:
+          patch.defaults.moldTotal !== undefined ? Number(patch.defaults.moldTotal) : patch.defaults.moldTotal,
+        moldActive:
+          patch.defaults.moldActive !== undefined ? Number(patch.defaults.moldActive) : patch.defaults.moldActive,
+      },
+    };
+  }
+
+  const result = await prisma.$transaction(async (tx) => {
+    const orgSettings = await ensureOrgSettings(tx, session.orgId, session.userId);
+    if (!orgSettings?.settings) throw new Error("SETTINGS_NOT_FOUND");
+
+    const existing = await tx.machineSettings.findUnique({
+      where: { machineId },
+      select: { overridesJson: true },
+    });
+
+    let nextOverrides: Record<string, unknown> | null = null;
+    if (patch === null) {
+      nextOverrides = null;
+    } else {
+      const merged = applyOverridePatch(existing?.overridesJson ?? {}, patch);
+      nextOverrides = Object.keys(merged).length ? merged : null;
+    }
+    const nextOverridesJson =
+      nextOverrides === null ? Prisma.DbNull : toJsonValue(nextOverrides);
+
+    const saved = await tx.machineSettings.upsert({
+      where: { machineId },
+      update: {
+        overridesJson: nextOverridesJson,
+        updatedBy: session.userId,
+      },
+      create: {
+        machineId,
+        orgId: session.orgId,
+        overridesJson: nextOverridesJson,
+        updatedBy: session.userId,
+      },
+    });
+
+    await tx.settingsAudit.create({
+      data: {
+        orgId: session.orgId,
+        machineId,
+        actorId: session.userId,
+        source,
+        payloadJson: body,
+      },
+    });
+
+    return {
+      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()
+      : undefined;
+  try {
+    await publishSettingsUpdate({
+      orgId: session.orgId,
+      machineId,
+      version: Number(result.orgSettingsRow.version ?? 0),
+      source,
+      overridesUpdatedAt,
+    });
+  } catch (err) {
+    console.warn("[settings machine PUT] MQTT publish failed", err);
+  }
+
+  return NextResponse.json({
+    ok: true,
+    machineId,
+    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

@@ -0,0 +1,471 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { createHash } from "crypto";
+import { revalidateTag, unstable_cache } from "next/cache";
+import { Prisma } from "@prisma/client";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import {
+  DEFAULT_ALERTS,
+  DEFAULT_DEFAULTS,
+  DEFAULT_SHIFT,
+  buildSettingsPayload,
+  normalizeAlerts,
+  normalizeDefaults,
+  stripUndefined,
+  validateDefaults,
+  validateShiftFields,
+  validateShiftSchedule,
+  validateShiftOverrides,
+  validateThresholds,
+} from "@/lib/settings";
+import { effectiveReasonCatalogForOrg } from "@/lib/reasonCatalogDb";
+import { publishSettingsUpdate } from "@/lib/mqtt";
+import { z } from "zod";
+
+type ValidShift = {
+  name: string;
+  startTime: string;
+  endTime: string;
+  sortOrder: number;
+  enabled: boolean;
+};
+
+function isPlainObject(value: unknown): value is Record<string, unknown> {
+  return !!value && typeof value === "object" && !Array.isArray(value);
+}
+
+function canManageSettings(role?: string | null) {
+  return role === "OWNER" || role === "ADMIN";
+}
+
+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: catalog,
+    reasonCatalogData: catalog,
+    reasonCatalogVersion: Number(catalog.version || 1),
+  };
+}
+
+const settingsPayloadSchema = z
+  .object({
+    source: z.string().trim().max(40).optional(),
+    modules: z.any().optional(),
+    timezone: z.string().trim().max(64).optional(),
+    shiftSchedule: z.any().optional(),
+    thresholds: z.any().optional(),
+    alerts: z.any().optional(),
+    defaults: z.any().optional(),
+    version: z.union([z.number(), z.string()]).optional(),
+  })
+  .passthrough();
+
+const SETTINGS_TTL_SEC = 10;
+const SETTINGS_SWR_SEC = 30;
+
+async function ensureOrgSettings(tx: Prisma.TransactionClient, orgId: string, userId: string) {
+  let settings = await tx.orgSettings.findUnique({
+    where: { orgId },
+  });
+
+  if (settings) {
+    let shifts = await tx.orgShift.findMany({
+      where: { orgId },
+      orderBy: { sortOrder: "asc" },
+    });
+    if (!shifts.length) {
+      await tx.orgShift.create({
+        data: {
+          orgId,
+          name: DEFAULT_SHIFT.name,
+          startTime: DEFAULT_SHIFT.start,
+          endTime: DEFAULT_SHIFT.end,
+          sortOrder: 1,
+          enabled: true,
+        },
+      });
+      shifts = await tx.orgShift.findMany({
+        where: { orgId },
+        orderBy: { sortOrder: "asc" },
+      });
+    }
+    return { settings, shifts };
+  }
+
+  settings = await tx.orgSettings.create({
+    data: {
+      orgId,
+      timezone: "UTC",
+      shiftChangeCompMin: 10,
+      lunchBreakMin: 30,
+      stoppageMultiplier: 1.5,
+      macroStoppageMultiplier: 5,
+      oeeAlertThresholdPct: 90,
+      performanceThresholdPct: 85,
+      qualitySpikeDeltaPct: 5,
+      alertsJson: DEFAULT_ALERTS,
+      defaultsJson: { ...(DEFAULT_DEFAULTS as any), modules: { screenlessMode: false } },
+      updatedBy: userId,
+    },
+  });
+
+  await tx.orgShift.create({
+    data: {
+      orgId,
+      name: DEFAULT_SHIFT.name,
+      startTime: DEFAULT_SHIFT.start,
+      endTime: DEFAULT_SHIFT.end,
+      sortOrder: 1,
+      enabled: true,
+    },
+  });
+
+  const shifts = await tx.orgShift.findMany({
+    where: { orgId },
+    orderBy: { sortOrder: "asc" },
+  });
+  return { settings, shifts };
+}
+
+async function loadSettingsPayload(orgId: string, userId: string) {
+  const loaded = await prisma.$transaction(async (tx) => {
+    const found = await ensureOrgSettings(tx, orgId, userId);
+    if (!found?.settings) throw new Error("SETTINGS_NOT_FOUND");
+    return found;
+  });
+
+  const base = buildSettingsPayload(loaded.settings, loaded.shifts ?? []) as Record<string, unknown>;
+  const payload = await attachReasonCatalog(
+    orgId,
+    loaded.settings.defaultsJson,
+    loaded.settings.version,
+    base
+  );
+  const defaultsRaw = isPlainObject(loaded.settings.defaultsJson) ? (loaded.settings.defaultsJson as any) : {};
+  const modulesRaw = isPlainObject(defaultsRaw.modules) ? defaultsRaw.modules : {};
+  const modules = { screenlessMode: modulesRaw.screenlessMode === true };
+
+  return { payload, modules };
+}
+
+async function loadSettingsCached(orgId: string, userId: string) {
+  const cached = unstable_cache(
+    () => loadSettingsPayload(orgId, userId),
+    ["settings", orgId],
+    { revalidate: SETTINGS_TTL_SEC, tags: [`settings:${orgId}`] }
+  );
+  return cached();
+}
+
+export async function GET(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+
+  try {
+    const url = new URL(req.url);
+    const refresh = url.searchParams.get("refresh") === "1";
+    const { payload, modules } = refresh
+      ? await loadSettingsPayload(session.orgId, session.userId)
+      : await loadSettingsCached(session.orgId, session.userId);
+
+    const version = payload.version ?? 0;
+    const etag = `W/"${createHash("sha1").update(`${session.orgId}:${version}`).digest("hex")}"`;
+    const responseHeaders = new Headers({
+      "Cache-Control": `private, max-age=${SETTINGS_TTL_SEC}, stale-while-revalidate=${SETTINGS_SWR_SEC}`,
+      ETag: etag,
+      Vary: "Cookie",
+    });
+
+    const ifNoneMatch = req.headers.get("if-none-match");
+    if (!refresh && ifNoneMatch && ifNoneMatch === etag) {
+      return new NextResponse(null, { status: 304, headers: responseHeaders });
+    }
+
+    return NextResponse.json({ ok: true, settings: { ...payload, modules } }, { headers: responseHeaders });
+
+  } catch (err) {
+    console.error("[settings GET] failed", err);
+    const message = err instanceof Error ? err.message : "Internal error";
+    return NextResponse.json({ ok: false, error: message }, { status: 500 });
+  }
+}
+
+export async function PUT(req: Request) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManageSettings(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  try {
+    const body = await req.json().catch(() => ({}));
+    const parsed = settingsPayloadSchema.safeParse(body);
+    if (!parsed.success) {
+      return NextResponse.json({ ok: false, error: "Invalid settings payload" }, { status: 400 });
+    }
+
+    const source = String(parsed.data.source ?? "control_tower");
+    const timezone = parsed.data.timezone;
+    const shiftSchedule = parsed.data.shiftSchedule;
+    const thresholds = parsed.data.thresholds;
+    const alerts = parsed.data.alerts;
+    const defaults = parsed.data.defaults;
+    const expectedVersion = parsed.data.version;
+    const modules = parsed.data.modules;
+
+
+
+    if (
+      timezone === undefined &&
+      shiftSchedule === undefined &&
+      thresholds === undefined &&
+      alerts === undefined &&
+      defaults === undefined &&
+      modules === undefined
+
+    ) {
+      return NextResponse.json({ ok: false, error: "No settings provided" }, { status: 400 });
+    }
+
+    if (shiftSchedule && !isPlainObject(shiftSchedule)) {
+      return NextResponse.json({ ok: false, error: "shiftSchedule must be an object" }, { status: 400 });
+    }
+    if (thresholds !== undefined && !isPlainObject(thresholds)) {
+      return NextResponse.json({ ok: false, error: "thresholds must be an object" }, { status: 400 });
+    }
+    if (alerts !== undefined && !isPlainObject(alerts)) {
+      return NextResponse.json({ ok: false, error: "alerts must be an object" }, { status: 400 });
+    }
+    if (defaults !== undefined && !isPlainObject(defaults)) {
+      return NextResponse.json({ ok: false, error: "defaults must be an object" }, { status: 400 });
+    }
+    if (modules !== undefined && !isPlainObject(modules)) {
+      return NextResponse.json({ ok: false, error: "Invalid modules payload" }, { status: 400 });
+    }
+
+    const screenlessMode =
+      modules && typeof (modules as any).screenlessMode === "boolean"
+        ? (modules as any).screenlessMode
+        : undefined;
+
+
+
+    const shiftValidation = validateShiftFields(
+      shiftSchedule?.shiftChangeCompensationMin,
+      shiftSchedule?.lunchBreakMin
+    );
+    if (!shiftValidation.ok) {
+      return NextResponse.json({ ok: false, error: shiftValidation.error }, { status: 400 });
+    }
+
+    const overridesResult =
+      shiftSchedule?.overrides !== undefined
+        ? validateShiftOverrides(shiftSchedule.overrides)
+        : ({ ok: true, overrides: undefined } as const);
+    if (!overridesResult.ok) {
+      return NextResponse.json({ ok: false, error: overridesResult.error }, { status: 400 });
+    }
+
+    const thresholdsValidation = validateThresholds(thresholds);
+    if (!thresholdsValidation.ok) {
+      return NextResponse.json({ ok: false, error: thresholdsValidation.error }, { status: 400 });
+    }
+
+    let shiftRows: ValidShift[] | null = null;
+    if (shiftSchedule?.shifts !== undefined) {
+      const shiftResult = validateShiftSchedule(shiftSchedule.shifts);
+      if (!shiftResult.ok) {
+        return NextResponse.json({ ok: false, error: shiftResult.error }, { status: 400 });
+      }
+      shiftRows = shiftResult.shifts ?? [];
+    }
+    const shiftRowsSafe = shiftRows ?? [];
+
+    const updated = await prisma.$transaction(async (tx) => {
+      const current = await ensureOrgSettings(tx, session.orgId, session.userId);
+      if (!current?.settings) throw new Error("SETTINGS_NOT_FOUND");
+
+    if (expectedVersion != null && Number(expectedVersion) !== Number(current.settings.version)) {
+      return { error: "VERSION_MISMATCH", currentVersion: current.settings.version } as const;
+    }
+
+    const nextAlerts =
+      alerts !== undefined ? { ...normalizeAlerts(current.settings.alertsJson), ...alerts } : undefined;
+    const currentDefaultsRaw = isPlainObject(current.settings.defaultsJson)
+      ? (current.settings.defaultsJson as any)
+      : {};
+    const currentModulesRaw = isPlainObject(currentDefaultsRaw.modules) ? currentDefaultsRaw.modules : {};
+
+    // Merge defaults core (moldTotal, etc.)
+    const nextDefaultsCore =
+      defaults !== undefined ? { ...normalizeDefaults(currentDefaultsRaw), ...defaults } : undefined;
+
+    // Validate merged defaults
+    if (nextDefaultsCore) {
+      const dv = validateDefaults(nextDefaultsCore);
+      if (!dv.ok) return { error: dv.error } as const;
+    }
+
+    // Merge modules
+    const nextModules =
+      screenlessMode === undefined
+        ? currentModulesRaw
+        : { ...currentModulesRaw, screenlessMode };
+
+    // Write defaultsJson if either defaults changed OR modules changed
+    const shouldWriteDefaultsJson = !!nextDefaultsCore || screenlessMode !== undefined;
+
+    const nextDefaultsJson = shouldWriteDefaultsJson
+      ? { ...(nextDefaultsCore ?? normalizeDefaults(currentDefaultsRaw)), modules: nextModules }
+      : undefined;
+
+    if (nextDefaultsJson) {
+      const defaultsTarget = nextDefaultsJson as Record<string, unknown>;
+      delete defaultsTarget.reasonCatalog;
+      delete defaultsTarget.reasonCatalogData;
+    }
+
+
+    const updateData = stripUndefined({
+      timezone: timezone !== undefined ? String(timezone) : undefined,
+      shiftChangeCompMin:
+        shiftSchedule?.shiftChangeCompensationMin !== undefined
+          ? Number(shiftSchedule.shiftChangeCompensationMin)
+          : undefined,
+      lunchBreakMin:
+        shiftSchedule?.lunchBreakMin !== undefined ? Number(shiftSchedule.lunchBreakMin) : undefined,
+      shiftScheduleOverridesJson:
+        shiftSchedule?.overrides !== undefined
+          ? overridesResult.overrides === null
+            ? null
+            : overridesResult.overrides
+          : undefined,
+      stoppageMultiplier:
+        thresholds?.stoppageMultiplier !== undefined ? Number(thresholds.stoppageMultiplier) : undefined,
+      macroStoppageMultiplier:
+        thresholds?.macroStoppageMultiplier !== undefined
+          ? Number(thresholds.macroStoppageMultiplier)
+          : undefined,
+      oeeAlertThresholdPct:
+        thresholds?.oeeAlertThresholdPct !== undefined ? Number(thresholds.oeeAlertThresholdPct) : undefined,
+      performanceThresholdPct:
+        thresholds?.performanceThresholdPct !== undefined
+          ? Number(thresholds.performanceThresholdPct)
+          : undefined,
+      qualitySpikeDeltaPct:
+        thresholds?.qualitySpikeDeltaPct !== undefined ? Number(thresholds.qualitySpikeDeltaPct) : undefined,
+      alertsJson: nextAlerts,
+      defaultsJson: nextDefaultsJson,
+    });
+
+    const hasShiftUpdate = shiftRows !== null;
+    const hasSettingsUpdate = Object.keys(updateData).length > 0;
+
+    if (!hasShiftUpdate && !hasSettingsUpdate) {
+      return { error: "No settings provided" } as const;
+    }
+
+    const updateWithMeta = {
+      ...updateData,
+      version: current.settings.version + 1,
+      updatedBy: session.userId,
+    };
+
+    await tx.orgSettings.update({
+      where: { orgId: session.orgId },
+      data: updateWithMeta,
+    });
+
+    if (hasShiftUpdate) {
+      await tx.orgShift.deleteMany({ where: { orgId: session.orgId } });
+      if (shiftRowsSafe.length) {
+        await tx.orgShift.createMany({
+          data: shiftRowsSafe.map((s) => ({
+            ...s,
+            orgId: session.orgId,
+          })),
+        });
+      }
+    }
+
+    const refreshed = await tx.orgSettings.findUnique({
+      where: { orgId: session.orgId },
+    });
+    if (!refreshed) throw new Error("SETTINGS_NOT_FOUND");
+    const refreshedShifts = await tx.orgShift.findMany({
+      where: { orgId: session.orgId },
+      orderBy: { sortOrder: "asc" },
+    });
+
+    await tx.settingsAudit.create({
+      data: {
+        orgId: session.orgId,
+        actorId: session.userId,
+        source,
+        payloadJson: body,
+      },
+    });
+
+      return { settings: refreshed, shifts: refreshedShifts };
+    });
+
+    if ("error" in updated && updated.error === "VERSION_MISMATCH") {
+      return NextResponse.json(
+        { ok: false, error: "Version mismatch", currentVersion: updated.currentVersion },
+        { status: 409 }
+      );
+    }
+
+    if ("error" in updated) {
+      return NextResponse.json({ ok: false, error: updated.error }, { status: 400 });
+    }
+
+    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 as Date).toISOString()
+        : undefined;
+    try {
+      await publishSettingsUpdate({
+        orgId: session.orgId,
+        version: Number(payload.version ?? 0),
+        source,
+        updatedAt,
+      });
+    } catch (err) {
+      console.warn("[settings PUT] MQTT publish failed", err);
+    }
+    const defaultsRaw = isPlainObject(updated.settings.defaultsJson) ? (updated.settings.defaultsJson as any) : {};
+    const modulesRaw = isPlainObject(defaultsRaw.modules) ? defaultsRaw.modules : {};
+    const modulesOut = { screenlessMode: modulesRaw.screenlessMode === true };
+
+    revalidateTag(`settings:${session.orgId}`, { expire: 0 });
+
+    return NextResponse.json({ ok: true, settings: { ...payload, modules: modulesOut } });
+
+  } catch (err) {
+    console.error("[settings PUT] failed", err);
+    const message = err instanceof Error ? err.message : "Internal error";
+    return NextResponse.json({ ok: false, error: message }, { status: 500 });
+  }
+}

app/api/signup/route.ts

@@ -0,0 +1,137 @@
+import { NextResponse } from "next/server";
+import bcrypt from "bcrypt";
+import { randomBytes } from "crypto";
+import { prisma } from "@/lib/prisma";
+import { DEFAULT_ALERTS, DEFAULT_DEFAULTS, DEFAULT_SHIFT } from "@/lib/settings";
+import { buildVerifyEmail, sendEmail } from "@/lib/email";
+import { getBaseUrl } from "@/lib/appUrl";
+import { logLine } from "@/lib/logger";
+import { z } from "zod";
+
+const signupSchema = z.object({
+  orgName: z.string().trim().min(1).max(120),
+  name: z.string().trim().min(1).max(80),
+  email: z.string().trim().min(1).max(254).email(),
+  password: z.string().min(8).max(256),
+});
+
+function slugify(input: string) {
+  const trimmed = input.trim().toLowerCase();
+  const slug = trimmed
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+  return slug || "org";
+}
+
+export async function POST(req: Request) {
+  const body = await req.json().catch(() => ({}));
+  const parsed = signupSchema.safeParse(body);
+  if (!parsed.success) {
+    return NextResponse.json({ ok: false, error: "Invalid signup payload" }, { status: 400 });
+  }
+  const orgName = parsed.data.orgName;
+  const name = parsed.data.name;
+  const email = parsed.data.email.toLowerCase();
+  const password = parsed.data.password;
+
+  const existing = await prisma.user.findUnique({ where: { email } });
+  if (existing) {
+    return NextResponse.json({ ok: false, error: "Email already in use" }, { status: 409 });
+  }
+
+  const baseSlug = slugify(orgName);
+  let slug = baseSlug;
+  let counter = 1;
+  while (await prisma.org.findUnique({ where: { slug } })) {
+    counter += 1;
+    slug = `${baseSlug}-${counter}`;
+  }
+
+  const passwordHash = await bcrypt.hash(password, 10);
+  const verificationToken = randomBytes(24).toString("hex");
+  const verificationExpiresAt = new Date(Date.now() + 24 * 60 * 60 * 1000);
+
+  await prisma.$transaction(async (tx) => {
+    const org = await tx.org.create({
+      data: { name: orgName, slug },
+    });
+
+    const user = await tx.user.create({
+      data: {
+        email,
+        name,
+        passwordHash,
+        emailVerificationToken: verificationToken,
+        emailVerificationExpiresAt: verificationExpiresAt,
+      },
+    });
+
+    await tx.orgUser.create({
+      data: {
+        orgId: org.id,
+        userId: user.id,
+        role: "OWNER",
+      },
+    });
+
+    await tx.orgSettings.create({
+      data: {
+        orgId: org.id,
+        timezone: "UTC",
+        shiftChangeCompMin: 10,
+        lunchBreakMin: 30,
+        stoppageMultiplier: 1.5,
+        macroStoppageMultiplier: 5,
+        oeeAlertThresholdPct: 90,
+        performanceThresholdPct: 85,
+        qualitySpikeDeltaPct: 5,
+        alertsJson: DEFAULT_ALERTS,
+        defaultsJson: DEFAULT_DEFAULTS,
+        updatedBy: user.id,
+      },
+    });
+
+    await tx.orgShift.create({
+      data: {
+        orgId: org.id,
+        name: DEFAULT_SHIFT.name,
+        startTime: DEFAULT_SHIFT.start,
+        endTime: DEFAULT_SHIFT.end,
+        sortOrder: 1,
+        enabled: true,
+      },
+    });
+
+    return { org, user };
+  });
+
+  const baseUrl = getBaseUrl(req);
+  const verifyUrl = `${baseUrl}/api/verify-email?token=${verificationToken}`;
+  const appName = "MIS Control Tower";
+  const emailContent = buildVerifyEmail({ appName, verifyUrl });
+
+  let emailSent = true;
+  try {
+    await sendEmail({
+      to: email,
+      subject: emailContent.subject,
+      text: emailContent.text,
+      html: emailContent.html,
+    });
+  } catch (err: unknown) {
+    emailSent = false;
+    const error = err as { message?: string; code?: string; response?: unknown; responseCode?: number };
+    logLine("signup.verify_email.failed", {
+      email,
+      message: error?.message,
+      code: error?.code,
+      response: error?.response,
+      responseCode: error?.responseCode,
+    });
+  }
+  return NextResponse.json({
+    ok: true,
+    verificationRequired: true,
+    emailSent,
+  });
+}

app/api/verify-email/route.ts

@@ -0,0 +1,62 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { buildSessionCookieOptions, COOKIE_NAME, SESSION_DAYS } from "@/lib/auth/sessionCookie";
+import { getBaseUrl } from "@/lib/appUrl";
+
+export async function GET(req: Request) {
+  const url = new URL(req.url);
+  const token = url.searchParams.get("token");
+  const wantsJson = req.headers.get("accept")?.includes("application/json");
+
+  if (!token) {
+    return NextResponse.json({ ok: false, error: "Missing token" }, { status: 400 });
+  }
+
+  const user = await prisma.user.findFirst({
+    where: {
+      emailVerificationToken: token,
+      emailVerificationExpiresAt: { gt: new Date() },
+    },
+  });
+
+  if (!user) {
+    return NextResponse.json({ ok: false, error: "Invalid or expired token" }, { status: 404 });
+  }
+
+  await prisma.user.update({
+    where: { id: user.id },
+    data: {
+      emailVerifiedAt: new Date(),
+      emailVerificationToken: null,
+      emailVerificationExpiresAt: null,
+    },
+  });
+
+  const membership = await prisma.orgUser.findFirst({
+    where: { userId: user.id },
+    orderBy: { createdAt: "asc" },
+  });
+
+  if (!membership) {
+    return NextResponse.json({ ok: false, error: "No organization found" }, { status: 403 });
+  }
+
+  const expiresAt = new Date(Date.now() + SESSION_DAYS * 24 * 60 * 60 * 1000);
+  const session = await prisma.session.create({
+    data: {
+      userId: user.id,
+      orgId: membership.orgId,
+      expiresAt,
+    },
+  });
+
+  if (wantsJson) {
+    const res = NextResponse.json({ ok: true, next: "/machines" });
+    res.cookies.set(COOKIE_NAME, session.id, buildSessionCookieOptions(req));
+    return res;
+  }
+
+  const res = NextResponse.redirect(new URL("/machines", getBaseUrl(req)));
+  res.cookies.set(COOKIE_NAME, session.id, buildSessionCookieOptions(req));
+  return res;
+}

app/api/work-orders/machines/[machineId]/route.ts

@@ -0,0 +1,52 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+
+export async function GET(
+  req: NextRequest,
+  { params }: { params: Promise<{ machineId: string }> }
+) {
+  const { machineId } = await params;
+
+  const session = await requireSession();
+  let orgId: string | null = null;
+
+  if (session) {
+    const machine = await prisma.machine.findFirst({
+      where: { id: machineId, orgId: session.orgId },
+      select: { id: true, orgId: true },
+    });
+    if (!machine) return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+    orgId = machine.orgId;
+  } else {
+    const apiKey = req.headers.get("x-api-key");
+    if (!apiKey) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    const machine = await prisma.machine.findFirst({
+      where: { id: machineId, apiKey },
+      select: { id: true, orgId: true },
+    });
+    if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+    orgId = machine.orgId;
+  }
+
+  const rows = await prisma.machineWorkOrder.findMany({
+    where: { machineId, orgId: orgId as string, status: { not: "DONE" } },
+    orderBy: { createdAt: "desc" },
+  });
+
+  return NextResponse.json({
+    ok: true,
+    machineId,
+    workOrders: rows.map((row) => ({
+      workOrderId: row.workOrderId,
+      sku: row.sku,
+      targetQty: row.targetQty,
+      cycleTime: row.cycleTime,
+      mold: row.mold,
+      cavitiesTotal: row.cavitiesTotal,
+      cavitiesActive: row.cavitiesActive,
+      status: row.status,
+    })),
+  });
+}

app/api/work-orders/route.ts

@@ -0,0 +1,280 @@
+import { NextResponse } from "next/server";
+import type { NextRequest } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { requireSession } from "@/lib/auth/requireSession";
+import { publishWorkOrdersUpdate } from "@/lib/mqtt";
+import { z } from "zod";
+
+function canManage(role?: string | null) {
+  return role === "OWNER" || role === "ADMIN";
+}
+
+const MAX_WORK_ORDERS = 2000;
+const MAX_WORK_ORDER_ID_LENGTH = 64;
+const MAX_SKU_LENGTH = 64;
+const MAX_MOLD_LENGTH = 256;
+const MAX_TARGET_QTY = 2_000_000_000;
+const MAX_CYCLE_TIME = 86_400;
+const MAX_CAVITIES = 100_000;
+const WORK_ORDER_ID_RE = /^[A-Za-z0-9._-]+$/;
+
+const uploadBodySchema = z.object({
+  machineId: z.string().trim().min(1),
+  workOrders: z.array(z.any()).optional(),
+  orders: z.array(z.any()).optional(),
+  workOrder: z.any().optional(),
+});
+
+function cleanText(value: unknown, maxLen: number) {
+  if (value === null || value === undefined) return null;
+  const text = String(value).trim();
+  if (!text) return null;
+  const sanitized = text.replace(/[\u0000-\u001f\u007f]/g, "");
+  if (!sanitized) return null;
+  return sanitized.length > maxLen ? sanitized.slice(0, maxLen) : sanitized;
+}
+
+function toIntOrNull(value: unknown) {
+  if (value === null || value === undefined || value === "") return null;
+  const n = Number(value);
+  if (!Number.isFinite(n)) return null;
+  return Math.trunc(n);
+}
+
+function toFloatOrNull(value: unknown) {
+  if (value === null || value === undefined || value === "") return null;
+  const n = Number(value);
+  if (!Number.isFinite(n)) return null;
+  return n;
+}
+
+type WorkOrderInput = {
+  workOrderId: string;
+  sku?: string | null;
+  targetQty?: number | null;
+  cycleTime?: number | null;
+  mold?: string | null;
+  cavitiesTotal?: number | null;
+  cavitiesActive?: number | null;
+};
+
+type RowIssue = {
+  row: number;
+  workOrderId: string | null;
+  errors: string[];
+};
+
+function normalizeWorkOrders(raw: unknown[]) {
+  const seen = new Set<string>();
+  const cleaned: WorkOrderInput[] = [];
+
+  for (const item of raw) {
+    const record = item && typeof item === "object" ? (item as Record<string, unknown>) : {};
+    const idRaw = cleanText(
+      record.workOrderId ?? record.id ?? record.work_order_id,
+      MAX_WORK_ORDER_ID_LENGTH
+    );
+    if (!idRaw || !WORK_ORDER_ID_RE.test(idRaw) || seen.has(idRaw)) continue;
+    seen.add(idRaw);
+
+    const sku = cleanText(record.sku ?? record.SKU ?? null, MAX_SKU_LENGTH);
+    const targetQtyRaw = toIntOrNull(
+      record.targetQty ?? record.target_qty ?? record.target ?? record.targetQuantity
+    );
+    const cycleTimeRaw = toFloatOrNull(
+      record.cycleTime ?? record.theoreticalCycleTime ?? record.theoretical_cycle_time ?? record.cycle_time
+    );
+    const targetQty =
+      targetQtyRaw == null ? null : Math.min(Math.max(targetQtyRaw, 0), MAX_TARGET_QTY);
+    const cycleTime =
+      cycleTimeRaw == null ? null : Math.min(Math.max(cycleTimeRaw, 0), MAX_CYCLE_TIME);
+
+    const mold = cleanText(
+      record.mold ?? record.moldId ?? record.mold_id ?? null,
+      MAX_MOLD_LENGTH
+    );
+    const cavitiesTotalRaw = toIntOrNull(
+      record.cavitiesTotal ??
+        record.cavities_total ??
+        record.totalCavities ??
+        record.total_cavities
+    );
+    const cavitiesActiveRaw = toIntOrNull(
+      record.cavitiesActive ??
+        record.cavities_active ??
+        record.activeCavities ??
+        record.active_cavities
+    );
+    const cavitiesTotal =
+      cavitiesTotalRaw == null
+        ? null
+        : Math.min(Math.max(cavitiesTotalRaw, 0), MAX_CAVITIES);
+    const cavitiesActive =
+      cavitiesActiveRaw == null
+        ? null
+        : Math.min(Math.max(cavitiesActiveRaw, 0), MAX_CAVITIES);
+
+    cleaned.push({
+      workOrderId: idRaw,
+      sku: sku ?? null,
+      targetQty: targetQty ?? null,
+      cycleTime: cycleTime ?? null,
+      mold: mold ?? null,
+      cavitiesTotal: cavitiesTotal ?? null,
+      cavitiesActive: cavitiesActive ?? null,
+    });
+  }
+
+  return cleaned;
+}
+
+// ✨ NUEVO: validación estricta del Excel
+// Cada fila debe tener mold (no vacío), cavitiesTotal (>=1), cavitiesActive (>=1, <=cavitiesTotal)
+// Si UNA SOLA fila falla, se rechaza el archivo completo (Opción A)
+function validateRows(rows: WorkOrderInput[], rawList: unknown[]): RowIssue[] {
+  const issues: RowIssue[] = [];
+
+  // Validar lista cruda primero (si hay duplicados o IDs inválidos no llegaron a `cleaned`)
+  // Pero aquí enfocamos en la validación de mold/cavidades sobre filas ya normalizadas.
+  rows.forEach((row, idx) => {
+    const errors: string[] = [];
+
+    // Mold requerido
+    if (!row.mold || row.mold.length === 0) {
+      errors.push("Mold is required");
+    }
+
+    // Cavities Total requerido y >= 1
+    if (row.cavitiesTotal == null) {
+      errors.push("Total Cavities is required");
+    } else if (row.cavitiesTotal < 1) {
+      errors.push("Total Cavities must be at least 1");
+    }
+
+    // Cavities Active requerido y >= 1
+    if (row.cavitiesActive == null) {
+      errors.push("Active Cavities is required");
+    } else if (row.cavitiesActive < 1) {
+      errors.push("Active Cavities must be at least 1");
+    }
+
+    // Active <= Total
+    if (
+      row.cavitiesActive != null &&
+      row.cavitiesTotal != null &&
+      row.cavitiesActive > row.cavitiesTotal
+    ) {
+      errors.push(
+        `Active Cavities (${row.cavitiesActive}) cannot exceed Total Cavities (${row.cavitiesTotal})`
+      );
+    }
+
+    if (errors.length > 0) {
+      issues.push({
+        row: idx + 1, // 1-indexed para el operador
+        workOrderId: row.workOrderId,
+        errors,
+      });
+    }
+  });
+
+  return issues;
+}
+
+export async function POST(req: NextRequest) {
+  const session = await requireSession();
+  if (!session) return 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 (!canManage(membership?.role)) {
+    return NextResponse.json({ ok: false, error: "Forbidden" }, { status: 403 });
+  }
+
+  const body = await req.json().catch(() => ({}));
+  const parsedBody = uploadBodySchema.safeParse(body);
+  if (!parsedBody.success) {
+    return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
+  }
+
+  const machineId = String(parsedBody.data.machineId ?? "").trim();
+  if (!machineId) {
+    return NextResponse.json({ ok: false, error: "machineId is required" }, { status: 400 });
+  }
+
+  const machine = await prisma.machine.findFirst({
+    where: { id: machineId, orgId: session.orgId },
+    select: { id: true },
+  });
+  if (!machine) return NextResponse.json({ ok: false, error: "Not found" }, { status: 404 });
+
+  const listRaw = Array.isArray(parsedBody.data.workOrders)
+    ? parsedBody.data.workOrders
+    : Array.isArray(parsedBody.data.orders)
+      ? parsedBody.data.orders
+      : parsedBody.data.workOrder
+        ? [parsedBody.data.workOrder]
+        : [];
+
+  if (listRaw.length > MAX_WORK_ORDERS) {
+    return NextResponse.json(
+      { ok: false, error: `Too many work orders (max ${MAX_WORK_ORDERS})` },
+      { status: 400 }
+    );
+  }
+
+  const cleaned = normalizeWorkOrders(listRaw);
+  if (!cleaned.length) {
+    return NextResponse.json({ ok: false, error: "No valid work orders provided" }, { status: 400 });
+  }
+
+  // ✨ NUEVO: validación estricta de mold/cavidades
+  // Si una sola fila falla, rechazamos el archivo completo
+  const issues = validateRows(cleaned, listRaw);
+  if (issues.length > 0) {
+    return NextResponse.json(
+      {
+        ok: false,
+        error: "Validation failed",
+        summary: `Excel rejected: ${issues.length} of ${cleaned.length} work order(s) have errors. All work orders must include mold name, total cavities, and active cavities. Fix and re-upload.`,
+        issues,
+      },
+      { status: 400 }
+    );
+  }
+
+  const created = await prisma.machineWorkOrder.createMany({
+    data: cleaned.map((row) => ({
+      orgId: session.orgId,
+      machineId,
+      workOrderId: row.workOrderId,
+      sku: row.sku ?? null,
+      targetQty: row.targetQty ?? null,
+      cycleTime: row.cycleTime ?? null,
+      mold: row.mold ?? null,
+      cavitiesTotal: row.cavitiesTotal ?? null,
+      cavitiesActive: row.cavitiesActive ?? null,
+      status: "PENDING",
+    })),
+    skipDuplicates: true,
+  });
+
+  try {
+    await publishWorkOrdersUpdate({
+      orgId: session.orgId,
+      machineId,
+      count: created.count,
+    });
+  } catch (err) {
+    console.warn("[work orders POST] MQTT publish failed", err);
+  }
+
+  return NextResponse.json({
+    ok: true,
+    machineId,
+    inserted: created.count,
+    total: cleaned.length,
+  });
+}

app/global-error.tsx

@@ -0,0 +1,37 @@
+"use client";
+
+export default function GlobalError({
+  error,
+  reset,
+}: {
+  error: Error & { digest?: string };
+  reset: () => void;
+}) {
+  return (
+    <html lang="en">
+      <body style={{ margin: 0, fontFamily: "system-ui, sans-serif", background: "#0a0a0a", color: "#e5e5e5", minHeight: "100vh", display: "flex", alignItems: "center", justifyContent: "center" }}>
+        <div style={{ textAlign: "center", padding: "2rem", maxWidth: "28rem" }}>
+          <h1 style={{ fontSize: "1.25rem", fontWeight: 600, marginBottom: "0.5rem" }}>Something went wrong</h1>
+          <p style={{ fontSize: "0.875rem", color: "#a3a3a3", marginBottom: "1.5rem" }}>
+            An unexpected error occurred. Please try again.
+          </p>
+          <button
+            type="button"
+            onClick={() => reset()}
+            style={{
+              padding: "0.5rem 1rem",
+              fontSize: "0.875rem",
+              borderRadius: "0.5rem",
+              border: "1px solid rgba(255,255,255,0.2)",
+              background: "rgba(255,255,255,0.05)",
+              color: "#e5e5e5",
+              cursor: "pointer",
+            }}
+          >
+            Try again
+          </button>
+        </div>
+      </body>
+    </html>
+  );
+}

app/globals.css

@@ -1,31 +1,168 @@
 @import "tailwindcss";
 
 :root {
-  --background: #ffffff;
-  --foreground: #171717;
+  color-scheme: dark;
+  --font-geist-sans: "Segoe UI", system-ui, sans-serif;
+  --font-geist-mono: ui-monospace, SFMono-Regular, Menlo, monospace;
+  --app-bg: #0b0f14;
+  --app-surface: rgba(255, 255, 255, 0.05);
+  --app-surface-2: rgba(255, 255, 255, 0.08);
+  --app-surface-3: rgba(0, 0, 0, 0.28);
+  --app-surface-4: rgba(0, 0, 0, 0.42);
+  --app-border: rgba(148, 163, 184, 0.18);
+  --app-text: #e5e7eb;
+  --app-text-strong: #f8fafc;
+  --app-text-muted: #94a3b8;
+  --app-text-subtle: #6b7280;
+  --app-text-faint: #475569;
+  --app-text-on-accent: #0b0f14;
+
+  --app-good-text: #6ee7b7;
+  --app-good-bg: rgba(34, 197, 94, 0.18);
+  --app-good-border: rgba(34, 197, 94, 0.28);
+  --app-good-solid: #34d399;
+
+  --app-warn-text: #facc15;
+  --app-warn-bg: rgba(250, 204, 21, 0.18);
+  --app-warn-border: rgba(250, 204, 21, 0.32);
+
+  --app-bad-text: #f87171;
+  --app-bad-bg: rgba(248, 113, 113, 0.18);
+  --app-bad-border: rgba(248, 113, 113, 0.32);
+
+  --app-info-text: #7ab8ff;
+  --app-info-bg: rgba(59, 130, 246, 0.18);
+  --app-info-border: rgba(59, 130, 246, 0.3);
+
+  --app-overlay: rgba(3, 6, 12, 0.65);
+  --app-modal-bg: rgba(9, 13, 19, 0.92);
+
+  --app-chart-grid: rgba(148, 163, 184, 0.2);
+  --app-chart-tick: #9ca3af;
+  --app-chart-tooltip-bg: rgba(2, 6, 23, 0.88);
+  --app-chart-tooltip-border: rgba(148, 163, 184, 0.25);
+  --app-chart-label: #f8fafc;
+  --app-chart-shadow: 0 0 30px rgba(2, 6, 23, 0.6);
 }
 
 @theme inline {
-  --color-background: var(--background);
-  --color-foreground: var(--foreground);
+  --color-background: var(--app-bg);
+  --color-foreground: var(--app-text);
   --font-sans: var(--font-geist-sans);
   --font-mono: var(--font-geist-mono);
 }
 
-@media (prefers-color-scheme: dark) {
-  :root {
-    --background: #0a0a0a;
-    --foreground: #ededed;
-  }
+:root[data-theme="light"] {
+  color-scheme: light;
+  --app-bg: #f4f6f9;
+  --app-surface: #ffffff;
+  --app-surface-2: #eef2f6;
+  --app-surface-3: #e7ecf2;
+  --app-surface-4: #dde3ea;
+  --app-border: rgba(15, 23, 42, 0.12);
+  --app-text: #1f2937;
+  --app-text-strong: #0f172a;
+  --app-text-muted: #4b5563;
+  --app-text-subtle: #6b7280;
+  --app-text-faint: #8b95a3;
+  --app-text-on-accent: #0f172a;
+
+  --app-good-text: #0f7a3e;
+  --app-good-bg: rgba(34, 197, 94, 0.16);
+  --app-good-border: rgba(34, 197, 94, 0.3);
+  --app-good-solid: #22c55e;
+
+  --app-warn-text: #a16207;
+  --app-warn-bg: rgba(234, 179, 8, 0.18);
+  --app-warn-border: rgba(234, 179, 8, 0.36);
+
+  --app-bad-text: #b91c1c;
+  --app-bad-bg: rgba(239, 68, 68, 0.16);
+  --app-bad-border: rgba(239, 68, 68, 0.34);
+
+  --app-info-text: #1d4ed8;
+  --app-info-bg: rgba(59, 130, 246, 0.16);
+  --app-info-border: rgba(59, 130, 246, 0.3);
+
+  --app-overlay: rgba(15, 23, 42, 0.45);
+  --app-modal-bg: rgba(255, 255, 255, 0.92);
+
+  --app-chart-grid: rgba(15, 23, 42, 0.12);
+  --app-chart-tick: #6b7280;
+  --app-chart-tooltip-bg: #ffffff;
+  --app-chart-tooltip-border: rgba(15, 23, 42, 0.16);
+  --app-chart-label: #0f172a;
+  --app-chart-shadow: 0 0 24px rgba(15, 23, 42, 0.12);
 }
 
 body {
-  background: var(--background);
-  color: var(--foreground);
-  font-family: Arial, Helvetica, sans-serif;
+  background: var(--app-bg);
+  color: var(--app-text);
+  font-family: var(--font-geist-sans), "Segoe UI", system-ui, sans-serif;
 }
 
 /* Hide scrollbar but keep scrolling */
 .no-scrollbar::-webkit-scrollbar { display: none; }
 .no-scrollbar { -ms-overflow-style: none; scrollbar-width: none; }
 
+/* Theme-friendly overrides for common utility classes */
+.text-white { color: var(--app-text-strong) !important; }
+.text-black { color: var(--app-text-on-accent) !important; }
+.text-zinc-200 { color: var(--app-text) !important; }
+.text-zinc-300 { color: var(--app-text-muted) !important; }
+.text-zinc-400 { color: var(--app-text-subtle) !important; }
+.text-zinc-500 { color: var(--app-text-faint) !important; }
+.text-emerald-100,
+.text-emerald-200,
+.text-emerald-300 { color: var(--app-good-text) !important; }
+.text-yellow-300 { color: var(--app-warn-text) !important; }
+.text-red-200,
+.text-red-300,
+.text-red-400 { color: var(--app-bad-text) !important; }
+.text-blue-300 { color: var(--app-info-text) !important; }
+.text-orange-300 { color: var(--app-warn-text) !important; }
+.text-rose-300 { color: var(--app-bad-text) !important; }
+
+.bg-black { background-color: var(--app-bg) !important; }
+.bg-black\/20 { background-color: var(--app-surface-2) !important; }
+.bg-black\/25 { background-color: var(--app-surface-3) !important; }
+.bg-black\/30 { background-color: var(--app-surface-3) !important; }
+.bg-black\/40 { background-color: var(--app-surface-4) !important; }
+.bg-black\/70 { background-color: var(--app-overlay) !important; }
+.bg-zinc-950\/80,
+.bg-zinc-950\/95 { background-color: var(--app-modal-bg) !important; }
+.bg-white\/5 { background-color: var(--app-surface) !important; }
+.bg-white\/10 { background-color: var(--app-surface-2) !important; }
+
+.border-white\/10,
+.border-white\/5 { border-color: var(--app-border) !important; }
+.border-emerald-500\/20,
+.border-emerald-400\/40,
+.border-emerald-500\/30 { border-color: var(--app-good-border) !important; }
+.border-red-500\/20,
+.border-red-500\/30 { border-color: var(--app-bad-border) !important; }
+.border-yellow-500\/20,
+.border-orange-500\/20 { border-color: var(--app-warn-border) !important; }
+.border-rose-500\/20 { border-color: var(--app-bad-border) !important; }
+.border-blue-500\/20 { border-color: var(--app-info-border) !important; }
+
+.bg-emerald-500\/10,
+.bg-emerald-500\/15,
+.bg-emerald-500\/20,
+.bg-emerald-500\/30 { background-color: var(--app-good-bg) !important; }
+.bg-emerald-400 { background-color: var(--app-good-solid) !important; }
+.bg-yellow-500\/15 { background-color: var(--app-warn-bg) !important; }
+.bg-red-500\/10,
+.bg-red-500\/15,
+.bg-red-500\/20 { background-color: var(--app-bad-bg) !important; }
+.bg-blue-500\/15 { background-color: var(--app-info-bg) !important; }
+.bg-orange-500\/15 { background-color: var(--app-warn-bg) !important; }
+.bg-rose-500\/15 { background-color: var(--app-bad-bg) !important; }
+
+.placeholder\:text-zinc-500::placeholder { color: var(--app-text-faint) !important; }
+
+.hover\:bg-white\/5:hover { background-color: var(--app-surface) !important; }
+.hover\:bg-white\/10:hover { background-color: var(--app-surface-2) !important; }
+.hover\:bg-emerald-500\/30:hover { background-color: var(--app-good-bg) !important; }
+.hover\:bg-red-500\/20:hover { background-color: var(--app-bad-bg) !important; }
+.hover\:text-white:hover { color: var(--app-text-strong) !important; }

app/invite/[token]/InviteAcceptForm.tsx

@@ -0,0 +1,155 @@
+"use client";
+
+import { useEffect, useState } from "react";
+import { useRouter } from "next/navigation";
+import { useI18n } from "@/lib/i18n/useI18n";
+
+type InviteInfo = {
+  email: string;
+  role: string;
+  org: { id: string; name: string; slug: string };
+  expiresAt: string;
+};
+
+type InviteAcceptFormProps = {
+  token: string;
+  initialInvite?: InviteInfo | null;
+  initialError?: string | null;
+};
+
+export default function InviteAcceptForm({
+  token,
+  initialInvite = null,
+  initialError = null,
+}: InviteAcceptFormProps) {
+  const router = useRouter();
+  const { t } = useI18n();
+  const cleanedToken = token.trim();
+  const [invite, setInvite] = useState<InviteInfo | null>(initialInvite);
+  const [loading, setLoading] = useState(!initialInvite && !initialError);
+  const [submitting, setSubmitting] = useState(false);
+  const [error, setError] = useState<string | null>(initialError);
+  const [name, setName] = useState("");
+  const [password, setPassword] = useState("");
+
+  useEffect(() => {
+    if (initialInvite || initialError) {
+      setLoading(false);
+      return;
+    }
+
+    let alive = true;
+    async function loadInvite() {
+      setLoading(true);
+      setError(null);
+      try {
+        const res = await fetch(`/api/invites/${encodeURIComponent(cleanedToken)}`, {
+          cache: "no-store",
+        });
+        const data = await res.json().catch(() => ({}));
+        if (!res.ok || !data.ok) {
+          throw new Error(data.error || t("invite.error.notFound"));
+        }
+        if (alive) setInvite(data.invite);
+      } catch (err: unknown) {
+        const message = err instanceof Error ? err.message : null;
+        if (alive) setError(message || t("invite.error.notFound"));
+      } finally {
+        if (alive) setLoading(false);
+      }
+    }
+
+    loadInvite();
+    return () => {
+      alive = false;
+    };
+  }, [cleanedToken, initialInvite, initialError, t]);
+
+  async function onSubmit(e: React.FormEvent) {
+    e.preventDefault();
+    setError(null);
+    setSubmitting(true);
+    try {
+      const res = await fetch(`/api/invites/${encodeURIComponent(cleanedToken)}`, {
+        method: "POST",
+        headers: { "Content-Type": "application/json" },
+        body: JSON.stringify({ name, password }),
+      });
+      const data = await res.json().catch(() => ({}));
+      if (!res.ok || !data.ok) {
+        throw new Error(data.error || t("invite.error.acceptFailed"));
+      }
+      router.push("/machines");
+      router.refresh();
+    } catch (err: unknown) {
+      const message = err instanceof Error ? err.message : null;
+      setError(message || t("invite.error.acceptFailed"));
+    } finally {
+      setSubmitting(false);
+    }
+  }
+
+  if (loading) {
+    return (
+      <div className="min-h-screen bg-black flex items-center justify-center p-6 text-zinc-300">
+        {t("invite.loading")}
+      </div>
+    );
+  }
+
+  if (!invite) {
+    return (
+      <div className="min-h-screen bg-black flex items-center justify-center p-6">
+        <div className="max-w-md rounded-2xl border border-red-500/30 bg-red-500/10 p-6 text-sm text-red-200">
+          {error || t("invite.notFound")}
+        </div>
+      </div>
+    );
+  }
+
+  return (
+    <div className="min-h-screen bg-black flex items-center justify-center p-6">
+      <form onSubmit={onSubmit} className="w-full max-w-lg rounded-2xl border border-white/10 bg-white/5 p-8">
+        <h1 className="text-2xl font-semibold text-white">
+          {t("invite.joinTitle", { org: invite.org.name })}
+        </h1>
+        <p className="mt-1 text-sm text-zinc-400">
+          {t("invite.acceptCopy", { email: invite.email, role: invite.role })}
+        </p>
+
+        <div className="mt-6 space-y-4">
+          <div>
+            <label className="text-sm text-zinc-300">{t("invite.yourName")}</label>
+            <input
+              className="mt-1 w-full rounded-xl border border-white/10 bg-black/40 px-4 py-3 text-white outline-none"
+              value={name}
+              onChange={(e) => setName(e.target.value)}
+              autoComplete="name"
+            />
+          </div>
+
+          <div>
+            <label className="text-sm text-zinc-300">{t("invite.password")}</label>
+            <input
+              type="password"
+              className="mt-1 w-full rounded-xl border border-white/10 bg-black/40 px-4 py-3 text-white outline-none"
+              value={password}
+              onChange={(e) => setPassword(e.target.value)}
+              autoComplete="new-password"
+            />
+          </div>
+
+          {error && <div className="text-sm text-red-400">{error}</div>}
+
+          <button
+            type="submit"
+            disabled={submitting}
+            className="mt-2 w-full rounded-xl bg-emerald-400 py-3 font-semibold text-black disabled:opacity-70"
+          >
+            {submitting ? t("invite.submit.loading") : t("invite.submit.default")}
+          </button>
+        </div>
+      </form>
+    </div>
+  );
+}