MIS-Contro-Tower/MACHINE_STATE_PROGRESS.md

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

• Step 1: Add "idle" and "data-loss" to RecapMachineStatus union
• Step 2: Create lib/recap/machineState.ts shared classifier with all reasons
• Step 3: Refactor statusFromMachine in redesign.ts to call classifier
• Step 4: Plumb new fields (status reason, ongoing min) through types/responses
• Step 5: UI rendering: IDLE (calm gray) on /recap, /machines, detail
• Step 6: UI rendering: DATA_LOSS (red + icon) on all surfaces
• Step 7: STOPPED reason text: show not_started vs machine_fault distinction
• Step 8: i18n keys (en + es-MX)
• 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)

• Removed not_started and data-loss branches from classifier
• Removed RecapStoppedReason and RecapDataLossReason types
• Simplified RecapStateContext to empty struct (kept for future use)
• Updated UI rendering: 5 states only (offline/stopped/mold-change/idle/running)
• i18n: removed dead keys