Initial commit, 90% there

.claude/file-history/e9a2a506-d6d3-44d7-b415-3c091d41d796/4615b29dd7e58293@v2

@@ -0,0 +1,134 @@
+const current = Number(msg.payload) || 0;
+
+let zeroStreak = flow.get("zeroStreak") || 0;
+zeroStreak = current === 0 ? zeroStreak + 1 : 0;
+flow.set("zeroStreak", zeroStreak);
+
+const prev = flow.get("lastMachineState") ?? 0;
+flow.set("lastMachineState", current);
+
+global.set("machineOnline", true);
+
+let productionRunning = !!global.get("productionStarted");
+let stateChanged = false;
+
+if (current === 1 && !productionRunning) {
+    productionRunning = true;
+    stateChanged = true;
+} else if (current === 0 && zeroStreak >= 2 && productionRunning) {
+    productionRunning = false;
+    stateChanged = true;
+}
+
+global.set("productionStarted", productionRunning);
+
+const stateMsg = stateChanged
+    ? {
+        _mode: "production-state",
+        machineOnline: true,
+        productionStarted: productionRunning
+    }
+    : null;
+
+const activeOrder = global.get("activeWorkOrder");
+// FIX: moldActive is object, extract cavities property
+const cavities = Number(global.get("moldActive")) || 1;
+if (!activeOrder || !activeOrder.id || cavities <= 0) {
+    return [null, stateMsg, { _triggerKPI: true }, null];
+}
+
+var trackingEnabled = !!global.get("trackingEnabled");
+if (!trackingEnabled) {
+    return [null, stateMsg, { _triggerKPI: true }, null];
+}
+
+if (prev === 1 || current !== 1) {
+    return [null, stateMsg, { _triggerKPI: true }, null];
+}
+
+let cycles = Number(global.get("cycleCount") || 0) + 1;
+global.set("cycleCount", cycles);
+
+// Clear startup mode after first real cycle
+if (global.get("kpiStartupMode")) {
+    global.set("kpiStartupMode", false);
+    node.warn('[MACHINE CYCLE] First cycle - cleared kpiStartupMode');
+}
+
+const now = Date.now();
+const lastCycleTime = global.get("lastCycleTime") || now;
+const timeSinceLastCycle = now - lastCycleTime;
+
+let operatingTime = global.get("operatingTime") || 0;
+operatingTime += (timeSinceLastCycle / 1000);
+
+global.set("operatingTime", operatingTime);
+node.warn(`[MACHINE CYCLE] operatingTime updated to ${operatingTime}`);
+global.set("lastCycleTime", now);
+
+const scrapTotal = Number(activeOrder.scrap) || 0;
+const totalProduced = cycles * cavities;
+// FIX: Guard negative produced
+const produced = Math.max(0, totalProduced - scrapTotal);
+const target = Number(activeOrder.target) || 0;
+const progress = target > 0 ? Math.min(100, Math.round((produced / target) * 100)) : 0;
+
+activeOrder.good = produced;
+activeOrder.progressPercent = progress;
+activeOrder.lastUpdateIso = new Date().toISOString();
+global.set("activeWorkOrder", activeOrder);
+
+const promptIssued = global.get("scrapPromptIssuedFor") || null;
+if (!promptIssued && target > 0 && produced >= target) {
+    global.set("scrapPromptIssuedFor", activeOrder.id);
+    msg._mode = "scrap-prompt";
+    msg.scrapPrompt = {
+        id: activeOrder.id,
+        sku: activeOrder.sku || "",
+        target,
+        produced
+    };
+    return [null, msg, null, null];
+}
+
+const dbMsg = {
+    _mode: "cycle",
+    cycle: {
+        id: activeOrder.id,
+        sku: activeOrder.sku || "",
+        target,
+        good: produced,
+        scrap: Number(activeOrder.scrap) || 0,
+        cycleTime: Number(activeOrder.cycleTime || activeOrder.theoreticalCycleTime || 0),
+        progressPercent: progress,
+        lastUpdateIso: activeOrder.lastUpdateIso,
+        machineOnline: true,
+        productionStarted: productionRunning
+    },
+    // SQL with bound parameters for safety
+    topic: "UPDATE work_orders SET good_parts = ?, progress_percent = ?, updated_at = NOW() WHERE work_order_id = ?",
+    payload: [produced, progress, activeOrder.id]
+};
+
+const kpiTrigger = { _triggerKPI: true };
+
+if (trackingEnabled && dbMsg) {
+    global.set("lastMachineCycleTime", Date.now());
+}
+
+// 4th output: persist cycle_count and good_parts (throttled to 5 seconds)
+const lastDbWrite = global.get("lastWorkOrderDbWrite") || 0;
+const timeSinceLastWrite = now - lastDbWrite;
+let persistCycleCount = null;
+
+// Only send DB update every 5 seconds (5000ms) to reduce DB load
+if (timeSinceLastWrite >= 5000) {
+    persistCycleCount = {
+        topic: "UPDATE work_orders SET cycle_count = ?, good_parts = ?, progress_percent = ?, updated_at = NOW() WHERE work_order_id = ?",
+        payload: [cycles, produced, progress, activeOrder.id]
+    };
+    global.set("lastWorkOrderDbWrite", now);
+    node.warn(`[DB PERSIST] Writing to work_orders: cycles=${cycles}, good_parts=${produced}, progress=${progress}%`);
+}
+
+return [dbMsg, stateMsg, kpiTrigger, persistCycleCount];