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mdares
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Documents/Implementation_Summary.txt
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Documents/Implementation_Summary.txt
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================================================================================
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WORK ORDER PERSISTENCE - IMPLEMENTATION SUMMARY
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Implementation Date: November 29, 2025
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Node-RED Location: /home/mdares/.node-red/
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Backup Location: flows.json.backup_ALL_PHASES_COMPLETE
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================================================================================
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OVERVIEW
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--------
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Successfully implemented all 7 phases of the work order persistence system.
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The system now ensures work order progress is preserved across Node-RED restarts,
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provides resume/restart functionality, and maintains database as source of truth.
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PHASES IMPLEMENTED
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------------------
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✅ PHASE 1: Database Schema Verification & Updates
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- Verified work_orders table has required columns
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- Confirmed: cycle_count, good_parts, scrap_parts, progress_percent columns exist
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- Status: COMPLETE (already had correct schema)
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✅ PHASE 2: Add Cycle Persistence to work_orders Table
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- Added 4th output to Machine Cycles function
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- Initially implemented with 5-second throttling
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- UPDATED: Changed to immediate write (every cycle) for accuracy
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- SQL: UPDATE work_orders SET cycle_count, good_parts, scrap_parts, progress_percent
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- Database now updates on EVERY cycle (no lag)
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- Files Modified: flows.json (Machine cycles function)
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✅ PHASE 3: Implement Resume/Restart Prompt on Load
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- Modified start-work-order to query DB for existing progress
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- Added Progress Check Handler node to evaluate progress
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- Created resume-work-order action handler
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- Created restart-work-order action handler
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- Added Resume/Restart prompt dialog to Home template UI
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- Fixed: Added scrap_parts to queries and resume logic
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- Files Modified: flows.json (Work Order buttons, Progress Check Handler, Home Template)
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✅ PHASE 4: Fix Complete Button to Persist Final Counts
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- Modified complete-work-order handler to capture final values
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- SQL: UPDATE work_orders SET status='DONE', cycle_count, good_parts, scrap_parts, progress_percent=100
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- Final production counts now permanently saved before marking DONE
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- Files Modified: flows.json (Work Order buttons)
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✅ PHASE 5: Update Session Restore to Set RUNNING Status
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- Modified restore-query handler in Back to UI
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- Automatically sets work order status back to RUNNING on Node-RED restart
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- User must still click Start button to begin counting (safety feature)
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- Fixed: Corrected start handler bug (removed undefined dbMsg reference)
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- Files Modified: flows.json (Back to UI function)
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✅ PHASE 6: Load Work Order Data from Database (Not Session)
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- Updated Progress Check Handler to use DB values as source of truth
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- Even when progress is 0, values are loaded from database (not hardcoded)
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- activeWorkOrder object now includes all DB fields (cycle_count, good_parts, scrap)
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- Files Modified: flows.json (Progress Check Handler)
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✅ PHASE 7: Add Tab Switch State Refresh (Optional Enhancement)
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- Added tab refresh polling (every 2 seconds when Home tab visible)
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- Added currentState message handler to Home template
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- UI now refreshes with latest data when switching back to Home tab
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- Files Modified: flows.json (Home Template)
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KEY IMPROVEMENTS & FIXES
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-------------------------
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1. SCRAP TRACKING FIX
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- Issue: Resume showed wrong good_parts count (calculation: cycles × cavities - scrap)
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- Root Cause: scrap value not loaded from database on resume
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- Fix: Added scrap_parts to all DB queries and resume/restart handlers
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- Result: Resume now shows accurate good_parts count
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2. DATABASE LAG FIX
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- Issue: Database was one cycle behind (5-second throttle)
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- User Feedback: Loading work order showed stale data
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- Fix: Removed throttle, now writes to DB on every cycle
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- Result: Database always current, Load shows exact progress
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3. LOAD BUTTON BUG FIX
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- Issue: After Phase 5, Load button stopped working (no UI update, no RUNNING status)
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- Root Cause: start handler referenced undefined dbMsg variable
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- Fix: Changed return [dbMsg, homeMsg, null, null] to [null, homeMsg, null, null]
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- Result: Load button works perfectly
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TECHNICAL DETAILS
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------------------
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Modified Nodes:
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1. Machine cycles (function) - Immediate DB persistence
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2. Work Order buttons (function) - start/resume/restart/complete handlers
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3. Progress Check Handler (function) - NEW node for progress evaluation
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4. Back to UI (function) - resume-prompt and restore-query handlers
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5. Home Template (ui_template) - Resume/Restart dialog and tab refresh
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Database Updates:
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- work_orders table: cycle_count, good_parts, scrap_parts, progress_percent updated on every cycle
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- Status transitions: PENDING → RUNNING → DONE
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- Session restore sets status back to RUNNING
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Flow Connections:
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- Machine cycles → Output 4 → DB Guard (Cycles) → mariaDB
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- Work Order buttons → Progress Check Handler → Back to UI → Home Template
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- All database writes use parameterized queries (SQL injection safe)
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USER WORKFLOWS
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--------------
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1. START NEW WORK ORDER
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- Click Load on work order with no progress
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- Status changes to RUNNING in database
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- Click Start button to begin production
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- Each cycle updates database immediately
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- Progress visible in UI and database
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2. RESUME EXISTING WORK ORDER
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- Click Load on work order with progress (e.g., 60/200 parts)
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- Resume/Restart prompt appears
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- Click "Resume from 60 parts"
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- Status changes to RUNNING
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- Production continues from 60 parts
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- Click Start to begin counting
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3. RESTART WORK ORDER
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- Click Load on work order with progress
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- Resume/Restart prompt appears
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- Click "Restart from 0"
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- Confirmation dialog appears
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- After confirm: cycle_count, good_parts, scrap_parts reset to 0
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- Status changes to RUNNING
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- Click Start to begin counting from 0
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4. COMPLETE WORK ORDER
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- Click Done button
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- Final cycle_count, good_parts, scrap_parts persisted to database
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- progress_percent set to 100
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- Status changes to DONE
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- All state cleared
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5. NODE-RED RESTART (SESSION RESTORE)
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- Node-RED restarts (crash or maintenance)
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- System queries for work orders with status='RUNNING'
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- Restores activeWorkOrder with cycle_count, good_parts, scrap
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- Status remains RUNNING (or is set back to RUNNING)
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- UI shows work order loaded
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- User must click Start to resume production
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6. TAB SWITCHING
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- User on Home tab with production running
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- Switches to Graphs tab
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- Production continues in background
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- Switches back to Home tab
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- Within 2 seconds, UI refreshes with latest data
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TESTING CHECKLIST
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-----------------
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✓ New work order start (0 progress)
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✓ Resume existing work order (with progress)
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✓ Restart existing work order (with progress)
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✓ Complete work order (final counts persisted)
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✓ Node-RED restart with running work order
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✓ Tab switching shows fresh data
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✓ Database updates on every cycle
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✓ Load button shows current progress (not stale)
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✓ Scrap tracking accurate on resume
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✓ Resume/Restart prompt appears when expected
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✓ Start button enabled/disabled correctly
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BACKUP FILES
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------------
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flows.json.backup_phase3 - After Phase 3 (Resume/Restart)
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flows.json.backup_phase3_complete - Phase 3 complete with scrap fix
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flows.json.backup_phase5_complete - After Phase 5 (Session Restore)
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flows.json.backup_phase6_complete - After Phase 6 (DB source of truth)
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flows.json.backup_phase7_complete - After Phase 7 (Tab refresh)
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flows.json.backup_ALL_PHASES_COMPLETE - FINAL BACKUP (all phases complete)
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To restore a backup:
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cd /home/mdares/.node-red
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cp flows.json.backup_ALL_PHASES_COMPLETE flows.json
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# Restart Node-RED
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KNOWN BEHAVIOR
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--------------
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1. Production must be started manually (safety feature)
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- After Load: Status = RUNNING, but production not started
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- User must click Start button
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- This prevents accidental production during debugging
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2. Database writes on every cycle
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- Originally throttled to 5 seconds
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- Changed to immediate for accuracy
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- Performance impact: negligible (1 query per cycle ~30-120s)
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3. Maximum data loss on crash: 1 incomplete cycle
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- Database updates after each complete cycle
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- If Node-RED crashes mid-cycle, that cycle is lost
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- Session restore recovers all complete cycles
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4. Tab refresh polls every 2 seconds
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- Only when Home tab is visible
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- Minimal performance impact
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- Ensures UI stays fresh
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SUCCESS CRITERIA MET
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--------------------
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✅ Work orders persist progress across Node-RED restarts
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✅ Resume/Restart prompt prevents accidental data loss
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✅ work_orders table always reflects current production state
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✅ Tab switches don't lose data
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✅ Multi-day work orders can be interrupted and resumed
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✅ Maximum data loss: 1 cycle on crash (acceptable)
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✅ Database is single source of truth
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✅ UI always shows current, accurate data
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IMPLEMENTATION NOTES
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--------------------
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- All SQL queries use parameterized statements (safe from SQL injection)
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- Database is source of truth (not session/memory)
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- UI updates use Angular scope watchers
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- Error handling includes node.warn() logging for debugging
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- Flow connections verified and tested
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- No backwards compatibility issues
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FINAL STATUS: ✅ ALL PHASES COMPLETE AND TESTED
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================================================================================
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