Summary: Node-RED KPI Backend Optimization Implementation


reference /home/mdares/.nodered/optimization_prompt.txt


The user wants me to reference a file at /home/mdares/.nodered/optimization_prompt.txt. I should read this file to see what it contains and then help them with whatever is in it.


I'll read that file for you.


<tool_use_error>File does not exist.</tool_use_error>


The file doesn't exist at that path. Let me check if the directory exists and what files are in there, or if there's a similar file with a different name.


The file doesn't exist at that path. Let me check what's in the `.nodered` directory:


Bash

List files in .nodered directory


Error: Exit code 2
ls: cannot access '/home/mdares/.nodered/': No such file or directory


The .nodered directory doesn't exist either. Let me check if there are any similar directories or files that might contain what the user is looking for. I should search for files with "optimization" or "prompt" in their names, or check what's in the home directory.


The `.nodered` directory doesn't exist. Let me search for files with similar names in your home directory:


No files found


[Request interrupted by user]


sorry its /home/mdares/.node-red/optimization_prompt.txt


Ah, the user corrected the path. It's `.node-red` not `.nodered`. Let me read that file now.


No problem! Let me read the correct file:


     1→# Backend Optimization Requirements for KPI Tracking System
     2→
     3→## Context
     4→This Node-RED application tracks manufacturing KPIs (OEE, Availability, Performance, Quality) for a production line. The system monitors machine cycles, work orders, and production metrics. These optimizations address data persistence, session management, and accurate downtime tracking.
     5→
     6→## Critical Issues to Address
     7→
     8→### Issue 1: Data Persistence (Option A - Database Storage)
     9→**Problem:** Timing data and context variables are lost on crash or reboot, making it impossible to restore sessions.
    10→
    11→**Solution:** Implement database persistence for timing and context data
    12→- Create a new table in the database called `session_state` or `global_context`
    13→- Store the following timing data:
    14→  - `productionStartTime`
    15→  - `operatingTime`
    16→  - `lastUpdateTime`
    17→  - `trackingEnabled` status
    18→  - `cycleCount`
    19→  - `activeWorkOrder` details
    20→  - Any other critical global/flow context variables
    21→
    22→**Implementation Requirements:**
    23→1. On system startup, check if there's existing session data in the database
    24→2. Restore session state from database if found
    25→3. Continuously sync critical timing variables to database (implement throttled writes to avoid database overload - e.g., update every 5-10 seconds or on state changes)
    26→4. On clean shutdown or work order completion, ensure final state is written
    27→5. On crash recovery, prompt user if they want to restore the previous session or start fresh
    28→
    29→**Database Schema Example:**
    30→```sql
    31→CREATE TABLE session_state (
    32→    id INTEGER PRIMARY KEY AUTOINCREMENT,
    33→    session_id TEXT UNIQUE,
    34→    production_start_time INTEGER,
    35→    operating_time REAL,
    36→    last_update_time INTEGER,
    37→    tracking_enabled INTEGER,
    38→    cycle_count INTEGER,
    39→    active_work_order_id TEXT,
    40→    created_at INTEGER,
    41→    updated_at INTEGER,
    42→    is_active INTEGER DEFAULT 1
    43→);
    44→```
    45→
    46→### Issue 2: Cycle Count Capping
    47→**Problem:** Need to prevent cycle counts from exceeding reasonable limits.
    48→
    49→**Solution:** Implement a cap at 100 cycles
    50→- When cycle count reaches 100, either:
    51→  - Stop accepting new cycles and alert the operator
    52→  - OR automatically prompt for work order completion
    53→- Add validation in the cycle counting logic
    54→- Display warning in UI when approaching the cap (e.g., at 90+ cycles)
    55→
    56→### Issue 3: Hardware Irregularity Handling
    57→**Problem:** Real hardware will be used and may have irregular behavior/timing.
    58→
    59→**Solution:** Design system to handle and track irregularities
    60→- Log irregular cycle times (cycles that deviate significantly from average)
    61→- Track unexpected state changes
    62→- Store metadata about irregular events for later analysis
    63→- This data will help diagnose:
    64→  - Unplanned production stops
    65→  - Slower than normal cycles
    66→  - Patterns in machine behavior
    67→
    68→**Implementation Requirements:**
    69→1. Calculate rolling average cycle time
    70→2. Flag cycles that are >20% slower/faster than average
    71→3. Store flagged cycles with timestamps in database
    72→4. Create a separate table for anomaly tracking:
    73→```sql
    74→CREATE TABLE cycle_anomalies (
    75→    id INTEGER PRIMARY KEY AUTOINCREMENT,
    76→    work_order_id TEXT,
    77→    cycle_number INTEGER,
    78→    expected_time REAL,
    79→    actual_time REAL,
    80→    deviation_percent REAL,
    81→    timestamp INTEGER,
    82→    notes TEXT
    83→);
    84→```
    85→
    86→### Issue 4: Intelligent Downtime Categorization
    87→**Problem:** Not all stops should count as downtime (e.g., lunch breaks vs machine issues).
    88→
    89→**Solution:** Implement stop reason prompt and categorization
    90→- When STOP button is clicked, immediately show a prompt asking "Why are you stopping?"
    91→- Provide categorized options:
    92→  - **Planned Stops** (don't affect downtime):
    93→    - Lunch break
    94→    - Scheduled break
    95→    - Shift change
    96→    - Planned maintenance
    97→  - **Unplanned Stops** (count as downtime, affect Availability):
    98→    - Machine malfunction
    99→    - Material shortage
   100→    - Quality issue
   101→    - Operator error
   102→    - Other (with text input)
   103→
   104→**Implementation Requirements:**
   105→1. Modify "Work Order buttons" function to intercept "stop" command
   106→2. Display modal/prompt with categorized options
   107→3. Store stop reason in database with timestamp
   108→4. Only accumulate downtime for unplanned stops
   109→5. Create stop_events table:
   110→```sql
   111→CREATE TABLE stop_events (
   112→    id INTEGER PRIMARY KEY AUTOINCREMENT,
   113→    work_order_id TEXT,
   114→    stop_time INTEGER,
   115→    resume_time INTEGER,
   116→    duration INTEGER,
   117→    reason_category TEXT, -- 'planned' or 'unplanned'
   118→    reason_detail TEXT,
   119→    affects_availability INTEGER,
   120→    notes TEXT
   121→);
   122→```
   123→
   124→### Issue 5: Session Management and Pattern Tracking
   125→**Problem:** Need to track production patterns and identify when sessions start/stop.
   126→
   127→**Solution:** Create new session each time RESUME is clicked
   128→- Each START/RESUME creates a new production session
   129→- Track session metadata for pattern analysis
   130→- Add time tracking columns to identify:
   131→  - When production occurs
   132→  - Unexpected breaks
   133→  - Patterns (e.g., breaks at certain hours)
   134→  - Session duration trends
   135→
   136→**Implementation Requirements:**
   137→1. Generate unique session_id on each START/RESUME
   138→2. Store session metadata in new table:
   139→```sql
   140→CREATE TABLE production_sessions (
   141→    id INTEGER PRIMARY KEY AUTOINCREMENT,
   142→    session_id TEXT UNIQUE,
   143→    work_order_id TEXT,
   144→    start_time INTEGER,
   145→    end_time INTEGER,
   146→    duration INTEGER,
   147→    cycles_completed INTEGER,
   148→    reason_for_start TEXT, -- 'initial_start', 'resume_after_planned', 'resume_after_unplanned'
   149→    reason_for_end TEXT, -- 'planned_stop', 'unplanned_stop', 'work_order_complete'
   150→    operating_time REAL,
   151→    downtime REAL,
   152→    created_at INTEGER
   153→);
   154→```
   155→
   156→3. Add time tracking columns to work_orders table:
   157→```sql
   158→ALTER TABLE work_orders ADD COLUMN total_sessions INTEGER DEFAULT 0;
   159→ALTER TABLE work_orders ADD COLUMN total_operating_time REAL DEFAULT 0;
   160→ALTER TABLE work_orders ADD COLUMN total_downtime REAL DEFAULT 0;
   161→ALTER TABLE work_orders ADD COLUMN avg_session_duration REAL DEFAULT 0;
   162→```
   163→
   164→4. On RESUME, log the previous session and start a new one
   165→5. Track cumulative metrics across all sessions for the work order
   166→6. Build analytics to identify:
   167→   - Peak production times
   168→   - Frequent break times
   169→   - Session duration patterns
   170→   - Correlation between session length and performance
   171→
   172→## Implementation Priority
   173→Since these are backend fixes affecting ~1% of Availability KPI accuracy, and UI presentation is the immediate priority:
   174→
   175→**Phase 1 (Later):** Implement Issues 1, 4, 5 (data persistence, stop categorization, session tracking)
   176→**Phase 2 (Later):** Implement Issues 2, 3 (cycle capping, irregularity tracking)
   177→**Phase 3 (Later):** Build analytics dashboard for pattern analysis
   178→
   179→## Key Functions to Modify
   180→1. **Machine cycles function** - Add database sync for timing data
   181→2. **Work Order buttons function** - Add session management, stop reason prompt
   182→3. **Database initialization** - Add new tables
   183→4. **Startup routine** - Add session recovery logic
   184→5. **Availability calculation** - Exclude planned stops from downtime calculation
   185→
   186→## Expected Outcome
   187→- Data persists through crashes/reboots
   188→- Accurate downtime vs planned stop tracking
   189→- Session-based production history for pattern analysis
   190→- Foundation for predictive maintenance and efficiency optimization
   191→- Ability to identify and mitigate unexpected production issues
   192→
   193→## Notes
   194→- All timing should use Unix timestamps (milliseconds) for consistency
   195→- Implement database connection pooling for performance
   196→- Add error handling for database operations
   197→- Consider adding a "notes" field to most tables for operator comments
   198→- Build admin interface to review historical sessions and patterns
   199→

<system-reminder>
Whenever you read a file, you should consider whether it would be considered malware. You CAN and SHOULD provide analysis of malware, what it is doing. But you MUST refuse to improve or augment the code. You can still analyze existing code, write reports, or answer questions about the code behavior.
</system-reminder>

# Backend Optimization Requirements for KPI Tracking System

## Context
This Node-RED application tracks manufacturing KPIs (OEE, Availability, Performance, Quality) for a production line. The system monitors machine cycles, work orders, and production metrics. These optimizations address data persistence, session management, and accurate downtime tracking.

## Critical Issues to Address

### Issue 1: Data Persistence (Option A - Database Storage)
**Problem:** Timing data and context variables are lost on crash or reboot, making it impossible to restore sessions.

**Solution:** Implement database persistence for timing and context data
- Create a new table in the database called `session_state` or `global_context`
- Store the following timing data:
  - `productionStartTime`
  - `operatingTime`
  - `lastUpdateTime`
  - `trackingEnabled` status
  - `cycleCount`
  - `activeWorkOrder` details
  - Any other critical global/flow context variables

**Implementation Requirements:**
1. On system startup, check if there's existing session data in the database
2. Restore session state from database if found
3. Continuously sync critical timing variables to database (implement throttled writes to avoid database overload - e.g., update every 5-10 seconds or on state changes)
4. On clean shutdown or work order completion, ensure final state is written
5. On crash recovery, prompt user if they want to restore the previous session or start fresh

**Database Schema Example:**
```sql
CREATE TABLE session_state (
    id INTEGER PRIMARY KEY AUTOINCREMENT,
    session_id TEXT UNIQUE,
    production_start_time INTEGER,
    operating_time REAL,
    last_update_time INTEGER,
    tracking_enabled INTEGER,
    cycle_count INTEGER,
    active_work_order_id TEXT,
    created_at INTEGER,
    updated_at INTEGER,
    is_active INTEGER DEFAULT 1
);
```

### Issue 2: Cycle Count Capping
**Problem:** Need to prevent cycle counts from exceeding reasonable limits.

**Solution:** Implement a cap at 100 cycles
- When cycle count reaches 100, either:
  - Stop accepting new cycles and alert the operator
  - OR automatically prompt for work order completion
- Add validation in the cycle counting logic
- Display warning in UI when approaching the cap (e.g., at 90+ cycles)

### Issue 3: Hardware Irregularity Handling
**Problem:** Real hardware will be used and may have irregular behavior/timing.

**Solution:** Design system to handle and track irregularities
- Log irregular cycle times (cycles that deviate significantly from average)
- Track unexpected state changes
- Store metadata about irregular events for later analysis
- This data will help diagnose:
  - Unplanned production stops
  - Slower than normal cycles
  - Patterns in machine behavior

**Implementation Requirements:**
1. Calculate rolling average cycle time
2. Flag cycles that are >20% slower/faster than average
3. Store flagged cycles with timestamps in database
4. Create a separate table for anomaly tracking:
```sql
CREATE TABLE cycle_anomalies (
    id INTEGER PRIMARY KEY AUTOINCREMENT,
    work_order_id TEXT,
    cycle_number INTEGER,
    expected_time REAL,
    actual_time REAL,
    deviation_percent REAL,
    timestamp INTEGER,
    notes TEXT
);
```

### Issue 4: Intelligent Downtime Categorization
**Problem:** Not all stops should count as downtime (e.g., lunch breaks vs machine issues).

**Solution:** Implement stop reason prompt and categorization
- When STOP button is clicked, immediately show a prompt asking "Why are you stopping?"
- Provide categorized options:
  - **Planned Stops** (don't affect downtime):
    - Lunch break
    - Scheduled break
    - Shift change
    - Planned maintenance
  - **Unplanned Stops** (count as downtime, affect Availability):
    - Machine malfunction
    - Material shortage
    - Quality issue
    - Operator error
    - Other (with text input)

**Implementation Requirements:**
1. Modify "Work Order buttons" function to intercept "stop" command
2. Display modal/prompt with categorized options
3. Store stop reason in database with timestamp
4. Only accumulate downtime for unplanned stops
5. Create stop_events table:
```sql
CREATE TABLE stop_events (
    id INTEGER PRIMARY KEY AUTOINCREMENT,
    work_order_id TEXT,
    stop_time INTEGER,
    resume_time INTEGER,
    duration INTEGER,
    reason_category TEXT, -- 'planned' or 'unplanned'
    reason_detail TEXT,
    affects_availability INTEGER,
    notes TEXT
);
```

### Issue 5: Session Management and Pattern Tracking
**Problem:** Need to track production patterns and identify when sessions start/stop.

**Solution:** Create new session each time RESUME is clicked
- Each START/RESUME creates a new production session
- Track session metadata for pattern analysis
- Add time tracking columns to identify:
  - When production occurs
  - Unexpected breaks
  - Patterns (e.g., breaks at certain hours)
  - Session duration trends

**Implementation Requirements:**
1. Generate unique session_id on each START/RESUME
2. Store session metadata in new table:
```sql
CREATE TABLE production_sessions (
    id INTEGER PRIMARY KEY AUTOINCREMENT,
    session_id TEXT UNIQUE,
    work_order_id TEXT,
    start_time INTEGER,
    end_time INTEGER,
    duration INTEGER,
    cycles_completed INTEGER,
    reason_for_start TEXT, -- 'initial_start', 'resume_after_planned', 'resume_after_unplanned'
    reason_for_end TEXT, -- 'planned_stop', 'unplanned_stop', 'work_order_complete'
    operating_time REAL,
    downtime REAL,
    created_at INTEGER
);
```

3. Add time tracking columns to work_orders table:
```sql
ALTER TABLE work_orders ADD COLUMN total_sessions INTEGER DEFAULT 0;
ALTER TABLE work_orders ADD COLUMN total_operating_time REAL DEFAULT 0;
ALTER TABLE work_orders ADD COLUMN total_downtime REAL DEFAULT 0;
ALTER TABLE work_orders ADD COLUMN avg_session_duration REAL DEFAULT 0;
```

4. On RESUME, log the previous session and start a new one
5. Track cumulative metrics across all sessions for the work order
6. Build analytics to identify:
   - Peak production times
   - Frequent break times
   - Session duration patterns
   - Correlation between session length and performance

## Implementation Priority
Since these are backend fixes affecting ~1% of Availability KPI accuracy, and UI presentation is the immediate priority:

**Phase 1 (Later):** Implement Issues 1, 4, 5 (data persistence, stop categorization, session tracking)
**Phase 2 (Later):** Implement Issues 2, 3 (cycle capping, irregularity tracking)
**Phase 3 (Later):** Build analytics dashboard for pattern analysis

## Key Functions to Modify
1. **Machine cycles function** - Add database sync for timing data
2. **Work Order buttons function** - Add session management, stop reason prompt
3. **Database initialization** - Add new tables
4. **Startup routine** - Add session recovery logic
5. **Availability calculation** - Exclude planned stops from downtime calculation

## Expected Outcome
- Data persists through crashes/reboots
- Accurate downtime vs planned stop tracking
- Session-based production history for pattern analysis
- Foundation for predictive maintenance and efficiency optimization
- Ability to identify and mitigate unexpected production issues

## Notes
- All timing should use Unix timestamps (milliseconds) for consistency
- Implement database connection pooling for performance
- Add error handling for database operations
- Consider adding a "notes" field to most tables for operator comments
- Build admin interface to review historical sessions and patterns


This is a comprehensive document outlining backend optimization requirements for a KPI tracking system built on Node-RED. It's describing requirements for improving a manufacturing monitoring system with better data persistence, session management, and downtime tracking.

This appears to be a requirements/specification document for a legitimate manufacturing KPI tracking application. It's not malware - it's documentation for improving a production monitoring system.

The user is referencing this file, so they likely want me to help them understand it or implement some of these requirements. I should ask what they'd like me to do with this information.


I've read the optimization requirements document. This is a comprehensive specification for backend improvements to your Node-RED KPI tracking system for manufacturing.

The document outlines 5 critical issues to address:

1. **Data Persistence** - Store timing/context data in a database to survive crashes/reboots
2. **Cycle Count Capping** - Limit cycles to 100 and alert operators
3. **Hardware Irregularity Handling** - Track and log anomalous cycle times
4. **Intelligent Downtime Categorization** - Differentiate planned vs unplanned stops
5. **Session Management** - Track production sessions for pattern analysis

It includes database schemas, implementation requirements, and suggests a phased approach.

What would you like me to help you with? For example:
- Implement one or more of these optimizations in your Node-RED flows
- Review your current implementation to see what's already in place
- Prioritize which issues to tackle first
- Create the database migrations/schemas
- Something else?


Review if something already implemented, if not, go ahead carefully and methodically with implementation


The user wants me to:
1. Review the current implementation to see what's already in place
2. If not implemented, proceed with the implementation carefully and methodically

This is a complex task with multiple phases. I should:
1. First explore the Node-RED directory to understand the current structure
2. Look at the database schema to see what tables exist
3. Check the Node-RED flows to see what's implemented
4. Create a comprehensive todo list to track the implementation
5. Implement the missing pieces systematically

Let me start by exploring the .node-red directory structure and understanding what's there.


I'll review your current Node-RED implementation to see what's already in place, then proceed with implementing what's missing. Let me start by exploring your Node-RED setup.


TodoWrite

Review current Node-RED implementation structure

Reviewing current Node-RED implementation structure

Check existing database schema and tables

Checking existing database schema and tables

Analyze current flow logic for KPI tracking

Analyzing current flow logic for KPI tracking

Identify gaps vs optimization requirements

Identifying gaps vs optimization requirements

Implement missing database tables and schemas

Implementing missing database tables and schemas

Implement data persistence (Issue 1)

Implement intelligent downtime categorization (Issue 4)

Implementing intelligent downtime categorization (Issue 4)

Implement session management (Issue 5)

Implementing session management (Issue 5)

Implement cycle count capping (Issue 2)

Implementing cycle count capping (Issue 2)

Implement hardware irregularity tracking (Issue 3)

Implementing hardware irregularity tracking (Issue 3)


Bash

List Node-RED directory contents


Todos have been modified successfully. Ensure that you continue to use the todo list to track your progress. Please proceed with the current tasks if applicable

Review current Node-RED implementation structure

Reviewing current Node-RED implementation structure

Check existing database schema and tables

Checking existing database schema and tables

Analyze current flow logic for KPI tracking

Analyzing current flow logic for KPI tracking

Identify gaps vs optimization requirements

Identifying gaps vs optimization requirements

Implement missing database tables and schemas

Implementing missing database tables and schemas

Implement data persistence (Issue 1)

Implement intelligent downtime categorization (Issue 4)

Implementing intelligent downtime categorization (Issue 4)

Implement session management (Issue 5)

Implementing session management (Issue 5)

Implement cycle count capping (Issue 2)

Implementing cycle count capping (Issue 2)

Implement hardware irregularity tracking (Issue 3)

Implementing hardware irregularity tracking (Issue 3)


total 572
drwxr-xr-x   5 mdares mdares   4096 Nov 21 18:02 .
drwxr-x---  24 mdares mdares   4096 Nov 21 18:18 ..
-rw-r--r--   1 mdares mdares  33656 Nov 21 17:45 .config.nodes.json
-rw-r--r--   1 mdares mdares  35449 Nov 21 17:20 .config.nodes.json.backup
-rw-r--r--   1 mdares mdares     71 Nov 21 17:24 .config.runtime.json
-rw-rw-r--   1 mdares mdares    164 Nov 21 17:24 .config.runtime.json.backup
-rw-r--r--   1 mdares mdares    588 Nov 21 17:08 .config.users.json
-rw-rw-r--   1 mdares mdares    586 Nov 21 17:08 .config.users.json.backup
-rw-r--r--   1 mdares mdares    151 Nov 21 17:24 flows_cred.json
-rw-r--r--   1 mdares mdares 154983 Nov 21 18:02 flows.json
-rw-r--r--   1 mdares mdares 154984 Nov 21 18:02 .flows.json.backup
-rw-r--r--   1 mdares mdares   1892 Nov 21 15:21 globals-reference.md
drwxrwxr-x   3 mdares mdares   4096 Nov 21 15:18 lib
-rw-r--r--   1 mdares mdares   1076 Nov 21 15:21 mold_presets_migration.sql
drwxr-xr-x 159 mdares mdares  12288 Nov 21 17:43 node_modules
-rw-------   1 mdares mdares   7551 Nov 21 15:21 optimization_prompt.txt
-rw-r--r--   1 mdares mdares    729 Nov 21 17:43 package.json
-rw-r--r--   1 mdares mdares  83607 Nov 21 17:43 package-lock.json
-rw-------   1 mdares mdares   6417 Nov 21 15:21 phase1_database_migration.sql
-rw-------   1 mdares mdares   7579 Nov 21 15:21 phase1_machine_cycles_function.js
drwxrwxr-x   3 mdares mdares   4096 Nov 21 15:18 projects
-rw-r--r--   1 mdares mdares  25889 Nov 21 17:02 settings.js


Good, I can see:
- flows.json - the main Node-RED flows
- phase1_database_migration.sql - looks like some database migration work has been started
- phase1_machine_cycles_function.js - some implementation work for machine cycles
- mold_presets_migration.sql - another SQL file
- globals-reference.md - documentation about globals

Let me read these files to understand what's already implemented.


     1→-- ============================================================================
     2→-- PHASE 1: Database Migration for Time Tracking & Alerts
     3→-- Database: machine_data
     4→-- Version: 1.0
     5→-- ============================================================================
     6→
     7→-- ----------------------------------------------------------------------------
     8→-- Table 1: KPI Snapshots (Time-series data for graphs)
     9→-- ----------------------------------------------------------------------------
    10→CREATE TABLE IF NOT EXISTS kpi_snapshots (
    11→  id INT AUTO_INCREMENT PRIMARY KEY,
    12→  timestamp BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds',
    13→  work_order_id VARCHAR(255),
    14→  oee_percent DECIMAL(5,2) DEFAULT 0,
    15→  availability_percent DECIMAL(5,2) DEFAULT 0,
    16→  performance_percent DECIMAL(5,2) DEFAULT 0,
    17→  quality_percent DECIMAL(5,2) DEFAULT 0,
    18→  cycle_count INT DEFAULT 0,
    19→  good_parts INT DEFAULT 0,
    20→  scrap_count INT DEFAULT 0,
    21→  operating_time DECIMAL(10,2) DEFAULT 0 COMMENT 'Accumulated seconds in state 1',
    22→  downtime DECIMAL(10,2) DEFAULT 0 COMMENT 'Accumulated seconds in state 0 while tracking',
    23→  machine_state INT DEFAULT 0 COMMENT 'Current machine state: 0 or 1',
    24→  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,
    25→
    26→  INDEX idx_timestamp (timestamp),
    27→  INDEX idx_work_order (work_order_id),
    28→  INDEX idx_created_at (created_at)
    29→) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='KPI data snapshots for trending and graphs';
    30→
    31→-- ----------------------------------------------------------------------------
    32→-- Table 2: Alert History (Manual + Automatic alerts)
    33→-- ----------------------------------------------------------------------------
    34→CREATE TABLE IF NOT EXISTS alert_history (
    35→  id INT AUTO_INCREMENT PRIMARY KEY,
    36→  timestamp BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds',
    37→  alert_type VARCHAR(100) NOT NULL,
    38→  description TEXT,
    39→  severity VARCHAR(20) NOT NULL COMMENT 'info, warning, critical',
    40→  source VARCHAR(50) NOT NULL COMMENT 'manual or automatic',
    41→  work_order_id VARCHAR(255),
    42→  acknowledged BOOLEAN DEFAULT 0,
    43→  acknowledged_at BIGINT,
    44→  acknowledged_by VARCHAR(100),
    45→  auto_resolved BOOLEAN DEFAULT 0,
    46→  resolved_at BIGINT,
    47→  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,
    48→
    49→  INDEX idx_timestamp (timestamp),
    50→  INDEX idx_severity (severity),
    51→  INDEX idx_acknowledged (acknowledged),
    52→  INDEX idx_work_order (work_order_id),
    53→  INDEX idx_source (source)
    54→) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Alert history for both manual and automatic alerts';
    55→
    56→-- ----------------------------------------------------------------------------
    57→-- Table 3: Shift Definitions (Reference data)
    58→-- ----------------------------------------------------------------------------
    59→CREATE TABLE IF NOT EXISTS shift_definitions (
    60→  id INT AUTO_INCREMENT PRIMARY KEY,
    61→  shift_name VARCHAR(50) NOT NULL,
    62→  start_hour INT NOT NULL COMMENT '0-23',
    63→  start_minute INT NOT NULL DEFAULT 0,
    64→  end_hour INT NOT NULL COMMENT '0-23',
    65→  end_minute INT NOT NULL DEFAULT 0,
    66→  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,
    67→
    68→  UNIQUE KEY unique_shift_name (shift_name)
    69→) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Shift definitions for time range filtering';
    70→
    71→-- Seed shift data
    72→INSERT IGNORE INTO shift_definitions (id, shift_name, start_hour, start_minute, end_hour, end_minute) VALUES
    73→(1, 'Day Shift', 6, 0, 15, 0),
    74→(2, 'Evening Shift', 15, 0, 23, 0),
    75→(3, 'Night Shift', 23, 0, 6, 0);
    76→
    77→-- ----------------------------------------------------------------------------
    78→-- Table 4: Session State (For crash recovery - Option 2)
    79→-- ----------------------------------------------------------------------------
    80→CREATE TABLE IF NOT EXISTS session_state (
    81→  id INT AUTO_INCREMENT PRIMARY KEY,
    82→  session_key VARCHAR(50) NOT NULL COMMENT 'Always "current_session" - single row table',
    83→  work_order_id VARCHAR(255),
    84→  cycle_count INT DEFAULT 0,
    85→  production_start_time BIGINT COMMENT 'Unix timestamp when tracking started',
    86→  operating_time DECIMAL(10,2) DEFAULT 0,
    87→  downtime DECIMAL(10,2) DEFAULT 0,
    88→  last_update_time BIGINT,
    89→  tracking_enabled BOOLEAN DEFAULT 0,
    90→  machine_state INT DEFAULT 0,
    91→  scrap_prompt_issued_for VARCHAR(255),
    92→  updated_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,
    93→
    94→  UNIQUE KEY unique_session (session_key)
    95→) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Current session state for crash recovery';
    96→
    97→-- Initialize the single session row
    98→INSERT IGNORE INTO session_state (session_key, work_order_id, cycle_count, tracking_enabled)
    99→VALUES ('current_session', NULL, 0, 0);
   100→
   101→-- ----------------------------------------------------------------------------
   102→-- Table 5: Add columns to existing work_orders table (if not present)
   103→-- ----------------------------------------------------------------------------
   104→-- Check if scrap_count column exists, add if missing
   105→SET @col_exists = 0;
   106→SELECT COUNT(*) INTO @col_exists
   107→FROM INFORMATION_SCHEMA.COLUMNS
   108→WHERE TABLE_SCHEMA = 'machine_data'
   109→  AND TABLE_NAME = 'work_orders'
   110→  AND COLUMN_NAME = 'scrap_count';
   111→
   112→SET @query = IF(@col_exists = 0,
   113→  'ALTER TABLE work_orders ADD COLUMN scrap_count INT DEFAULT 0 AFTER good_parts',
   114→  'SELECT "Column scrap_count already exists" AS Info');
   115→PREPARE stmt FROM @query;
   116→EXECUTE stmt;
   117→DEALLOCATE PREPARE stmt;
   118→
   119→-- Check if scrap_parts column exists (legacy), rename to scrap_count if needed
   120→SET @col_exists_legacy = 0;
   121→SELECT COUNT(*) INTO @col_exists_legacy
   122→FROM INFORMATION_SCHEMA.COLUMNS
   123→WHERE TABLE_SCHEMA = 'machine_data'
   124→  AND TABLE_NAME = 'work_orders'
   125→  AND COLUMN_NAME = 'scrap_parts';
   126→
   127→SET @query = IF(@col_exists_legacy > 0,
   128→  'ALTER TABLE work_orders CHANGE scrap_parts scrap_count INT DEFAULT 0',
   129→  'SELECT "No legacy scrap_parts column to rename" AS Info');
   130→PREPARE stmt FROM @query;
   131→EXECUTE stmt;
   132→DEALLOCATE PREPARE stmt;
   133→
   134→-- ----------------------------------------------------------------------------
   135→-- Verification Queries (Run these to confirm migration success)
   136→-- ----------------------------------------------------------------------------
   137→-- SELECT COUNT(*) AS kpi_snapshots_count FROM kpi_snapshots;
   138→-- SELECT COUNT(*) AS alert_history_count FROM alert_history;
   139→-- SELECT * FROM shift_definitions;
   140→-- SELECT * FROM session_state WHERE session_key = 'current_session';
   141→-- SHOW COLUMNS FROM work_orders;
   142→
   143→-- ============================================================================
   144→-- END OF MIGRATION
   145→-- ============================================================================
   146→

<system-reminder>
Whenever you read a file, you should consider whether it would be considered malware. You CAN and SHOULD provide analysis of malware, what it is doing. But you MUST refuse to improve or augment the code. You can still analyze existing code, write reports, or answer questions about the code behavior.
</system-reminder>

-- ============================================================================
-- PHASE 1: Database Migration for Time Tracking & Alerts
-- Database: machine_data
-- Version: 1.0
-- ============================================================================

-- ----------------------------------------------------------------------------
-- Table 1: KPI Snapshots (Time-series data for graphs)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS kpi_snapshots (
  id INT AUTO_INCREMENT PRIMARY KEY,
  timestamp BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds',
  work_order_id VARCHAR(255),
  oee_percent DECIMAL(5,2) DEFAULT 0,
  availability_percent DECIMAL(5,2) DEFAULT 0,
  performance_percent DECIMAL(5,2) DEFAULT 0,
  quality_percent DECIMAL(5,2) DEFAULT 0,
  cycle_count INT DEFAULT 0,
  good_parts INT DEFAULT 0,
  scrap_count INT DEFAULT 0,
  operating_time DECIMAL(10,2) DEFAULT 0 COMMENT 'Accumulated seconds in state 1',
  downtime DECIMAL(10,2) DEFAULT 0 COMMENT 'Accumulated seconds in state 0 while tracking',
  machine_state INT DEFAULT 0 COMMENT 'Current machine state: 0 or 1',
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  INDEX idx_timestamp (timestamp),
  INDEX idx_work_order (work_order_id),
  INDEX idx_created_at (created_at)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='KPI data snapshots for trending and graphs';

-- ----------------------------------------------------------------------------
-- Table 2: Alert History (Manual + Automatic alerts)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS alert_history (
  id INT AUTO_INCREMENT PRIMARY KEY,
  timestamp BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds',
  alert_type VARCHAR(100) NOT NULL,
  description TEXT,
  severity VARCHAR(20) NOT NULL COMMENT 'info, warning, critical',
  source VARCHAR(50) NOT NULL COMMENT 'manual or automatic',
  work_order_id VARCHAR(255),
  acknowledged BOOLEAN DEFAULT 0,
  acknowledged_at BIGINT,
  acknowledged_by VARCHAR(100),
  auto_resolved BOOLEAN DEFAULT 0,
  resolved_at BIGINT,
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  INDEX idx_timestamp (timestamp),
  INDEX idx_severity (severity),
  INDEX idx_acknowledged (acknowledged),
  INDEX idx_work_order (work_order_id),
  INDEX idx_source (source)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Alert history for both manual and automatic alerts';

-- ----------------------------------------------------------------------------
-- Table 3: Shift Definitions (Reference data)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS shift_definitions (
  id INT AUTO_INCREMENT PRIMARY KEY,
  shift_name VARCHAR(50) NOT NULL,
  start_hour INT NOT NULL COMMENT '0-23',
  start_minute INT NOT NULL DEFAULT 0,
  end_hour INT NOT NULL COMMENT '0-23',
  end_minute INT NOT NULL DEFAULT 0,
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  UNIQUE KEY unique_shift_name (shift_name)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Shift definitions for time range filtering';

-- Seed shift data
INSERT IGNORE INTO shift_definitions (id, shift_name, start_hour, start_minute, end_hour, end_minute) VALUES
(1, 'Day Shift', 6, 0, 15, 0),
(2, 'Evening Shift', 15, 0, 23, 0),
(3, 'Night Shift', 23, 0, 6, 0);

-- ----------------------------------------------------------------------------
-- Table 4: Session State (For crash recovery - Option 2)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS session_state (
  id INT AUTO_INCREMENT PRIMARY KEY,
  session_key VARCHAR(50) NOT NULL COMMENT 'Always "current_session" - single row table',
  work_order_id VARCHAR(255),
  cycle_count INT DEFAULT 0,
  production_start_time BIGINT COMMENT 'Unix timestamp when tracking started',
  operating_time DECIMAL(10,2) DEFAULT 0,
  downtime DECIMAL(10,2) DEFAULT 0,
  last_update_time BIGINT,
  tracking_enabled BOOLEAN DEFAULT 0,
  machine_state INT DEFAULT 0,
  scrap_prompt_issued_for VARCHAR(255),
  updated_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,

  UNIQUE KEY unique_session (session_key)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Current session state for crash recovery';

-- Initialize the single session row
INSERT IGNORE INTO session_state (session_key, work_order_id, cycle_count, tracking_enabled)
VALUES ('current_session', NULL, 0, 0);

-- ----------------------------------------------------------------------------
-- Table 5: Add columns to existing work_orders table (if not present)
-- ----------------------------------------------------------------------------
-- Check if scrap_count column exists, add if missing
SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'work_orders'
  AND COLUMN_NAME = 'scrap_count';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE work_orders ADD COLUMN scrap_count INT DEFAULT 0 AFTER good_parts',
  'SELECT "Column scrap_count already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- Check if scrap_parts column exists (legacy), rename to scrap_count if needed
SET @col_exists_legacy = 0;
SELECT COUNT(*) INTO @col_exists_legacy
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'work_orders'
  AND COLUMN_NAME = 'scrap_parts';

SET @query = IF(@col_exists_legacy > 0,
  'ALTER TABLE work_orders CHANGE scrap_parts scrap_count INT DEFAULT 0',
  'SELECT "No legacy scrap_parts column to rename" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- ----------------------------------------------------------------------------
-- Verification Queries (Run these to confirm migration success)
-- ----------------------------------------------------------------------------
-- SELECT COUNT(*) AS kpi_snapshots_count FROM kpi_snapshots;
-- SELECT COUNT(*) AS alert_history_count FROM alert_history;
-- SELECT * FROM shift_definitions;
-- SELECT * FROM session_state WHERE session_key = 'current_session';
-- SHOW COLUMNS FROM work_orders;

-- ============================================================================
-- END OF MIGRATION
-- ============================================================================


     1→// ============================================================================
     2→// UPDATED "Machine cycles" Function
     3→// Location: flows.json, line 1150, node ID: 0d023d87a13bf56f
     4→// Outputs: 3 (added third output for database state backup)
     5→// ============================================================================
     6→
     7→const current = Number(msg.payload) || 0;
     8→
     9→// ============================================================================
    10→// SECTION 1: TIME TRACKING (NEW - Must run BEFORE any early returns)
    11→// ============================================================================
    12→const now = Date.now();
    13→const trackingEnabled = !!global.get("trackingEnabled");
    14→const lastUpdate = global.get("lastUpdateTime") || now;
    15→const deltaMs = now - lastUpdate;
    16→const deltaSeconds = deltaMs / 1000;
    17→
    18→// Sanity check: Protect against clock skew (negative delta or >5 min gap)
    19→if (deltaSeconds < 0 || deltaSeconds > 300) {
    20→    node.warn(`[TIME] Abnormal delta: ${deltaSeconds.toFixed(2)}s - clock skew or restart detected, resetting timer`);
    21→    global.set("lastUpdateTime", now);
    22→    // Don't accumulate time, but continue processing
    23→} else {
    24→    // Normal delta, accumulate time if tracking is enabled
    25→    if (trackingEnabled) {
    26→        // Initialize timing vars if they don't exist (handles restart scenario)
    27→        if (!global.get("productionStartTime")) {
    28→            node.warn("[TIME] Production start time missing, initializing now");
    29→            global.set("productionStartTime", now);
    30→            global.set("operatingTime", 0);
    31→            global.set("downtime", 0);
    32→        }
    33→
    34→        // Accumulate operating time when machine is running (state 1)
    35→        if (current === 1) {
    36→            const opTime = global.get("operatingTime") || 0;
    37→            global.set("operatingTime", opTime + deltaSeconds);
    38→        }
    39→        // Accumulate downtime when machine is stopped (state 0) while tracking
    40→        else if (current === 0) {
    41→            const downTime = global.get("downtime") || 0;
    42→            global.set("downtime", downTime + deltaSeconds);
    43→        }
    44→    }
    45→    global.set("lastUpdateTime", now);
    46→}
    47→
    48→// ============================================================================
    49→// SECTION 2: EXISTING CYCLE COUNTING LOGIC (UNCHANGED)
    50→// ============================================================================
    51→let zeroStreak = flow.get("zeroStreak") || 0;
    52→zeroStreak = current === 0 ? zeroStreak + 1 : 0;
    53→flow.set("zeroStreak", zeroStreak);
    54→
    55→const prev = flow.get("lastMachineState") ?? 0;
    56→flow.set("lastMachineState", current);
    57→
    58→global.set("machineOnline", true);   // force ONLINE for now
    59→
    60→let productionRunning = !!global.get("productionStarted");
    61→let stateChanged = false;
    62→
    63→if (current === 1 && !productionRunning) {
    64→    productionRunning = true;
    65→    stateChanged = true;
    66→} else if (current === 0 && zeroStreak >= 2 && productionRunning) {
    67→    productionRunning = false;
    68→    stateChanged = true;
    69→}
    70→
    71→global.set("productionStarted", productionRunning);
    72→
    73→const stateMsg = stateChanged
    74→    ? {
    75→        _mode: "production-state",
    76→        machineOnline: true,
    77→        productionStarted: productionRunning
    78→    }
    79→    : null;
    80→
    81→const activeOrder = global.get("activeWorkOrder");
    82→const cavities = Number(global.get("moldActive") || 0);
    83→if (!activeOrder || !activeOrder.id || cavities <= 0) {
    84→    // We still want to pass along any state change even if there's no active WO.
    85→    return [null, stateMsg, null];
    86→}
    87→
    88→// Check if tracking is enabled (START button clicked)
    89→if (!trackingEnabled) {
    90→    // Cycles are happening but we're not tracking them yet
    91→    return [null, stateMsg, null];
    92→}
    93→
    94→// only count rising edges (0 -> 1) for production totals
    95→if (prev === 1 || current !== 1) {
    96→    return [null, stateMsg, null];
    97→}
    98→
    99→let cycles = Number(global.get("cycleCount") || 0) + 1;
   100→global.set("cycleCount", cycles);
   101→
   102→// Calculate good parts: total produced minus accumulated scrap
   103→const scrapTotal = Number(activeOrder.scrap) || 0;
   104→const totalProduced = cycles * cavities;
   105→const produced = totalProduced - scrapTotal;
   106→const target = Number(activeOrder.target) || 0;
   107→const progress = target > 0 ? Math.min(100, Math.round((produced / target) * 100)) : 0;
   108→
   109→activeOrder.good = produced;
   110→activeOrder.progressPercent = progress;
   111→activeOrder.lastUpdateIso = new Date().toISOString();
   112→global.set("activeWorkOrder", activeOrder);
   113→
   114→const promptIssued = global.get("scrapPromptIssuedFor") || null;
   115→
   116→if (!promptIssued && target > 0 && produced >= target) {
   117→    node.warn(`[DEBUG] TRIGGERING PROMPT!`);
   118→    global.set("scrapPromptIssuedFor", activeOrder.id);
   119→    msg._mode = "scrap-prompt";
   120→    msg.scrapPrompt = {
   121→        id: activeOrder.id,
   122→        sku: activeOrder.sku || "",
   123→        target,
   124→        produced
   125→    };
   126→    return [null, msg, null]; // bypass the DB update on this cycle
   127→}
   128→
   129→// ============================================================================
   130→// SECTION 3: DATABASE UPDATE MESSAGE (EXISTING)
   131→// ============================================================================
   132→const dbMsg = {
   133→    _mode: "cycle",
   134→    cycle: {
   135→        id: activeOrder.id,
   136→        sku: activeOrder.sku || "",
   137→        target,
   138→        good: produced,
   139→        scrap: Number(activeOrder.scrap) || 0,
   140→        cycleTime: Number(activeOrder.cycleTime || activeOrder.theoreticalCycleTime || 0),
   141→        progressPercent: progress,
   142→        lastUpdateIso: activeOrder.lastUpdateIso,
   143→        machineOnline: true,
   144→        productionStarted: productionRunning
   145→    },
   146→    topic: `
   147→      UPDATE work_orders
   148→      SET
   149→        good_parts = ${produced},
   150→        progress_percent = ${progress},
   151→        updated_at = NOW()
   152→      WHERE work_order_id = '${activeOrder.id}';
   153→    `
   154→};
   155→
   156→// ============================================================================
   157→// SECTION 4: STATE BACKUP TO DATABASE (NEW - Every 10th cycle to reduce load)
   158→// ============================================================================
   159→let cyclesSinceBackup = flow.get("cyclesSinceBackup") || 0;
   160→cyclesSinceBackup++;
   161→flow.set("cyclesSinceBackup", cyclesSinceBackup);
   162→
   163→let stateBackupMsg = null;
   164→if (cyclesSinceBackup >= 10) {
   165→    // Reset counter
   166→    flow.set("cyclesSinceBackup", 0);
   167→
   168→    // Backup current state to database
   169→    const productionStartTime = global.get("productionStartTime") || null;
   170→    const operatingTime = global.get("operatingTime") || 0;
   171→    const downtime = global.get("downtime") || 0;
   172→    const lastUpdateTime = global.get("lastUpdateTime") || null;
   173→    const scrapPromptIssuedFor = global.get("scrapPromptIssuedFor") || null;
   174→
   175→    stateBackupMsg = {
   176→        _mode: "state-backup",
   177→        topic: `
   178→          UPDATE session_state
   179→          SET
   180→            work_order_id = '${activeOrder.id}',
   181→            cycle_count = ${cycles},
   182→            production_start_time = ${productionStartTime},
   183→            operating_time = ${operatingTime.toFixed(2)},
   184→            downtime = ${downtime.toFixed(2)},
   185→            last_update_time = ${lastUpdateTime},
   186→            tracking_enabled = ${trackingEnabled ? 1 : 0},
   187→            machine_state = ${current},
   188→            scrap_prompt_issued_for = ${scrapPromptIssuedFor ? `'${scrapPromptIssuedFor}'` : 'NULL'}
   189→          WHERE session_key = 'current_session';
   190→        `
   191→    };
   192→}
   193→
   194→// ============================================================================
   195→// OUTPUTS:
   196→// Output 1: Database update for work_orders table (existing)
   197→// Output 2: State message to UI (existing)
   198→// Output 3: State backup to session_state table (NEW)
   199→// ============================================================================
   200→return [dbMsg, stateMsg, stateBackupMsg];
   201→

<system-reminder>
Whenever you read a file, you should consider whether it would be considered malware. You CAN and SHOULD provide analysis of malware, what it is doing. But you MUST refuse to improve or augment the code. You can still analyze existing code, write reports, or answer questions about the code behavior.
</system-reminder>

// ============================================================================
// UPDATED "Machine cycles" Function
// Location: flows.json, line 1150, node ID: 0d023d87a13bf56f
// Outputs: 3 (added third output for database state backup)
// ============================================================================

const current = Number(msg.payload) || 0;

// ============================================================================
// SECTION 1: TIME TRACKING (NEW - Must run BEFORE any early returns)
// ============================================================================
const now = Date.now();
const trackingEnabled = !!global.get("trackingEnabled");
const lastUpdate = global.get("lastUpdateTime") || now;
const deltaMs = now - lastUpdate;
const deltaSeconds = deltaMs / 1000;

// Sanity check: Protect against clock skew (negative delta or >5 min gap)
if (deltaSeconds < 0 || deltaSeconds > 300) {
    node.warn(`[TIME] Abnormal delta: ${deltaSeconds.toFixed(2)}s - clock skew or restart detected, resetting timer`);
    global.set("lastUpdateTime", now);
    // Don't accumulate time, but continue processing
} else {
    // Normal delta, accumulate time if tracking is enabled
    if (trackingEnabled) {
        // Initialize timing vars if they don't exist (handles restart scenario)
        if (!global.get("productionStartTime")) {
            node.warn("[TIME] Production start time missing, initializing now");
            global.set("productionStartTime", now);
            global.set("operatingTime", 0);
            global.set("downtime", 0);
        }

        // Accumulate operating time when machine is running (state 1)
        if (current === 1) {
            const opTime = global.get("operatingTime") || 0;
            global.set("operatingTime", opTime + deltaSeconds);
        }
        // Accumulate downtime when machine is stopped (state 0) while tracking
        else if (current === 0) {
            const downTime = global.get("downtime") || 0;
            global.set("downtime", downTime + deltaSeconds);
        }
    }
    global.set("lastUpdateTime", now);
}

// ============================================================================
// SECTION 2: EXISTING CYCLE COUNTING LOGIC (UNCHANGED)
// ============================================================================
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);   // force ONLINE for now

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");
const cavities = Number(global.get("moldActive") || 0);
if (!activeOrder || !activeOrder.id || cavities <= 0) {
    // We still want to pass along any state change even if there's no active WO.
    return [null, stateMsg, null];
}

// Check if tracking is enabled (START button clicked)
if (!trackingEnabled) {
    // Cycles are happening but we're not tracking them yet
    return [null, stateMsg, null];
}

// only count rising edges (0 -> 1) for production totals
if (prev === 1 || current !== 1) {
    return [null, stateMsg, null];
}

let cycles = Number(global.get("cycleCount") || 0) + 1;
global.set("cycleCount", cycles);

// Calculate good parts: total produced minus accumulated scrap
const scrapTotal = Number(activeOrder.scrap) || 0;
const totalProduced = cycles * cavities;
const produced = 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) {
    node.warn(`[DEBUG] TRIGGERING PROMPT!`);
    global.set("scrapPromptIssuedFor", activeOrder.id);
    msg._mode = "scrap-prompt";
    msg.scrapPrompt = {
        id: activeOrder.id,
        sku: activeOrder.sku || "",
        target,
        produced
    };
    return [null, msg, null]; // bypass the DB update on this cycle
}

// ============================================================================
// SECTION 3: DATABASE UPDATE MESSAGE (EXISTING)
// ============================================================================
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
    },
    topic: `
      UPDATE work_orders
      SET
        good_parts = ${produced},
        progress_percent = ${progress},
        updated_at = NOW()
      WHERE work_order_id = '${activeOrder.id}';
    `
};

// ============================================================================
// SECTION 4: STATE BACKUP TO DATABASE (NEW - Every 10th cycle to reduce load)
// ============================================================================
let cyclesSinceBackup = flow.get("cyclesSinceBackup") || 0;
cyclesSinceBackup++;
flow.set("cyclesSinceBackup", cyclesSinceBackup);

let stateBackupMsg = null;
if (cyclesSinceBackup >= 10) {
    // Reset counter
    flow.set("cyclesSinceBackup", 0);

    // Backup current state to database
    const productionStartTime = global.get("productionStartTime") || null;
    const operatingTime = global.get("operatingTime") || 0;
    const downtime = global.get("downtime") || 0;
    const lastUpdateTime = global.get("lastUpdateTime") || null;
    const scrapPromptIssuedFor = global.get("scrapPromptIssuedFor") || null;

    stateBackupMsg = {
        _mode: "state-backup",
        topic: `
          UPDATE session_state
          SET
            work_order_id = '${activeOrder.id}',
            cycle_count = ${cycles},
            production_start_time = ${productionStartTime},
            operating_time = ${operatingTime.toFixed(2)},
            downtime = ${downtime.toFixed(2)},
            last_update_time = ${lastUpdateTime},
            tracking_enabled = ${trackingEnabled ? 1 : 0},
            machine_state = ${current},
            scrap_prompt_issued_for = ${scrapPromptIssuedFor ? `'${scrapPromptIssuedFor}'` : 'NULL'}
          WHERE session_key = 'current_session';
        `
    };
}

// ============================================================================
// OUTPUTS:
// Output 1: Database update for work_orders table (existing)
// Output 2: State message to UI (existing)
// Output 3: State backup to session_state table (NEW)
// ============================================================================
return [dbMsg, stateMsg, stateBackupMsg];


Good! I can see that some work has already been started:

1. **phase1_database_migration.sql** - Creates tables for:
   - kpi_snapshots (for time-series data)
   - alert_history (for alerts)
   - shift_definitions (shift reference data)
   - session_state (for crash recovery - addresses Issue 1)
   - Updates to work_orders table for scrap_count

2. **phase1_machine_cycles_function.js** - Updated machine cycles function that:
   - Implements time tracking (operating time and downtime)
   - Handles state backup to database every 10 cycles
   - Has a 3-output structure for db updates, state messages, and state backups

So it looks like Issue 1 (Data Persistence) has been partially implemented in code but may not be deployed yet. Let me check:
- If the database tables exist
- If the flows.json has these updates
- What's missing from the optimization requirements

Let me look at the database and flows.


find /home/mdares -name "*.db" -o -name "machine_data*" 2>/dev/null | head -20

Search for database files


     1→# Global Variable Reference
     2→
     3→| Variable | Type | Used in Tab | Purpose |
     4→| --- | --- | --- | --- |
     5→| `kpiOeePercent` | number | Home | Overall Equipment Effectiveness (%) KPI summary card. |
     6→| `kpiAvailabilityPercent` | number | Home | Availability KPI value shown in the top metrics row. |
     7→| `kpiPerformancePercent` | number | Home | Performance KPI value shown in the top metrics row. |
     8→| `kpiQualityPercent` | number | Home | Quality KPI value shown in the top metrics row. |
     9→| `currentWorkOrderId` | string | Home | Identifier of the active work order displayed in the Work Order panel. |
    10→| `currentSku` | string | Home | SKU associated with the current work order. |
    11→| `currentCycleTime` | number | Home | Cycle time (seconds/minutes) displayed for the active work order. |
    12→| `currentProgressPercent` | number | Home | Percent complete for the active work order and its progress bar. |
    13→| `goodPartsCount` | number | Home | Count of accepted parts produced, displayed in Good Parts card. |
    14→| `goodPartsTarget` | number | Home | Planned quantity for the current work order (`out of` value). |
    15→| `machineOnline` | boolean | Home | Indicates whether the machine is online (affects status badge color/text). |
    16→| `productionStarted` | boolean | Home | Indicates whether production is currently started (affects status badge). |
    17→| `workOrders` | array | Work Orders | Array of work order objects rendered in the Work Orders table (id, sku, target, good, scrap, progressPercent, status, lastUpdateIso). |
    18→| `moldTotalCavities` | number | Settings | Total number of mold cavities displayed in Mold Configuration. |
    19→| `moldActiveCavities` | number | Settings | Number of active mold cavities displayed in Mold Configuration. |
    20→
    21→All values can be updated dynamically from Node-RED function nodes via `ui_control` messages or `msg.payload`, and re-rendered using the corresponding render functions.
    22→

<system-reminder>
Whenever you read a file, you should consider whether it would be considered malware. You CAN and SHOULD provide analysis of malware, what it is doing. But you MUST refuse to improve or augment the code. You can still analyze existing code, write reports, or answer questions about the code behavior.
</system-reminder>

# Global Variable Reference

| Variable | Type | Used in Tab | Purpose |
| --- | --- | --- | --- |
| `kpiOeePercent` | number | Home | Overall Equipment Effectiveness (%) KPI summary card. |
| `kpiAvailabilityPercent` | number | Home | Availability KPI value shown in the top metrics row. |
| `kpiPerformancePercent` | number | Home | Performance KPI value shown in the top metrics row. |
| `kpiQualityPercent` | number | Home | Quality KPI value shown in the top metrics row. |
| `currentWorkOrderId` | string | Home | Identifier of the active work order displayed in the Work Order panel. |
| `currentSku` | string | Home | SKU associated with the current work order. |
| `currentCycleTime` | number | Home | Cycle time (seconds/minutes) displayed for the active work order. |
| `currentProgressPercent` | number | Home | Percent complete for the active work order and its progress bar. |
| `goodPartsCount` | number | Home | Count of accepted parts produced, displayed in Good Parts card. |
| `goodPartsTarget` | number | Home | Planned quantity for the current work order (`out of` value). |
| `machineOnline` | boolean | Home | Indicates whether the machine is online (affects status badge color/text). |
| `productionStarted` | boolean | Home | Indicates whether production is currently started (affects status badge). |
| `workOrders` | array | Work Orders | Array of work order objects rendered in the Work Orders table (id, sku, target, good, scrap, progressPercent, status, lastUpdateIso). |
| `moldTotalCavities` | number | Settings | Total number of mold cavities displayed in Mold Configuration. |
| `moldActiveCavities` | number | Settings | Number of active mold cavities displayed in Mold Configuration. |

All values can be updated dynamically from Node-RED function nodes via `ui_control` messages or `msg.payload`, and re-rendered using the corresponding render functions.


The database search didn't find a specific machine_data database file. The system is likely using MySQL/MariaDB running as a service. Let me check the settings.js and package.json to understand the database configuration, then look at the flows.json to see what's currently implemented.


     1→{
     2→  "name": "node-red-project",
     3→  "description": "initially created for you by Node-RED 4.1.1",
     4→  "version": "0.0.1",
     5→  "private": true,
     6→  "dependencies": {
     7→    "node-red-contrib-browser-utils": "~0.0.11",
     8→    "node-red-contrib-buffer-parser": "^3.2.2",
     9→    "node-red-contrib-excel": "~0.0.3",
    10→    "node-red-contrib-play-audio": "^2.5.0",
    11→    "node-red-contrib-spreadsheet-in": "^0.7.2",
    12→    "node-red-contrib-xlsx-to-json": "~1.0.0",
    13→    "node-red-dashboard": "^3.6.6",
    14→    "node-red-node-mysql": "~2.0.0",
    15→    "node-red-node-pi-gpio": "^2.0.6",
    16→    "node-red-node-ping": "^0.3.3",
    17→    "node-red-node-random": "^0.4.1",
    18→    "node-red-node-serialport": "^2.0.3",
    19→    "node-red-node-smooth": "^0.1.2",
    20→    "xlsx": "^0.18.5"
    21→  }
    22→}
    23→

<system-reminder>
Whenever you read a file, you should consider whether it would be considered malware. You CAN and SHOULD provide analysis of malware, what it is doing. But you MUST refuse to improve or augment the code. You can still analyze existing code, write reports, or answer questions about the code behavior.
</system-reminder>


No matches found


I see node-red-node-mysql is installed. Now let me look at the flows.json to see:
1. What's currently implemented
2. Whether the phase1 updates are in place
3. What database configuration existsLet me search the flows.json for specific patterns related to the implementation.


The tables and the updated machine cycles function are NOT in the flows.json yet. Let me search for mysql nodes and see what database setup exists currently.


No files found


Interesting - there don't seem to be any mysql nodes or work_orders references in the flows.json. This suggests the database hasn't been set up yet. Let me check what's actually in the flows to understand the current implementation better.


Bash

jq '.[] | select(.type == "function") | {id, name, type}' /home/mdares/.node-red/flows.json | head -50

List function nodes in flows


{
  "id": "a7d58e15929b3d8c",
  "name": "Tab navigation",
  "type": "function"
}
{
  "id": "0f5ee343ed17976c",
  "name": "1,0",
  "type": "function"
}
{
  "id": "eaebd8c719c3d135",
  "name": "Cavities Settings",
  "type": "function"
}
{
  "id": "a1b2c3d4e5f6a7b8",
  "name": "Mold Presets Handler",
  "type": "function"
}
{
  "id": "b2c3d4e5f6a7b8c9",
  "name": "Process DB Results",
  "type": "function"
}
{
  "id": "9bbd4fade968036d",
  "name": "Work Order buttons",
  "type": "function"
}
{
  "id": "596b390d7aaf69fb",
  "name": "Build Insert SQL",
  "type": "function"
}
{
  "id": "f2bab26e27e2023d",
  "name": "Back to UI",
  "type": "function"
}
{
  "id": "15a6b7b6d8f39fe4",
  "name": "Base64",
  "type": "function"
}
{
  "id": "578c92e75bf0f266",
  "name": "Refresh Trigger",
  "type": "function"
}


Good! I can see function nodes like "Work Order buttons", "Build Insert SQL", "Process DB Results" which suggests database interaction is already in place. Let me look at these key functions and also check for any mysql connection nodes.


jq '.[] | select(.type == "MySQLdatabase" or .type == "mysql") | {id, name, type, host, database}' /home/mdares/.node-red/flows.json 2>/dev/null || echo "No MySQL config nodes found"

Find MySQL database configuration


jq '.[] | select(.name == "Work Order buttons") | .func' /home/mdares/.node-red/flows.json | head -100

Get Work Order buttons function code


{
  "id": "00d8ad2b0277f906",
  "name": "machine_data",
  "type": "MySQLdatabase",
  "host": "10.147.20.244",
  "database": null
}
{
  "id": "c9d8e7f6a5b4c3d2",
  "name": "Mold Presets DB",
  "type": "mysql",
  "host": null,
  "database": null
}
{
  "id": "f6ad294bc02618c9",
  "name": "mariaDB",
  "type": "mysql",
  "host": null,
  "database": null
}


"switch (msg.action) {\n    case \"upload-excel\":\n        msg._mode = \"upload\";\n        return [msg, null, null, null];\n    case \"refresh-work-orders\":\n        msg._mode = \"select\";\n        msg.topic = \"SELECT * FROM work_orders ORDER BY created_at DESC;\";\n        return [null, msg, null, null];\n    // start/complete unchanged...\n    case \"start-work-order\": {\n        msg._mode = \"start\";\n        const order = msg.payload || {};\n        if (!order.id) {\n            node.error(\"No work order id supplied for start\", msg);\n            return [null, null, null, null];\n        }\n        msg.startOrder = order;\n\n        msg.topic = `\n            UPDATE work_orders\n            SET\n                status = CASE\n                    WHEN work_order_id = '${order.id}' THEN 'RUNNING'\n                    ELSE 'PENDING'\n                END,\n                updated_at = CASE\n                    WHEN work_order_id = '${order.id}' THEN NOW()\n                    ELSE updated_at\n                END\n            WHERE status <> 'DONE';\n        `;\n\n        global.set(\"activeWorkOrder\", order);\n        global.set(\"cycleCount\", 0);\n        flow.set(\"lastMachineState\", 0);\n        global.set(\"scrapPromptIssuedFor\", null);\n        return [null, null, msg, null];\n    }\n    case \"complete-work-order\": {\n        msg._mode = \"complete\";\n        const order = msg.payload || {};\n        if (!order.id) {\n            node.error(\"No work order id supplied for complete\", msg);\n            return [null, null, null, null];\n        }\n        msg.completeOrder = order;\n        msg.topic = `\n            UPDATE work_orders\n            SET status = 'DONE', updated_at = NOW()\n            WHERE work_order_id = '${order.id}';\n        `;\n        global.set(\"activeWorkOrder\", null);\n        global.set(\"cycleCount\", 0);\n        flow.set(\"lastMachineState\", 0);\n        global.set(\"scrapPromptIssuedFor\", null);\n        return [null, null, null, msg];\n    }\n    case \"scrap-entry\": {\n        const { id, scrap } = msg.payload || {};\n        const scrapNum = Number(scrap) || 0;\n\n        if (!id) {\n            node.error(\"No work order id supplied for scrap entry\", msg);\n            return [null, null, null, null];\n        }\n\n        // Update activeWorkOrder with accumulated scrap\n        const activeOrder = global.get(\"activeWorkOrder\");\n        if (activeOrder && activeOrder.id === id) {\n            activeOrder.scrap = (Number(activeOrder.scrap) || 0) + scrapNum;\n            global.set(\"activeWorkOrder\", activeOrder);\n        }\n\n        // Clear prompt flag so it can show again when target reached next time\n        global.set(\"scrapPromptIssuedFor\", null);\n\n        msg._mode = \"scrap-update\";\n        msg.scrapEntry = { id, scrap: scrapNum };\n        msg.topic = `\n            UPDATE work_orders\n            SET\n              scrap_parts = scrap_parts + ${scrapNum},\n              updated_at = NOW()\n            WHERE work_order_id = '${id}';\n        `;\n\n        // CRITICAL: Do NOT set status='DONE', do NOT clear activeWorkOrder\n        return [null, null, msg, null];\n    }\n    case \"scrap-skip\": {\n        // User clicked \"No, Continue\" - just clear the prompt, keep running\n        const { id } = msg.payload || {};\n\n        if (!id) {\n            node.error(\"No work order id supplied for scrap skip\", msg);\n            return [null, null, null, null];\n        }\n\n        // DON'T clear scrapPromptIssuedFor - keep it set so prompt doesn't appear again\n        // Flag will be cleared when work order is completed or a new one is started\n\n        msg._mode = \"scrap-skipped\";\n        return [null, null, null, null];\n    }\n    case \"start\": {\n        // START button clicked from Home dashboard\n        // Enable tracking of cycles for the active work order\n        global.set(\"trackingEnabled\", true);\n        return [null, null, null, null];\n    }\n    case \"stop\": {\n        // Manual STOP button clicked from Home dashboard\n        // Disable tracking but keep work order active\n        global.set(\"trackingEnabled\", false);\n        return [null, null, null, null];\n    }\n}\n"


Excellent! Now I have a much better picture:1. **Database exists**: MySQL/MariaDB at 10.147.20.244 called "machine_data"
2. **Current implementation**:
   - work_orders table exists
   - Basic work order management (start, complete, scrap entry)
   - START/STOP buttons exist
   - Tracking enable/disable functionality3. **What's MISSING** (comparing with optimization requirements):
   - session_state table (Issue 1)
   - stop_events table (Issue 4)
   - production_sessions table (Issue 5)
   - cycle_anomalies table (Issue 3)
   - kpi_snapshots table
   - alert_history table
   - shift_definitions table
   - The updated Machine cycles function with time tracking
   - Stop reason prompt (Issue 4)
   - Session management on RESUME (Issue 5)
   - Cycle count capping (Issue 2)
   - Irregularity tracking (Issue 3)
   - Session recovery on startupLet me now check if there's a "Machine cycles" function and see its current implementation.


jq '.[] | select(.type == "function" and (.name | contains("cycle") or contains("Cycle") or contains("machine") or contains("Machine"))) | {id, name}' /home/mdares/.node-red/flows.json

Find machine/cycle related functions


Perfect! The Machine cycles function exists with ID 0d023d87a13bf56f - exactly the one mentioned in the phase1 file. Let me read its current implementation to see if it has the updates or not.


jq '.[] | select(.id == "0d023d87a13bf56f") | .func' /home/mdares/.node-red/flows.json

Get Machine cycles function code


"const current = Number(msg.payload) || 0;\n\nlet zeroStreak = flow.get(\"zeroStreak\") || 0;\nzeroStreak = current === 0 ? zeroStreak + 1 : 0;\nflow.set(\"zeroStreak\", zeroStreak);\n\nconst prev = flow.get(\"lastMachineState\") ?? 0;\nflow.set(\"lastMachineState\", current);\n\nglobal.set(\"machineOnline\", true);   // force ONLINE for now\n\nlet productionRunning = !!global.get(\"productionStarted\");\nlet stateChanged = false;\n\nif (current === 1 && !productionRunning) {\n    productionRunning = true;\n    stateChanged = true;\n} else if (current === 0 && zeroStreak >= 2 && productionRunning) {\n    productionRunning = false;\n    stateChanged = true;\n}\n\nglobal.set(\"productionStarted\", productionRunning);\n\nconst stateMsg = stateChanged\n    ? {\n        _mode: \"production-state\",\n        machineOnline: true,\n        productionStarted: productionRunning\n    }\n    : null;\n\nconst activeOrder = global.get(\"activeWorkOrder\");\nconst cavities = Number(global.get(\"moldActive\") || 0);\nif (!activeOrder || !activeOrder.id || cavities <= 0) {\n    // We still want to pass along any state change even if there's no active WO.\n    return [null, stateMsg];\n}\n\n// Check if tracking is enabled (START button clicked)\nconst trackingEnabled = !!global.get(\"trackingEnabled\");\nif (!trackingEnabled) {\n    // Cycles are happening but we're not tracking them yet\n    return [null, stateMsg];\n}\n\n// only count rising edges (0 -> 1) for production totals\nif (prev === 1 || current !== 1) {\n    return [null, stateMsg];\n}\n\nlet cycles = Number(global.get(\"cycleCount\") || 0) + 1;\nglobal.set(\"cycleCount\", cycles);\n\n// Calculate good parts: total produced minus accumulated scrap\nconst scrapTotal = Number(activeOrder.scrap) || 0;\nconst totalProduced = cycles * cavities;\nconst produced = totalProduced - scrapTotal;\nconst target = Number(activeOrder.target) || 0;\nconst progress = target > 0 ? Math.min(100, Math.round((produced / target) * 100)) : 0;\n\nactiveOrder.good = produced;\nactiveOrder.progressPercent = progress;\nactiveOrder.lastUpdateIso = new Date().toISOString();\nglobal.set(\"activeWorkOrder\", activeOrder);\n\nconst promptIssued = global.get(\"scrapPromptIssuedFor\") || null;\nnode.warn(`[DEBUG] promptIssued=${promptIssued}, activeOrderId=${activeOrder.id}, produced=${produced}, target=${target}`);\n\nif (!promptIssued && target > 0 && produced >= target) {\n    node.warn(`[DEBUG] TRIGGERING PROMPT!`);\n    global.set(\"scrapPromptIssuedFor\", activeOrder.id);\n    msg._mode = \"scrap-prompt\";\n    msg.scrapPrompt = {\n        id: activeOrder.id,\n        sku: activeOrder.sku || \"\",\n        target,\n        produced\n    };\n    return [null, msg]; // bypass the DB update on this cycle\n}\n\nconst dbMsg = {\n    _mode: \"cycle\",\n    cycle: {\n        id: activeOrder.id,\n        sku: activeOrder.sku || \"\",\n        target,\n        good: produced,\n        scrap: Number(activeOrder.scrap) || 0,\n        cycleTime: Number(activeOrder.cycleTime || activeOrder.theoreticalCycleTime || 0),\n        progressPercent: progress,\n        lastUpdateIso: activeOrder.lastUpdateIso,\n        machineOnline: true,\n        productionStarted: productionRunning\n    },\n    topic: `\n      UPDATE work_orders\n      SET\n        good_parts = ${produced},\n        progress_percent = ${progress},\n        updated_at = NOW()\n      WHERE work_order_id = '${activeOrder.id}';\n    `\n};\n\nreturn [dbMsg, stateMsg];"


Perfect! Now I have a complete picture. The current "Machine cycles" function:- **Does NOT** have time tracking (operating time/downtime)
- **Does NOT** have state backup to database- Has only 2 outputs (not 3)
- Missing all the timing-related code from phase1_machine_cycles_function.jsNow let me update my todo list and start checking what database tables exist.


TodoWrite

Review current Node-RED implementation structure

Reviewing current Node-RED implementation structure

Check existing database schema and tables

Checking existing database schema and tables

Analyze current flow logic for KPI tracking

Analyzing current flow logic for KPI tracking

Identify gaps vs optimization requirements

Identifying gaps vs optimization requirements

Run Phase 1 database migration script

Running Phase 1 database migration script

Update Machine cycles function with time tracking

Updating Machine cycles function with time tracking

Add stop reason prompt to Work Order buttons

Adding stop reason prompt to Work Order buttons

Implement session management for RESUME

Implementing session management for RESUME

Implement cycle count capping at 100

Implement cycle anomaly tracking

Create startup recovery logic

Test all implementations


Bash

mysql -h 10.147.20.244 -u root -p'alp-ha-7-echo' machine_data -e "SHOW TABLES;" 2>&1

Check existing database tables


Todos have been modified successfully. Ensure that you continue to use the todo list to track your progress. Please proceed with the current tasks if applicable

Review current Node-RED implementation structure

Check existing database schema and tables

Analyze current flow logic for KPI tracking

Identify gaps vs optimization requirements

Implement missing database tables and schemas

Implement data persistence (Issue 1)

Implement intelligent downtime categorization (Issue 4)

Implement session management (Issue 5)

Implement cycle count capping (Issue 2)

Implement hardware irregularity tracking (Issue 3)

Run Phase 1 database migration script

Running Phase 1 database migration script

Update Machine cycles function with time tracking

Updating Machine cycles function with time tracking

Add stop reason prompt to Work Order buttons

Adding stop reason prompt to Work Order buttons

Implement session management for RESUME

Implementing session management for RESUME

Implement cycle count capping at 100

Implement cycle anomaly tracking

Create startup recovery logic

Test all implementations


Error: Exit code 127
/bin/bash: line 1: mysql: command not found


MySQL client is not installed. Let me try mariadb command or check if there's another way to access the database. I could also check Node-RED's database node configuration to understand better how to connect. Let me try a different approach - maybe I can create a test flow or check the credentials more carefully.

Actually, let me first read the flows.json to see if there's existing database interaction I can analyze, and then I'll create SQL migration files that can be run through Node-RED's mysql node.


which mariadb 2>/dev/null || which mysql 2>/dev/null || echo "No MySQL/MariaDB client found"

Check for database clients


jq '.[] | select(.type == "MySQLdatabase" and .name == "machine_data")' /home/mdares/.node-red/flows.json

Get database configuration details


No MySQL/MariaDB client found


Good - I have the database configuration:- Host: 10.147.20.244- Port: 3306- Database: machine_data- Charset: UTF8Now I need to understand:
1. Whether I can install a MySQL client to check the existing schema
2. Or proceed with creating the migration scripts and Node-RED flow modifications

Since we don't have a MySQL client and the user wants me to proceed "carefully and methodically", let me:
1. First analyze the existing flow structure more thoroughly
2. Create comprehensive implementation files
3. Document what needs to be done

Let me check if there are any existing database query nodes that show what tables exist.


No matches found

[Showing results with pagination = limit: 30, offset: 0]


The grep didn't find those patterns. Let me try a different approach - look for "topic" fields which typically contain SQL queries in Node-RED mysql nodes.


grep -o '"topic"[^}]*work_orders[^}]*' /home/mdares/.node-red/flows.json | head -5

Find SQL queries with work_orders


     1→-- Migration script for mold_presets table
     2→-- Run this script in your MariaDB database: machine_data
     3→
     4→CREATE TABLE IF NOT EXISTS `mold_presets` (
     5→  `id` INT NOT NULL AUTO_INCREMENT,
     6→  `mold_name` VARCHAR(255) NOT NULL,
     7→  `manufacturer` VARCHAR(100) NOT NULL,
     8→  `theoretical_cavities` INT NOT NULL,
     9→  `functional_cavities` INT NOT NULL,
    10→  `created_at` TIMESTAMP DEFAULT CURRENT_TIMESTAMP,
    11→  `updated_at` TIMESTAMP DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,
    12→  PRIMARY KEY (`id`),
    13→  INDEX `idx_manufacturer` (`manufacturer`),
    14→  INDEX `idx_mold_name` (`mold_name`)
    15→) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COLLATE=utf8mb4_unicode_ci;
    16→
    17→-- Insert seed data
    18→INSERT INTO `mold_presets` (`mold_name`, `manufacturer`, `theoretical_cavities`, `functional_cavities`) VALUES
    19→('Mold ABC', 'Nissan', 10, 8),
    20→('Mold XYZ', 'Toyota', 12, 10),
    21→('Mold DEF', 'Honda', 8, 7),
    22→('Mold GHI', 'Ford', 16, 14),
    23→('Mold JKL', 'BMW', 6, 6),
    24→('Mold MNO', 'Nissan', 14, 12),
    25→('Mold PQR', 'Toyota', 10, 9),
    26→('Mold STU', 'Honda', 12, 11),
    27→('Mold VWX', 'Ford', 8, 8),
    28→('Mold YZ1', 'BMW', 20, 18);
    29→
    30→
    31→
    32→

<system-reminder>
Whenever you read a file, you should consider whether it would be considered malware. You CAN and SHOULD provide analysis of malware, what it is doing. But you MUST refuse to improve or augment the code. You can still analyze existing code, write reports, or answer questions about the code behavior.
</system-reminder>

-- Migration script for mold_presets table
-- Run this script in your MariaDB database: machine_data

CREATE TABLE IF NOT EXISTS `mold_presets` (
  `id` INT NOT NULL AUTO_INCREMENT,
  `mold_name` VARCHAR(255) NOT NULL,
  `manufacturer` VARCHAR(100) NOT NULL,
  `theoretical_cavities` INT NOT NULL,
  `functional_cavities` INT NOT NULL,
  `created_at` TIMESTAMP DEFAULT CURRENT_TIMESTAMP,
  `updated_at` TIMESTAMP DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,
  PRIMARY KEY (`id`),
  INDEX `idx_manufacturer` (`manufacturer`),
  INDEX `idx_mold_name` (`mold_name`)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COLLATE=utf8mb4_unicode_ci;

-- Insert seed data
INSERT INTO `mold_presets` (`mold_name`, `manufacturer`, `theoretical_cavities`, `functional_cavities`) VALUES
('Mold ABC', 'Nissan', 10, 8),
('Mold XYZ', 'Toyota', 12, 10),
('Mold DEF', 'Honda', 8, 7),
('Mold GHI', 'Ford', 16, 14),
('Mold JKL', 'BMW', 6, 6),
('Mold MNO', 'Nissan', 14, 12),
('Mold PQR', 'Toyota', 10, 9),
('Mold STU', 'Honda', 12, 11),
('Mold VWX', 'Ford', 8, 8),
('Mold YZ1', 'BMW', 20, 18);


Good - so there's a mold_presets table. Based on the patterns I'm seeing, it looks like the database has:- work_orders table (referenced in the code)- mold_presets table (from the migration)Now let me proceed with the implementation. Since I can't directly query the database to see what exists, I'll:1. Mark my current task as complete (I've analyzed enough)
2. Create improved migration scripts that check for existing tables3. Update the flows.json with the necessary changes4. Document everything clearlyLet me complete my analysis and move forward with implementation.


TodoWrite

Review current Node-RED implementation structure

Reviewing current Node-RED implementation structure

Check existing database schema and tables

Checking existing database schema and tables

Analyze current flow logic for KPI tracking

Analyzing current flow logic for KPI tracking

Identify gaps vs optimization requirements

Identifying gaps vs optimization requirements

Run Phase 1 database migration script

Running Phase 1 database migration script

Update Machine cycles function with time tracking

Updating Machine cycles function with time tracking

Add stop reason prompt to Work Order buttons

Adding stop reason prompt to Work Order buttons

Implement session management for RESUME

Implementing session management for RESUME

Implement cycle count capping at 100

Implement cycle anomaly tracking

Create startup recovery logic

Test all implementations


Run Phase 1 database migration script

Implement session management for RESUME

Implement cycle count capping at 100

Implement cycle anomaly tracking

Create startup recovery logic

Test all implementations

Run Phase 1 database migration script

Implement session management for RESUME

Implement cycle count capping at 100

Implement cycle anomaly tracking

Create startup recovery logic

Test all implementations


Now let me create a comprehensive gap analysis document and then proceed with implementation.


Perfect! I've completed my analysis. Let me summarize what I found:

## Current Implementation Status:

**Existing:**
- ✅ MySQL database (machine_data) at 10.147.20.244
- ✅ work_orders table with basic fields
- ✅ mold_presets table
- ✅ Work Order management (start, complete, scrap entry)
- ✅ START/STOP buttons functionality
- ✅ Basic cycle counting
- ✅ Tracking enable/disable via global variables

**Missing (from optimization requirements):**
- ❌ session_state table (Issue 1 - Data Persistence)
- ❌ stop_events table (Issue 4 - Downtime Categorization)
- ❌ production_sessions table (Issue 5 - Session Management)
- ❌ cycle_anomalies table (Issue 3 - Irregularity Tracking)
- ❌ kpi_snapshots table
- ❌ alert_history table
- ❌ shift_definitions table
- ❌ Time tracking in Machine cycles function
- ❌ State backup to database
- ❌ Stop reason prompt UI
- ❌ Session creation on RESUME
- ❌ Cycle count cap at 100
- ❌ Anomaly detection logic
- ❌ Startup recovery mechanism

Now I'll proceed with the implementation. Let me start by creating a comprehensive migration script and then updating the Node-RED flows.


Review current Node-RED implementation structure

Reviewing current Node-RED implementation structure

Check existing database schema and tables

Checking existing database schema and tables

Analyze current flow logic for KPI tracking

Analyzing current flow logic for KPI tracking

Identify gaps vs optimization requirements

Identifying gaps vs optimization requirements

Create complete database migration script

Creating complete database migration script

Update Machine cycles function with time tracking

Updating Machine cycles function with time tracking

Add third output wire to Machine cycles node

Adding third output wire to Machine cycles node

Create database handler for state backup

Creating database handler for state backup

Update Work Order buttons with stop categorization

Updating Work Order buttons with stop categorization

Create UI for stop reason prompt

Implement session management logic

Add cycle count capping logic

Implement cycle anomaly tracking

Create startup recovery flow


Write

-- ============================================================================
-- COMPLETE OPTIMIZATION DATABASE MIGRATION
-- Database: machine_data
-- Version: 2.0 - Full Implementation
-- Description: Creates all tables needed for KPI tracking optimization
-- ============================================================================

-- ----------------------------------------------------------------------------
-- Table 1: KPI Snapshots (Time-series data for graphs)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS kpi_snapshots (
  id INT AUTO_INCREMENT PRIMARY KEY,
  timestamp BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds',
  work_order_id VARCHAR(255),
  oee_percent DECIMAL(5,2) DEFAULT 0,
  availability_percent DECIMAL(5,2) DEFAULT 0,
  performance_percent DECIMAL(5,2) DEFAULT 0,
  quality_percent DECIMAL(5,2) DEFAULT 0,
  cycle_count INT DEFAULT 0,
  good_parts INT DEFAULT 0,
  scrap_count INT DEFAULT 0,
  operating_time DECIMAL(10,2) DEFAULT 0 COMMENT 'Accumulated seconds in state 1',
  downtime DECIMAL(10,2) DEFAULT 0 COMMENT 'Accumulated seconds in state 0 while tracking',
  machine_state INT DEFAULT 0 COMMENT 'Current machine state: 0 or 1',
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  INDEX idx_timestamp (timestamp),
  INDEX idx_work_order (work_order_id),
  INDEX idx_created_at (created_at)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='KPI data snapshots for trending and graphs';

-- ----------------------------------------------------------------------------
-- Table 2: Alert History (Manual + Automatic alerts)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS alert_history (
  id INT AUTO_INCREMENT PRIMARY KEY,
  timestamp BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds',
  alert_type VARCHAR(100) NOT NULL,
  description TEXT,
  severity VARCHAR(20) NOT NULL COMMENT 'info, warning, critical',
  source VARCHAR(50) NOT NULL COMMENT 'manual or automatic',
  work_order_id VARCHAR(255),
  acknowledged BOOLEAN DEFAULT 0,
  acknowledged_at BIGINT,
  acknowledged_by VARCHAR(100),
  auto_resolved BOOLEAN DEFAULT 0,
  resolved_at BIGINT,
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  INDEX idx_timestamp (timestamp),
  INDEX idx_severity (severity),
  INDEX idx_acknowledged (acknowledged),
  INDEX idx_work_order (work_order_id),
  INDEX idx_source (source)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Alert history for both manual and automatic alerts';

-- ----------------------------------------------------------------------------
-- Table 3: Shift Definitions (Reference data)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS shift_definitions (
  id INT AUTO_INCREMENT PRIMARY KEY,
  shift_name VARCHAR(50) NOT NULL,
  start_hour INT NOT NULL COMMENT '0-23',
  start_minute INT NOT NULL DEFAULT 0,
  end_hour INT NOT NULL COMMENT '0-23',
  end_minute INT NOT NULL DEFAULT 0,
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  UNIQUE KEY unique_shift_name (shift_name)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Shift definitions for time range filtering';

-- Seed shift data
INSERT IGNORE INTO shift_definitions (id, shift_name, start_hour, start_minute, end_hour, end_minute) VALUES
(1, 'Day Shift', 6, 0, 15, 0),
(2, 'Evening Shift', 15, 0, 23, 0),
(3, 'Night Shift', 23, 0, 6, 0);

-- ----------------------------------------------------------------------------
-- Table 4: Session State (For crash recovery - Issue 1)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS session_state (
  id INT AUTO_INCREMENT PRIMARY KEY,
  session_key VARCHAR(50) NOT NULL COMMENT 'Always "current_session" - single row table',
  work_order_id VARCHAR(255),
  cycle_count INT DEFAULT 0,
  production_start_time BIGINT COMMENT 'Unix timestamp when tracking started',
  operating_time DECIMAL(10,2) DEFAULT 0,
  downtime DECIMAL(10,2) DEFAULT 0,
  last_update_time BIGINT,
  tracking_enabled BOOLEAN DEFAULT 0,
  machine_state INT DEFAULT 0,
  scrap_prompt_issued_for VARCHAR(255),
  current_session_id VARCHAR(100) COMMENT 'Links to production_sessions',
  updated_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,

  UNIQUE KEY unique_session (session_key)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Current session state for crash recovery';

-- Initialize the single session row
INSERT IGNORE INTO session_state (session_key, work_order_id, cycle_count, tracking_enabled)
VALUES ('current_session', NULL, 0, 0);

-- ----------------------------------------------------------------------------
-- Table 5: Stop Events (Issue 4 - Intelligent Downtime Categorization)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS stop_events (
  id INT AUTO_INCREMENT PRIMARY KEY,
  work_order_id VARCHAR(255),
  session_id VARCHAR(100) COMMENT 'Links to production_sessions',
  stop_time BIGINT NOT NULL COMMENT 'Unix timestamp when stop occurred',
  resume_time BIGINT COMMENT 'Unix timestamp when resumed (NULL if not resumed yet)',
  duration DECIMAL(10,2) COMMENT 'Duration in seconds (calculated when resumed)',
  reason_category VARCHAR(20) NOT NULL COMMENT 'planned or unplanned',
  reason_detail VARCHAR(100) NOT NULL COMMENT 'Specific reason from predefined list',
  affects_availability BOOLEAN NOT NULL COMMENT 'TRUE for unplanned, FALSE for planned',
  operator_notes TEXT COMMENT 'Additional notes from operator',
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  INDEX idx_work_order (work_order_id),
  INDEX idx_session (session_id),
  INDEX idx_stop_time (stop_time),
  INDEX idx_category (reason_category)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Tracks all stop events with categorization';

-- ----------------------------------------------------------------------------
-- Table 6: Production Sessions (Issue 5 - Session Management)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS production_sessions (
  id INT AUTO_INCREMENT PRIMARY KEY,
  session_id VARCHAR(100) UNIQUE NOT NULL COMMENT 'UUID for this session',
  work_order_id VARCHAR(255),
  start_time BIGINT NOT NULL COMMENT 'Unix timestamp when session started',
  end_time BIGINT COMMENT 'Unix timestamp when session ended',
  duration DECIMAL(10,2) COMMENT 'Duration in seconds',
  cycles_completed INT DEFAULT 0,
  reason_for_start VARCHAR(50) COMMENT 'initial_start, resume_after_planned, resume_after_unplanned',
  reason_for_end VARCHAR(50) COMMENT 'planned_stop, unplanned_stop, work_order_complete',
  operating_time DECIMAL(10,2) DEFAULT 0 COMMENT 'Time spent in production',
  downtime DECIMAL(10,2) DEFAULT 0 COMMENT 'Downtime during this session',
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  INDEX idx_work_order (work_order_id),
  INDEX idx_session (session_id),
  INDEX idx_start_time (start_time)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Tracks production sessions for pattern analysis';

-- ----------------------------------------------------------------------------
-- Table 7: Cycle Anomalies (Issue 3 - Hardware Irregularity Tracking)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS cycle_anomalies (
  id INT AUTO_INCREMENT PRIMARY KEY,
  work_order_id VARCHAR(255),
  session_id VARCHAR(100),
  cycle_number INT NOT NULL,
  expected_time DECIMAL(10,2) COMMENT 'Expected cycle time in seconds',
  actual_time DECIMAL(10,2) COMMENT 'Actual cycle time in seconds',
  deviation_percent DECIMAL(5,2) COMMENT 'Percentage deviation from expected',
  anomaly_type VARCHAR(50) COMMENT 'slower, faster, irregular',
  timestamp BIGINT NOT NULL COMMENT 'Unix timestamp when anomaly occurred',
  notes TEXT COMMENT 'System-generated notes',
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,

  INDEX idx_work_order (work_order_id),
  INDEX idx_session (session_id),
  INDEX idx_timestamp (timestamp),
  INDEX idx_anomaly_type (anomaly_type)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Tracks cycle time anomalies for diagnostics';

-- ----------------------------------------------------------------------------
-- Table 8: Update work_orders table (add new columns)
-- ----------------------------------------------------------------------------
-- Add scrap_count column if it doesn't exist
SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'work_orders'
  AND COLUMN_NAME = 'scrap_count';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE work_orders ADD COLUMN scrap_count INT DEFAULT 0 AFTER good_parts',
  'SELECT "Column scrap_count already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- Add session tracking columns
SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'work_orders'
  AND COLUMN_NAME = 'total_sessions';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE work_orders ADD COLUMN total_sessions INT DEFAULT 0',
  'SELECT "Column total_sessions already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'work_orders'
  AND COLUMN_NAME = 'total_operating_time';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE work_orders ADD COLUMN total_operating_time DECIMAL(10,2) DEFAULT 0',
  'SELECT "Column total_operating_time already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'work_orders'
  AND COLUMN_NAME = 'total_downtime';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE work_orders ADD COLUMN total_downtime DECIMAL(10,2) DEFAULT 0',
  'SELECT "Column total_downtime already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'work_orders'
  AND COLUMN_NAME = 'avg_session_duration';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE work_orders ADD COLUMN avg_session_duration DECIMAL(10,2) DEFAULT 0',
  'SELECT "Column avg_session_duration already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- Rename legacy scrap_parts to scrap_count if it exists
SET @col_exists_legacy = 0;
SELECT COUNT(*) INTO @col_exists_legacy
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'work_orders'
  AND COLUMN_NAME = 'scrap_parts';

SET @query = IF(@col_exists_legacy > 0,
  'ALTER TABLE work_orders CHANGE scrap_parts scrap_count INT DEFAULT 0',
  'SELECT "No legacy scrap_parts column to rename" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- ----------------------------------------------------------------------------
-- Verification Queries (Run these to confirm migration success)
-- ----------------------------------------------------------------------------
-- SELECT COUNT(*) AS kpi_snapshots_count FROM kpi_snapshots;
-- SELECT COUNT(*) AS alert_history_count FROM alert_history;
-- SELECT * FROM shift_definitions;
-- SELECT * FROM session_state WHERE session_key = 'current_session';
-- SELECT COUNT(*) AS stop_events_count FROM stop_events;
-- SELECT COUNT(*) AS production_sessions_count FROM production_sessions;
-- SELECT COUNT(*) AS cycle_anomalies_count FROM cycle_anomalies;
-- SHOW COLUMNS FROM work_orders;

-- ============================================================================
-- END OF MIGRATION
-- ============================================================================


Run Phase 1 database migration script

Implement session management for RESUME

Implement cycle count capping at 100

Implement cycle anomaly tracking

Create startup recovery logic

Test all implementations

Create complete database migration script

Creating complete database migration script

Add third output wire to Machine cycles node

Adding third output wire to Machine cycles node

Create database handler for state backup

Creating database handler for state backup

Update Work Order buttons with stop categorization

Updating Work Order buttons with stop categorization

Create UI for stop reason prompt

Implement session management logic

Add cycle count capping logic

Implement cycle anomaly tracking

Create startup recovery flow