PLease reference /home/mdares/.node-red/optimization_prompt.txt, work on that. Thanks


The user wants me to reference a file at `/home/mdares/.node-red/optimization_prompt.txt` and work on whatever is mentioned there. Let me first read that file to understand what needs to be done.


I'll read the optimization prompt file to see what needs to be done.


     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


The user has provided an optimization prompt for a Node-RED application that tracks manufacturing KPIs. This is clearly a legitimate manufacturing/industrial IoT system, not malware. It's a KPI tracking system for production monitoring.

The document outlines several backend optimization requirements:
1. Data persistence using database storage
2. Cycle count capping at 100
3. Hardware irregularity handling
4. Intelligent downtime categorization
5. Session management and pattern tracking

The user wants me to "work on that" - which means I should help implement these optimizations. Let me first understand the current state of the Node-RED application by exploring the .node-red directory to see what files exist.

I should:
1. First explore the .node-red directory to understand the current structure
2. Look for existing flows and database schema
3. Create a todo list to track the implementation
4. Start implementing the optimizations as outlined

Let me start by exploring the directory structure and understanding what currently exists.


I'll help you implement these backend optimizations for your KPI tracking system. Let me first explore the current Node-RED setup to understand the existing structure.


Bash

List files in Node-RED directory


total 572
drwxr-xr-x   5 mdares mdares   4096 Nov 21 18:02 .
drwxr-x---  23 mdares mdares   4096 Nov 21 18:11 ..
-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


No files found


Good! I can see there are:
- flows.json - the main Node-RED flow file
- phase1_database_migration.sql - an existing migration script
- phase1_machine_cycles_function.js - an existing machine cycles function
- mold_presets_migration.sql - another migration script
- globals-reference.md - documentation about global variables

Let me read these files to understand the current state before creating a plan to implement the optimizations.


     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];


     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.


Great! Now I have a good understanding of the current state:

1. **Database Migration (phase1_database_migration.sql)**: Already has:
   - kpi_snapshots table
   - alert_history table
   - shift_definitions table
   - session_state table (for crash recovery)
   - This addresses Issue 1 (Data Persistence) partially

2. **Machine Cycles Function (phase1_machine_cycles_function.js)**: Already has:
   - Time tracking logic (operating time, downtime)
   - Session state backup every 10 cycles
   - Cycle counting logic
   - Database updates for work_orders

3. **globals-reference.md**: Shows the global variables being used

Now, looking at the optimization_prompt.txt requirements, I need to implement:

**Issue 1**: ✅ Partially done - session_state table exists, but missing:
- Session recovery logic on startup
- Crash recovery prompt

**Issue 2**: ❌ Not implemented - Cycle count capping at 100

**Issue 3**: ❌ Not implemented - Hardware irregularity handling with cycle_anomalies table

**Issue 4**: ❌ Not implemented - Intelligent downtime categorization with stop_events table

**Issue 5**: ❌ Not implemented - Session management with production_sessions table

Let me create a comprehensive todo list and then start implementing these features. I'll need to:
1. Create additional database migration scripts for the missing tables
2. Update the machine cycles function to handle cycle capping and anomaly detection
3. Create/update the work order buttons function to handle stop categorization
4. Create a startup recovery function

Let me create a todo list first.


Now let me check the flows.json file to understand the current Node-RED flow structure, particularly looking for the "Work Order buttons" function mentioned in the requirements.


grep -n "Work Order buttons\|workorder.*button\|stop.*button" /home/mdares/.node-red/flows.json | head -20

Search for work order button nodes


TodoWrite

Create phase2_database_migration.sql with missing tables (stop_events, production_sessions, cycle_anomalies)

Creating phase2_database_migration.sql with missing tables

Implement cycle count capping at 100 in machine cycles function

Implement hardware irregularity tracking with anomaly detection

Implementing hardware irregularity tracking

Create phase2_work_order_buttons_function.js with stop reason categorization

Creating work order buttons function with stop categorization

Implement session management logic with unique session IDs

Create startup_recovery_function.js for crash recovery

Update machine cycles function to integrate all new features

Updating machine cycles function with all features


390:        "format": "\n
\n  \n
\n      <button class=\"sb-btn active\" data-label=\"Home\" ng-click=\"gotoTab('Home')\">🏠</button>\n      <button class=\"sb-btn\" data-label=\"Work Orders\" ng-click=\"gotoTab('Work Orders')\">📋</button>\n      <button class=\"sb-btn\" data-label=\"Alerts\" ng-click=\"gotoTab('Alerts')\">⚠</button>\n      <button class=\"sb-btn\" data-label=\"Graphs\" ng-click=\"gotoTab('Graphs')\">📊</button>\n      <button class=\"sb-btn\" data-label=\"Help\" ng-click=\"gotoTab('Help')\">❓</button>\n      <button class=\"sb-btn\" data-label=\"Settings\" ng-click=\"gotoTab('Settings')\">⚙</button>\n
\n
OEE V1.0
\n  \n\n  \n
\n
\n
\n
OEE
\n
0%
\n
\n
\n
Availability
\n
0%
\n
\n
\n
Performance
\n
0%
\n
\n
\n
Quality
\n
0%
\n
\n
\n\n
\n

Current Work Order

\n
\n
\n
Work Order ID
\n

\n
\n
\n
SKU
\n

\n
\n
\n
Cycle Time
\n
0
\n
\n
\n
\n

\n
0%
\n
\n
\n\n
\n
\n
Good Parts
\n
0
\n
out of 0
\n
\n\n
\n
MachineOFFLINE
\n
ProductionSTOPPED
\n
\n\n
\n          <button id=\"start-button\" type=\"button\" class=\"start\" ng-click=\"toggleStartStop()\" ng-class=\"{'stop-btn': isProductionRunning}\" ng-disabled=\"!hasActiveOrder && !isProductionRunning\">{{ isProductionRunning ? 'STOP' : 'START' }}</button>\n
\n
\n
\n  \n
\n
\n
\n
Work Order Complete
\n
{{ scrapPrompt.orderId }}
\n
Produced {{ scrapPrompt.produced }} of {{ scrapPrompt.target }} pieces
\n\n
Were there any scrap parts?
\n\n    \n
\n
{{ scrapPrompt.scrapCount || 0 }}
\n
{{ scrapPrompt.error }}
\n\n
\n        <button class=\"numpad-btn\" ng-click=\"addDigit(7)\">7</button>\n        <button class=\"numpad-btn\" ng-click=\"addDigit(8)\">8</button>\n        <button class=\"numpad-btn\" ng-click=\"addDigit(9)\">9</button>\n\n        <button class=\"numpad-btn\" ng-click=\"addDigit(4)\">4</button>\n        <button class=\"numpad-btn\" ng-click=\"addDigit(5)\">5</button>\n        <button class=\"numpad-btn\" ng-click=\"addDigit(6)\">6</button>\n\n        <button class=\"numpad-btn\" ng-click=\"addDigit(1)\">1</button>\n        <button class=\"numpad-btn\" ng-click=\"addDigit(2)\">2</button>\n        <button class=\"numpad-btn\" ng-click=\"addDigit(3)\">3</button>\n\n        <button class=\"numpad-btn numpad-clear\" ng-click=\"clearScrap()\">C</button>\n        <button class=\"numpad-btn\" ng-click=\"addDigit(0)\">0</button>\n        <button class=\"numpad-btn numpad-back\" ng-click=\"backspace()\">⌫</button>\n
\n\n
\n        <button class=\"scrap-submit-btn\" ng-click=\"submitScrapValidated(scrapPrompt.scrapCount)\">\n          Submit Scrap\n        </button>\n
\n
\n\n    \n
\n      <button class=\"prompt-continue\" ng-click=\"skipScrap()\">\n        No, Continue Production\n      </button>\n      <button class=\"prompt-yes\" ng-click=\"openScrapEntry()\">\n        Yes, Enter Scrap\n      </button>\n
\n
\n
\n\n\n


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

Create phase2_database_migration.sql with missing tables (stop_events, production_sessions, cycle_anomalies)

Creating phase2_database_migration.sql with missing tables

Implement cycle count capping at 100 in machine cycles function

Implement hardware irregularity tracking with anomaly detection

Implementing hardware irregularity tracking

Create phase2_work_order_buttons_function.js with stop reason categorization

Creating work order buttons function with stop categorization

Implement session management logic with unique session IDs

Create startup_recovery_function.js for crash recovery

Update machine cycles function to integrate all new features

Updating machine cycles function with all features


The grep result shows mostly CSS and front-end code from the flows.json. Let me search for work order button functions more specifically. I need to find where the "start" and "stop" actions are being handled in the Node-RED flows. Let me search the flows.json more specifically for the function nodes that handle these actions.


Let me search more specifically for the backend functions that handle work order actions:


Bash

grep -n '"action".*"start"\|"action".*"stop"\|Work Order buttons' /home/mdares/.node-red/flows.json | head -20

Search for action handlers in flows


854:        "name": "Work Order buttons",

854:        "name": "Work Order buttons",


Good! I found the "Work Order buttons" node at line 854. Let me read that section of the flows.json file to see the current implementation.


   850→        "id": "9bbd4fade968036d",
   851→        "type": "function",
   852→        "z": "cac3a4383120cb57",
   853→        "g": "b7ab5e0cc02b9508",
   854→        "name": "Work Order buttons",
   855→        "func": "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",
   856→        "outputs": 4,
   857→        "timeout": 0,
   858→        "noerr": 0,
   859→        "initialize": "",
   860→        "finalize": "",
   861→        "libs": [],
   862→        "x": 970,
   863→        "y": 400,
   864→        "wires": [
   865→            [
   866→                "15a6b7b6d8f39fe4"
   867→            ],
   868→            [
   869→                "f6ad294bc02618c9"
   870→            ],
   871→            [
   872→                "f6ad294bc02618c9"
   873→            ],
   874→            [
   875→                "f6ad294bc02618c9"
   876→            ]
   877→        ]
   878→    },
   879→    {
   880→        "id": "010de5af3ced0ae3",
   881→        "type": "link out",
   882→        "z": "cac3a4383120cb57",
   883→        "g": "ec32d0a62eacfb22",
   884→        "name": "link out 2",
   885→        "mode": "link",
   886→        "links": [
   887→            "65ddb4cca6787bde"
   888→        ],
   889→        "x": 305,
   890→        "y": 100,
   891→        "wires": []
   892→    },
   893→    {
   894→        "id": "65ddb4cca6787bde",
   895→        "type": "link in",
   896→        "z": "cac3a4383120cb57",
   897→        "g": "b7ab5e0cc02b9508",
   898→        "name": "link in 2",
   899→        "links": [
   900→            "010de5af3ced0ae3"
   901→        ],
   902→        "x": 845,
   903→        "y": 400,
   904→        "wires": [
   905→            [
   906→                "9bbd4fade968036d"
   907→            ]
   908→        ]
   909→    },
   910→    {
   911→        "id": "596b390d7aaf69fb",
   912→        "type": "function",
   913→        "z": "cac3a4383120cb57",
   914→        "g": "b7ab5e0cc02b9508",
   915→        "name": "Build Insert SQL",
   916→        "func": "const rows = Array.isArray(msg.payload) ? msg.payload : [];\nconst vals = rows.map(r => `(\n'${r[\"Work Order ID\"]}',\n'${r[\"SKU\"]}',\n${Number(r[\"Target Quantity\"]) || 0},\n${Number(r[\"Theoretical Cycle Time (Seconds)\"]) || 0},\n'PENDING')`).join(',\\n');\n\nmsg.topic = `\nINSERT INTO work_orders (work_order_id, sku, target_qty, cycle_time, status)\nVALUES\n${vals}\nON DUPLICATE KEY UPDATE\n  sku=VALUES(sku),\n  target_qty=VALUES(target_qty),\n  cycle_time=VALUES(cycle_time);\n`;\nreturn msg;",
   917→        "outputs": 1,
   918→        "timeout": 0,
   919→        "noerr": 0,
   920→        "initialize": "",
   921→        "finalize": "",
   922→        "libs": [],
   923→        "x": 1240,
   924→        "y": 360,
   925→        "wires": [
   926→            [
   927→                "f6ad294bc02618c9"
   928→            ]
   929→        ]
   930→    },
   931→    {
   932→        "id": "f6ad294bc02618c9",
   933→        "type": "mysql",
   934→        "z": "cac3a4383120cb57",
   935→        "g": "b7ab5e0cc02b9508",
   936→        "mydb": "00d8ad2b0277f906",
   937→        "name": "mariaDB",
   938→        "x": 1220,
   939→        "y": 400,
   940→        "wires": [
   941→            [
   942→                "578c92e75bf0f266"
   943→            ]
   944→        ]
   945→    },
   946→    {
   947→        "id": "f2bab26e27e2023d",
   948→        "type": "function",
   949→        "z": "cac3a4383120cb57",

<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>

        "id": "9bbd4fade968036d",
        "type": "function",
        "z": "cac3a4383120cb57",
        "g": "b7ab5e0cc02b9508",
        "name": "Work Order buttons",
        "func": "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",
        "outputs": 4,
        "timeout": 0,
        "noerr": 0,
        "initialize": "",
        "finalize": "",
        "libs": [],
        "x": 970,
        "y": 400,
        "wires": [
            [
                "15a6b7b6d8f39fe4"
            ],
            [
                "f6ad294bc02618c9"
            ],
            [
                "f6ad294bc02618c9"
            ],
            [
                "f6ad294bc02618c9"
            ]
        ]
    },
    {
        "id": "010de5af3ced0ae3",
        "type": "link out",
        "z": "cac3a4383120cb57",
        "g": "ec32d0a62eacfb22",
        "name": "link out 2",
        "mode": "link",
        "links": [
            "65ddb4cca6787bde"
        ],
        "x": 305,
        "y": 100,
        "wires": []
    },
    {
        "id": "65ddb4cca6787bde",
        "type": "link in",
        "z": "cac3a4383120cb57",
        "g": "b7ab5e0cc02b9508",
        "name": "link in 2",
        "links": [
            "010de5af3ced0ae3"
        ],
        "x": 845,
        "y": 400,
        "wires": [
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        "id": "596b390d7aaf69fb",
        "type": "function",
        "z": "cac3a4383120cb57",
        "g": "b7ab5e0cc02b9508",
        "name": "Build Insert SQL",
        "func": "const rows = Array.isArray(msg.payload) ? msg.payload : [];\nconst vals = rows.map(r => `(\n'${r[\"Work Order ID\"]}',\n'${r[\"SKU\"]}',\n${Number(r[\"Target Quantity\"]) || 0},\n${Number(r[\"Theoretical Cycle Time (Seconds)\"]) || 0},\n'PENDING')`).join(',\\n');\n\nmsg.topic = `\nINSERT INTO work_orders (work_order_id, sku, target_qty, cycle_time, status)\nVALUES\n${vals}\nON DUPLICATE KEY UPDATE\n  sku=VALUES(sku),\n  target_qty=VALUES(target_qty),\n  cycle_time=VALUES(cycle_time);\n`;\nreturn msg;",
        "outputs": 1,
        "timeout": 0,
        "noerr": 0,
        "initialize": "",
        "finalize": "",
        "libs": [],
        "x": 1240,
        "y": 360,
        "wires": [
            [
                "f6ad294bc02618c9"
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    {
        "id": "f6ad294bc02618c9",
        "type": "mysql",
        "z": "cac3a4383120cb57",
        "g": "b7ab5e0cc02b9508",
        "mydb": "00d8ad2b0277f906",
        "name": "mariaDB",
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    {
        "id": "f2bab26e27e2023d",
        "type": "function",
        "z": "cac3a4383120cb57",


Perfect! I found the "Work Order buttons" function. I can see it handles:- upload-excel
- refresh-work-orders
- start-work-order
- complete-work-order
- scrap-entry
- scrap-skip
- start (enables trackingEnabled)
- stop (disables trackingEnabled)

Currently, the "stop" action just disables tracking but doesn't capture any reason for the stop. According to Issue 4 in the optimization requirements, I need to modify this to prompt for a stop reason and categorize it as planned or unplanned.

Now let me start creating the implementation files. I'll start with the Phase 2 database migration since that's the foundation for the other changes.


Perfect! Now I have a good understanding of the current implementation. Let me start implementing the optimization requirements. I'll begin with creating the Phase 2 database migration script.


TodoWrite

Create phase2_database_migration.sql with missing tables (stop_events, production_sessions, cycle_anomalies)

Creating phase2_database_migration.sql with missing tables

Implement cycle count capping at 100 in machine cycles function

Implement hardware irregularity tracking with anomaly detection

Implementing hardware irregularity tracking

Create phase2_work_order_buttons_function.js with stop reason categorization

Creating work order buttons function with stop categorization

Implement session management logic with unique session IDs

Create startup_recovery_function.js for crash recovery

Update machine cycles function to integrate all new features

Updating machine cycles function with all features


Write

-- ============================================================================
-- PHASE 2: Database Migration for Advanced Optimization Features
-- Database: machine_data
-- Version: 2.0
-- Purpose: Stop categorization, session management, and anomaly tracking
-- ============================================================================

-- ----------------------------------------------------------------------------
-- Table 1: 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 'UUID of the production session',
  stop_time BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds when STOP was clicked',
  resume_time BIGINT COMMENT 'Unix timestamp in milliseconds when RESUME was clicked',
  duration INT COMMENT 'Duration in seconds (calculated on resume)',
  reason_category VARCHAR(20) NOT NULL COMMENT 'planned or unplanned',
  reason_detail VARCHAR(100) NOT NULL COMMENT 'Specific reason selected by operator',
  affects_availability BOOLEAN NOT NULL COMMENT '0 for planned stops, 1 for unplanned stops',
  notes TEXT COMMENT 'Optional operator notes',
  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),
  INDEX idx_affects_availability (affects_availability)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Stop events with categorization for accurate downtime tracking';

-- ----------------------------------------------------------------------------
-- Table 2: 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 generated on each START/RESUME',
  work_order_id VARCHAR(255),
  start_time BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds',
  end_time BIGINT COMMENT 'Unix timestamp when session ended',
  duration INT COMMENT 'Duration in seconds (calculated on end)',
  cycles_completed INT DEFAULT 0,
  reason_for_start VARCHAR(50) NOT NULL COMMENT 'initial_start, resume_after_planned, resume_after_unplanned',
  reason_for_end VARCHAR(50) COMMENT 'planned_stop, unplanned_stop, work_order_complete, null if still running',
  operating_time DECIMAL(10,2) DEFAULT 0 COMMENT 'Seconds machine was running in state 1',
  downtime DECIMAL(10,2) DEFAULT 0 COMMENT 'Seconds machine was stopped in state 0',
  created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,
  updated_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,

  INDEX idx_session_id (session_id),
  INDEX idx_work_order (work_order_id),
  INDEX idx_start_time (start_time),
  INDEX idx_reason_start (reason_for_start)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4 COMMENT='Production sessions for pattern analysis';

-- ----------------------------------------------------------------------------
-- Table 3: Cycle Anomalies (Issue 3 - Hardware Irregularity Handling)
-- ----------------------------------------------------------------------------
CREATE TABLE IF NOT EXISTS cycle_anomalies (
  id INT AUTO_INCREMENT PRIMARY KEY,
  work_order_id VARCHAR(255),
  session_id VARCHAR(100) COMMENT 'UUID of the production session',
  cycle_number INT NOT NULL,
  expected_time DECIMAL(10,2) COMMENT 'Expected cycle time based on rolling average',
  actual_time DECIMAL(10,2) NOT NULL COMMENT 'Actual cycle time measured',
  deviation_percent DECIMAL(5,2) NOT NULL COMMENT 'Percentage deviation from expected',
  anomaly_type VARCHAR(50) NOT NULL COMMENT 'faster_than_average, slower_than_average',
  timestamp BIGINT NOT NULL COMMENT 'Unix timestamp in milliseconds',
  notes TEXT COMMENT 'System-generated or operator 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 irregular cycle times for analysis';

-- ----------------------------------------------------------------------------
-- Table 4: Add Session Tracking Columns to work_orders Table
-- ----------------------------------------------------------------------------
-- Add total_sessions column
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 AFTER scrap_count',
  'SELECT "Column total_sessions already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- Add total_operating_time column
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 AFTER total_sessions',
  'SELECT "Column total_operating_time already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- Add total_downtime column
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 AFTER total_operating_time',
  'SELECT "Column total_downtime already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- Add avg_session_duration column
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 AFTER total_downtime',
  'SELECT "Column avg_session_duration already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- ----------------------------------------------------------------------------
-- Table 5: Add current_session_id to session_state Table
-- ----------------------------------------------------------------------------
SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'session_state'
  AND COLUMN_NAME = 'current_session_id';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE session_state ADD COLUMN current_session_id VARCHAR(100) AFTER session_key',
  'SELECT "Column current_session_id already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- Add pending_stop_time to track when STOP was clicked (before reason is given)
SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'session_state'
  AND COLUMN_NAME = 'pending_stop_time';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE session_state ADD COLUMN pending_stop_time BIGINT AFTER current_session_id',
  'SELECT "Column pending_stop_time already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- Add last_stop_category to track most recent stop type
SET @col_exists = 0;
SELECT COUNT(*) INTO @col_exists
FROM INFORMATION_SCHEMA.COLUMNS
WHERE TABLE_SCHEMA = 'machine_data'
  AND TABLE_NAME = 'session_state'
  AND COLUMN_NAME = 'last_stop_category';

SET @query = IF(@col_exists = 0,
  'ALTER TABLE session_state ADD COLUMN last_stop_category VARCHAR(20) AFTER pending_stop_time',
  'SELECT "Column last_stop_category already exists" AS Info');
PREPARE stmt FROM @query;
EXECUTE stmt;
DEALLOCATE PREPARE stmt;

-- ----------------------------------------------------------------------------
-- Verification Queries (Run these to confirm migration success)
-- ----------------------------------------------------------------------------
-- 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 WHERE Field LIKE '%session%' OR Field LIKE '%operating%' OR Field LIKE '%downtime%';
-- SHOW COLUMNS FROM session_state WHERE Field = 'current_session_id' OR Field = 'pending_stop_time' OR Field = 'last_stop_category';

-- ============================================================================
-- END OF PHASE 2 MIGRATION
-- ============================================================================


Error: The user doesn't want to proceed with this tool use. The tool use was rejected (eg. if it was a file edit, the new_string was NOT written to the file). STOP what you are doing and wait for the user to tell you how to proceed.


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