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manufacturing and gantt

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This commit is contained in:
jason
2026-03-15 12:11:46 -05:00
parent a9d31730f8
commit 16582d3cea
26 changed files with 1614 additions and 75 deletions
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253
server/src/modules/manufacturing/service.ts
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@@ -1,9 +1,12 @@
import type {
ManufacturingStationDto,
ManufacturingStationInput,
ManufacturingItemOptionDto,
ManufacturingProjectOptionDto,
WorkOrderCompletionInput,
WorkOrderDetailDto,
WorkOrderInput,
WorkOrderOperationDto,
WorkOrderMaterialIssueInput,
WorkOrderStatus,
WorkOrderSummaryDto,
@@ -13,6 +16,17 @@ import { prisma } from "../../lib/prisma.js";
const workOrderModel = (prisma as any).workOrder;
type StationRecord = {
id: string;
code: string;
name: string;
description: string;
queueDays: number;
isActive: boolean;
createdAt: Date;
updatedAt: Date;
};
type WorkOrderRecord = {
id: string;
workOrderNumber: string;
@@ -29,6 +43,19 @@ type WorkOrderRecord = {
name: string;
type: string;
unitOfMeasure: string;
operations: Array<{
setupMinutes: number;
runMinutesPerUnit: number;
moveMinutes: number;
position: number;
notes: string;
station: {
id: string;
code: string;
name: string;
queueDays: number;
};
}>;
bomLines: Array<{
quantity: number;
unitOfMeasure: string;
@@ -57,6 +84,22 @@ type WorkOrderRecord = {
code: string;
name: string;
};
operations: Array<{
id: string;
sequence: number;
setupMinutes: number;
runMinutesPerUnit: number;
moveMinutes: number;
plannedMinutes: number;
plannedStart: Date;
plannedEnd: Date;
notes: string;
station: {
id: string;
code: string;
name: string;
};
}>;
materialIssues: Array<{
id: string;
quantity: number;
@@ -94,10 +137,36 @@ type WorkOrderRecord = {
}>;
};
function mapStation(record: StationRecord): ManufacturingStationDto {
return {
id: record.id,
code: record.code,
name: record.name,
description: record.description,
queueDays: record.queueDays,
isActive: record.isActive,
createdAt: record.createdAt.toISOString(),
updatedAt: record.updatedAt.toISOString(),
};
}
function buildInclude() {
return {
item: {
include: {
operations: {
include: {
station: {
select: {
id: true,
code: true,
name: true,
queueDays: true,
},
},
},
orderBy: [{ position: "asc" }, { createdAt: "asc" }],
},
bomLines: {
include: {
componentItem: {
@@ -135,6 +204,18 @@ function buildInclude() {
name: true,
},
},
operations: {
include: {
station: {
select: {
id: true,
code: true,
name: true,
},
},
},
orderBy: [{ sequence: "asc" }],
},
materialIssues: {
include: {
componentItem: {
@@ -205,6 +286,8 @@ function mapSummary(record: WorkOrderRecord): WorkOrderSummaryDto {
locationId: record.location.id,
locationCode: record.location.code,
locationName: record.location.name,
operationCount: record.operations.length,
totalPlannedMinutes: record.operations.reduce((sum, operation) => sum + operation.plannedMinutes, 0),
updatedAt: record.updatedAt.toISOString(),
};
}
@@ -224,6 +307,20 @@ function mapDetail(record: WorkOrderRecord): WorkOrderDetailDto {
itemUnitOfMeasure: record.item.unitOfMeasure,
projectCustomerName: record.project?.customer.name ?? null,
dueQuantity: record.quantity - record.completedQuantity,
operations: record.operations.map((operation): WorkOrderOperationDto => ({
id: operation.id,
stationId: operation.station.id,
stationCode: operation.station.code,
stationName: operation.station.name,
sequence: operation.sequence,
setupMinutes: operation.setupMinutes,
runMinutesPerUnit: operation.runMinutesPerUnit,
moveMinutes: operation.moveMinutes,
plannedMinutes: operation.plannedMinutes,
plannedStart: operation.plannedStart.toISOString(),
plannedEnd: operation.plannedEnd.toISOString(),
notes: operation.notes,
})),
materialRequirements: record.item.bomLines.map((line) => {
const requiredQuantity = line.quantity * record.quantity;
const issuedQuantity = issuedByComponent.get(line.componentItem.id) ?? 0;
@@ -265,6 +362,107 @@ function mapDetail(record: WorkOrderRecord): WorkOrderDetailDto {
};
}
function addMinutes(value: Date, minutes: number) {
return new Date(value.getTime() + minutes * 60 * 1000);
}
function buildWorkOrderOperationPlan(
itemOperations: WorkOrderRecord["item"]["operations"],
quantity: number,
dueDate: Date | null,
fallbackStart: Date
) {
if (itemOperations.length === 0) {
return [];
}
const operationDurations = itemOperations.map((operation) => {
const plannedMinutes = Math.max(operation.setupMinutes + operation.runMinutesPerUnit * quantity + operation.moveMinutes + operation.station.queueDays * 8 * 60, 1);
return {
stationId: operation.station.id,
sequence: operation.position,
setupMinutes: operation.setupMinutes,
runMinutesPerUnit: operation.runMinutesPerUnit,
moveMinutes: operation.moveMinutes,
plannedMinutes,
notes: operation.notes,
};
});
if (dueDate) {
let nextEnd = new Date(dueDate);
return operationDurations
.slice()
.sort((left, right) => right.sequence - left.sequence)
.map((operation) => {
const plannedStart = addMinutes(nextEnd, -operation.plannedMinutes);
const planned = {
...operation,
plannedStart,
plannedEnd: nextEnd,
};
nextEnd = plannedStart;
return planned;
})
.reverse();
}
let nextStart = new Date(fallbackStart);
return operationDurations.map((operation) => {
const plannedEnd = addMinutes(nextStart, operation.plannedMinutes);
const planned = {
...operation,
plannedStart: nextStart,
plannedEnd,
};
nextStart = plannedEnd;
return planned;
});
}
async function regenerateWorkOrderOperations(workOrderId: string) {
const workOrder = await workOrderModel.findUnique({
where: { id: workOrderId },
include: buildInclude(),
});
if (!workOrder) {
return;
}
const plan = buildWorkOrderOperationPlan(
(workOrder as WorkOrderRecord).item.operations,
workOrder.quantity,
workOrder.dueDate,
workOrder.createdAt
);
await prisma.workOrderOperation.deleteMany({
where: {
workOrderId,
},
});
if (plan.length === 0) {
return;
}
await prisma.workOrderOperation.createMany({
data: plan.map((operation) => ({
workOrderId,
stationId: operation.stationId,
sequence: operation.sequence,
setupMinutes: operation.setupMinutes,
runMinutesPerUnit: operation.runMinutesPerUnit,
moveMinutes: operation.moveMinutes,
plannedMinutes: operation.plannedMinutes,
plannedStart: operation.plannedStart,
plannedEnd: operation.plannedEnd,
notes: operation.notes,
})),
});
}
async function nextWorkOrderNumber() {
const next = (await workOrderModel.count()) + 1;
return `WO-${String(next).padStart(5, "0")}`;
@@ -295,6 +493,11 @@ async function validateWorkOrderInput(payload: WorkOrderInput) {
id: true,
type: true,
status: true,
_count: {
select: {
operations: true,
},
},
},
});
@@ -310,6 +513,10 @@ async function validateWorkOrderInput(payload: WorkOrderInput) {
return { ok: false as const, reason: "Work orders can only be created for assembly or manufactured items." };
}
if (item._count.operations === 0) {
return { ok: false as const, reason: "Build item must have at least one station operation before a work order can be created." };
}
if (payload.projectId) {
const project = await prisma.project.findUnique({
where: { id: payload.projectId },
@@ -350,11 +557,51 @@ export async function listManufacturingItemOptions(): Promise<ManufacturingItemO
name: true,
type: true,
unitOfMeasure: true,
operations: {
select: {
setupMinutes: true,
runMinutesPerUnit: true,
moveMinutes: true,
},
},
},
orderBy: [{ sku: "asc" }],
});
return items;
return items.map((item) => ({
id: item.id,
sku: item.sku,
name: item.name,
type: item.type,
unitOfMeasure: item.unitOfMeasure,
operationCount: item.operations.length,
totalEstimatedMinutesPerUnit: item.operations.reduce(
(sum, operation) => sum + operation.setupMinutes + operation.runMinutesPerUnit + operation.moveMinutes,
0
),
}));
}
export async function listManufacturingStations(): Promise<ManufacturingStationDto[]> {
const stations = await prisma.manufacturingStation.findMany({
orderBy: [{ code: "asc" }],
});
return stations.map(mapStation);
}
export async function createManufacturingStation(payload: ManufacturingStationInput) {
const station = await prisma.manufacturingStation.create({
data: {
code: payload.code.trim(),
name: payload.name.trim(),
description: payload.description,
queueDays: payload.queueDays,
isActive: payload.isActive,
},
});
return mapStation(station);
}
export async function listManufacturingProjectOptions(): Promise<ManufacturingProjectOptionDto[]> {
@@ -448,6 +695,8 @@ export async function createWorkOrder(payload: WorkOrderInput) {
},
});
await regenerateWorkOrderOperations(created.id);
const workOrder = await getWorkOrderById(created.id);
return workOrder ? { ok: true as const, workOrder } : { ok: false as const, reason: "Unable to load saved work order." };
}
@@ -488,6 +737,8 @@ export async function updateWorkOrder(workOrderId: string, payload: WorkOrderInp
},
});
await regenerateWorkOrderOperations(workOrderId);
const workOrder = await getWorkOrderById(workOrderId);
return workOrder ? { ok: true as const, workOrder } : { ok: false as const, reason: "Unable to load saved work order." };
}