ultimatepos/Modules/AdvancedPlanning/Services/SopCycleService.php

<?php

namespace Modules\AdvancedPlanning\Services;

use App\Transaction;
use Illuminate\Support\Carbon;
use Illuminate\Support\Facades\DB;
use Modules\AdvancedPlanning\Models\CapacityResource;
use Modules\AdvancedPlanning\Models\ScheduleRun;
use Modules\AdvancedPlanning\Models\SopCycle;

class SopCycleService
{
    public function __construct(
        protected IntegrationBridgeService $bridge,
        protected FiniteCapacitySchedulerService $scheduler
    ) {
    }

    public function createCycle(int $businessId, Carbon $cycleMonth, ?int $userId = null): SopCycle
    {
        $monthStart = $cycleMonth->copy()->startOfMonth();

        return SopCycle::firstOrCreate(
            [
                'business_id' => $businessId,
                'cycle_month' => $monthStart->toDateString(),
            ],
            [
                'status' => 'draft',
                'created_by' => $userId ?? auth()->id(),
            ]
        );
    }

    /**
     * Build or refresh demand, supply, financial plans and gap analysis.
     */
    public function refreshPlans(SopCycle $cycle): SopCycle
    {
        return DB::transaction(function () use ($cycle) {
            $businessId = (int) $cycle->business_id;
            $monthStart = Carbon::parse($cycle->cycle_month)->startOfMonth();
            $monthEnd = $monthStart->copy()->endOfMonth();

            $demandPlan = $this->buildDemandPlan($businessId, $monthStart, $monthEnd);
            $supplyPlan = $this->buildSupplyPlan($businessId, $monthStart, $monthEnd);
            $financialPlan = $this->buildFinancialPlan($demandPlan, $supplyPlan);
            $gaps = $this->calculateGaps($demandPlan, $supplyPlan, $financialPlan);

            $cycle->update([
                'demand_plan' => $demandPlan,
                'supply_plan' => $supplyPlan,
                'financial_plan' => $financialPlan,
                'gaps' => $gaps,
            ]);

            return $cycle->fresh();
        });
    }

    public function advanceStatus(SopCycle $cycle, string $newStatus): SopCycle
    {
        $allowed = [
            'draft' => ['consensus'],
            'consensus' => ['approved', 'draft'],
            'approved' => ['draft'],
        ];

        $current = $cycle->status;
        if (! in_array($newStatus, $allowed[$current] ?? [], true)) {
            throw new \InvalidArgumentException(__('advancedplanning::lang.invalid_status_transition', [
                'from' => $current,
                'to' => $newStatus,
            ]));
        }

        $cycle->update(['status' => $newStatus]);

        return $cycle->fresh();
    }

    /**
     * @return array<string, mixed>
     */
    protected function buildDemandPlan(int $businessId, Carbon $monthStart, Carbon $monthEnd): array
    {
        $salesLines = Transaction::where('business_id', $businessId)
            ->where('type', 'sell')
            ->where('status', 'final')
            ->whereBetween('transaction_date', [$monthStart, $monthEnd])
            ->with(['sell_lines' => fn ($q) => $q->select('id', 'transaction_id', 'product_id', 'variation_id', 'quantity')])
            ->get();

        $byProduct = [];
        foreach ($salesLines as $txn) {
            foreach ($txn->sell_lines ?? [] as $line) {
                $key = (string) ($line->variation_id ?: $line->product_id);
                if (! isset($byProduct[$key])) {
                    $byProduct[$key] = [
                        'product_id' => $line->product_id,
                        'variation_id' => $line->variation_id,
                        'quantity' => 0,
                    ];
                }
                $byProduct[$key]['quantity'] += (float) $line->quantity;
            }
        }

        $mrpDemand = $this->bridge->loadMrpDemandForPeriod($businessId, $monthStart, $monthEnd);

        return [
            'period' => [
                'start' => $monthStart->toDateString(),
                'end' => $monthEnd->toDateString(),
            ],
            'sales_history' => array_values($byProduct),
            'mrp_demand' => $mrpDemand,
            'total_demand_units' => collect($byProduct)->sum('quantity') + collect($mrpDemand)->sum('quantity'),
            'generated_at' => now()->toIso8601String(),
        ];
    }

    /**
     * @return array<string, mixed>
     */
    protected function buildSupplyPlan(int $businessId, Carbon $monthStart, Carbon $monthEnd): array
    {
        $resources = CapacityResource::forBusiness($businessId)
            ->where('is_active', true)
            ->get();

        $days = $monthStart->diffInDays($monthEnd) + 1;
        $capacityByResource = $resources->map(fn ($r) => [
            'resource_id' => $r->id,
            'name' => $r->name,
            'type' => $r->resource_type,
            'available_hours' => round((float) $r->effectiveDailyHours() * $days, 2),
        ])->values()->all();

        $scheduledRuns = ScheduleRun::forBusiness($businessId)
            ->where('status', 'completed')
            ->where('horizon_start', '<=', $monthEnd)
            ->where('horizon_end', '>=', $monthStart)
            ->with('scheduledOperations')
            ->latest('id')
            ->limit(5)
            ->get();

        $scheduledHours = $scheduledRuns->flatMap(fn ($run) => $run->scheduledOperations)
            ->sum(fn ($op) => (float) $op->duration_hours);

        $workOrders = $this->bridge->loadSchedulableWorkOrders($businessId, $monthStart, $monthEnd);

        return [
            'capacity_resources' => $capacityByResource,
            'total_available_hours' => collect($capacityByResource)->sum('available_hours'),
            'scheduled_hours' => round($scheduledHours, 2),
            'open_work_orders' => $workOrders->count(),
            'open_work_order_qty' => $workOrders->sum('planned_quantity'),
            'generated_at' => now()->toIso8601String(),
        ];
    }

    /**
     * @param  array<string, mixed>  $demand
     * @param  array<string, mixed>  $supply
     * @return array<string, mixed>
     */
    protected function buildFinancialPlan(array $demand, array $supply): array
    {
        $demandUnits = (float) ($demand['total_demand_units'] ?? 0);
        $supplyHours = (float) ($supply['total_available_hours'] ?? 0);
        $scheduledHours = (float) ($supply['scheduled_hours'] ?? 0);

        $avgRevenuePerUnit = 100; // placeholder; extend with product pricing integration
        $avgCostPerHour = 50;

        return [
            'projected_revenue' => round($demandUnits * $avgRevenuePerUnit, 2),
            'projected_supply_cost' => round($scheduledHours * $avgCostPerHour, 2),
            'capacity_cost_ceiling' => round($supplyHours * $avgCostPerHour, 2),
            'margin_estimate' => round(($demandUnits * $avgRevenuePerUnit) - ($scheduledHours * $avgCostPerHour), 2),
            'generated_at' => now()->toIso8601String(),
        ];
    }

    /**
     * @param  array<string, mixed>  $demand
     * @param  array<string, mixed>  $supply
     * @param  array<string, mixed>  $financial
     * @return array<string, mixed>
     */
    protected function calculateGaps(array $demand, array $supply, array $financial): array
    {
        $demandUnits = (float) ($demand['total_demand_units'] ?? 0);
        $openWoQty = (float) ($supply['open_work_order_qty'] ?? 0);
        $capacityHours = (float) ($supply['total_available_hours'] ?? 0);
        $scheduledHours = (float) ($supply['scheduled_hours'] ?? 0);

        $demandSupplyGap = $demandUnits - $openWoQty;
        $capacityGap = $capacityHours - $scheduledHours;

        return [
            'demand_vs_supply_units' => round($demandSupplyGap, 2),
            'demand_exceeds_supply' => $demandSupplyGap > 0,
            'capacity_vs_scheduled_hours' => round($capacityGap, 2),
            'capacity_shortfall' => $capacityGap < 0,
            'financial_margin' => $financial['margin_estimate'] ?? 0,
            'recommendations' => $this->buildRecommendations($demandSupplyGap, $capacityGap),
            'generated_at' => now()->toIso8601String(),
        ];
    }

    /**
     * @return array<int, string>
     */
    protected function buildRecommendations(float $demandGap, float $capacityGap): array
    {
        $recs = [];

        if ($demandGap > 0) {
            $recs[] = __('advancedplanning::lang.rec_increase_production', ['units' => round($demandGap, 0)]);
        } elseif ($demandGap < -10) {
            $recs[] = __('advancedplanning::lang.rec_reduce_inventory');
        }

        if ($capacityGap < 0) {
            $recs[] = __('advancedplanning::lang.rec_add_capacity', ['hours' => round(abs($capacityGap), 1)]);
        }

        if (empty($recs)) {
            $recs[] = __('advancedplanning::lang.rec_balanced');
        }

        return $recs;
    }
}