ultimatepos/Modules/IndustrialEngineering/Services/DigitalThreadAnalyticsService.php

<?php

namespace Modules\IndustrialEngineering\Services;

use Modules\IndustrialEngineering\Models\Bom;
use Modules\IndustrialEngineering\Models\EngineeringChangeOrder;
use Modules\IndustrialEngineering\Models\ItemMaster;
use Modules\IndustrialEngineering\Models\LineRevision;
use Modules\IndustrialEngineering\Models\LineTemplate;
use Modules\IndustrialEngineering\Models\MrpRun;
use Modules\IndustrialEngineering\Models\ProductPlatform;
use Modules\IndustrialEngineering\Models\ReleasePackage;
use Modules\IndustrialEngineering\Models\ResearchProject;
use Modules\IndustrialEngineering\Support\CmmsAvailability;

/**
 * Enterprise PLM analytics — digital thread health across ERP, CMMS, quality, time, R&D.
 */
class DigitalThreadAnalyticsService
{
    public function __construct(
        protected ConnectionGateService $connectionGate,
        protected LiveBomCostingService $liveCosting
    ) {
    }

    public function dashboard(int $businessId): array
    {
        $items = ItemMaster::forBusiness($businessId)->get(['id', 'variation_id', 'product_id']);
        $erpLinked = $items->filter(fn ($i) => $i->variation_id || $i->product_id)->count();
        $itemTotal = max(1, $items->count());

        $lines = LineTemplate::forBusiness($businessId)->productionLines()->get(['id', 'maintenance_equipment_id', 'cmms_synced_at']);
        $cmmsLinked = CmmsAvailability::isReady()
            ? $lines->filter(fn ($l) => $l->maintenance_equipment_id)->count()
            : 0;
        $lineTotal = max(1, $lines->count());

        $mboms = Bom::forBusiness($businessId)->where('bom_type', 'mbom')->with('lines.itemMaster')->get();
        $gateScores = [];
        $totalShortageValue = 0;
        foreach ($mboms as $mbom) {
            $gate = $this->connectionGate->assessBom($mbom, 1);
            $gateScores[] = $gate['stats']['erp_linked'] / max(1, $gate['stats']['total_leaves']);
            $totalShortageValue += $gate['analysis']['totals']['shortage_value'] ?? 0;
        }
        $bomHealth = $gateScores ? round(array_sum($gateScores) / count($gateScores) * 100) : 100;

        return [
            'erp_link_pct' => round($erpLinked / $itemTotal * 100),
            'cmms_link_pct' => CmmsAvailability::isReady() ? round($cmmsLinked / $lineTotal * 100) : 0,
            'cmms_available' => CmmsAvailability::isReady(),
            'bom_integration_health' => $bomHealth,
            'total_shortage_value' => $totalShortageValue,
            'open_ecos' => EngineeringChangeOrder::forBusiness($businessId)->whereIn('status', ['draft', 'review'])->count(),
            'draft_revisions' => LineRevision::forBusiness($businessId)->where('status', 'draft')->count(),
            'pending_releases' => ReleasePackage::forBusiness($businessId)->whereIn('status', ['draft', 'pending_approval'])->count(),
            'active_research' => ResearchProject::forBusiness($businessId)->where('status', 'active')->count(),
            'mrp_runs_month' => MrpRun::forBusiness($businessId)->where('created_at', '>=', now()->startOfMonth())->count(),
            'products' => ProductPlatform::forBusiness($businessId)->count(),
            'production_lines' => $lineTotal,
            'recent_ecos' => EngineeringChangeOrder::forBusiness($businessId)
                ->with(['lineRevision', 'requestedBy'])
                ->latest('id')
                ->limit(5)
                ->get(),
            'lines_needing_attention' => $this->linesNeedingAttention($businessId),
        ];
    }

    protected function linesNeedingAttention(int $businessId): array
    {
        $result = [];
        $lines = LineTemplate::forBusiness($businessId)
            ->productionLines()
            ->with(['revisions.boms', 'productPlatform'])
            ->get();

        foreach ($lines as $line) {
            $assessment = $this->assessLine($line);
            if ($assessment['status'] !== 'ok') {
                $result[] = $assessment;
            }
        }

        return array_slice($result, 0, 8);
    }

    public function assessLine(LineTemplate $line): array
    {
        $revision = $line->revisions->sortByDesc('id')->first();
        $mbom = $revision?->boms->where('bom_type', 'mbom')->first();

        if (! $mbom) {
            return [
                'line' => $line,
                'status' => 'no_mbom',
                'issues' => [__('industrialengineering::lang.issue_no_mbom')],
                'can_run_mrp' => false,
                'erp_unlinked' => 0,
            ];
        }

        $gate = $this->connectionGate->assessBom($mbom, 1);
        $issues = array_merge($gate['blockers'], $gate['warnings']);
        $cmmsMissing = CmmsAvailability::isReady() && ! $line->maintenance_equipment_id;
        if ($cmmsMissing) {
            $issues[] = __('industrialengineering::lang.issue_no_cmms');
        }

        $status = 'ok';
        if (! empty($gate['blockers'])) {
            $status = 'empty_bom';
        } elseif ($gate['stats']['unlinked'] > 0) {
            $status = 'erp_pending';
        } elseif ($cmmsMissing) {
            $status = 'cmms_pending';
        }

        return [
            'line' => $line->fresh(),
            'status' => $status,
            'issues' => array_slice($issues, 0, 5),
            'can_run_mrp' => (bool) ($gate['can_run_mrp'] ?? false),
            'erp_unlinked' => (int) ($gate['stats']['unlinked'] ?? 0),
            'cmms_linked' => (bool) $line->maintenance_equipment_id,
        ];
    }
}