ultimatepos/Modules/ShopFloor/Services/OeeCalculationService.php

<?php

namespace Modules\ShopFloor\Services;

use Carbon\Carbon;
use Modules\ShopFloor\Models\DowntimeEvent;
use Modules\ShopFloor\Models\OeeSnapshot;
use Modules\ShopFloor\Models\ProductionEvent;
use Modules\ShopFloor\Models\WorkCenter;

class OeeCalculationService
{
    /**
     * OEE = Availability × Performance × Quality
     */
    public function calculateForWorkCenter(int $businessId, int $workCenterId, Carbon $date): OeeSnapshot
    {
        $workCenter = WorkCenter::forBusiness($businessId)->findOrFail($workCenterId);
        $start = $date->copy()->startOfDay();
        $end = $date->copy()->endOfDay();

        $plannedMinutes = $this->plannedMinutes($date);
        $downtimeMinutes = $this->downtimeMinutes($businessId, $workCenterId, $start, $end);
        $runMinutes = max(0, $plannedMinutes - $downtimeMinutes);

        $availability = $plannedMinutes > 0
            ? round(($runMinutes / $plannedMinutes) * 100, 4)
            : 0;

        $output = $this->outputTotals($businessId, $workCenterId, $start, $end);
        $idealOutput = $this->idealOutput($workCenter, $runMinutes);

        $performance = $idealOutput > 0
            ? round(min(100, ($output['actual'] / $idealOutput) * 100), 4)
            : 0;

        $quality = $output['actual'] > 0
            ? round(($output['good'] / $output['actual']) * 100, 4)
            : 0;

        $oee = round(($availability / 100) * ($performance / 100) * ($quality / 100) * 100, 4);

        return OeeSnapshot::updateOrCreate(
            [
                'business_id' => $businessId,
                'work_center_id' => $workCenterId,
                'snapshot_date' => $date->toDateString(),
            ],
            [
                'availability_pct' => $availability,
                'performance_pct' => $performance,
                'quality_pct' => $quality,
                'oee_pct' => $oee,
                'planned_minutes' => $plannedMinutes,
                'run_minutes' => $runMinutes,
                'downtime_minutes' => $downtimeMinutes,
                'ideal_output' => $idealOutput,
                'actual_output' => $output['actual'],
                'good_output' => $output['good'],
            ]
        );
    }

    public function calculateAllForDate(int $businessId, Carbon $date): array
    {
        $snapshots = [];
        $workCenters = WorkCenter::forBusiness($businessId)->where('status', 'active')->get();

        foreach ($workCenters as $workCenter) {
            $snapshots[] = $this->calculateForWorkCenter($businessId, $workCenter->id, $date);
        }

        return $snapshots;
    }

    public function dashboardStats(int $businessId): array
    {
        $today = now()->toDateString();
        $snapshots = OeeSnapshot::forBusiness($businessId)
            ->where('snapshot_date', $today)
            ->get();

        $avgOee = $snapshots->avg('oee_pct') ?? 0;
        $activeCenters = WorkCenter::forBusiness($businessId)->where('status', 'active')->count();
        $openDowntime = DowntimeEvent::forBusiness($businessId)->whereNull('ended_at')->count();
        $todayEvents = ProductionEvent::forBusiness($businessId)
            ->whereDate('recorded_at', $today)
            ->count();

        return [
            'avg_oee' => round($avgOee, 2),
            'active_work_centers' => $activeCenters,
            'open_downtime' => $openDowntime,
            'today_events' => $todayEvents,
        ];
    }

    protected function plannedMinutes(Carbon $date): int
    {
        return 8 * 60;
    }

    protected function downtimeMinutes(int $businessId, int $workCenterId, Carbon $start, Carbon $end): int
    {
        $events = DowntimeEvent::forBusiness($businessId)
            ->where('work_center_id', $workCenterId)
            ->where('started_at', '<=', $end)
            ->where(function ($q) use ($start) {
                $q->whereNull('ended_at')->orWhere('ended_at', '>=', $start);
            })
            ->get();

        $total = 0;
        foreach ($events as $event) {
            $eventStart = $event->started_at->greaterThan($start) ? $event->started_at : $start;
            $eventEnd = $event->ended_at ? ($event->ended_at->lessThan($end) ? $event->ended_at : $end) : $end;
            $total += max(0, $eventStart->diffInMinutes($eventEnd));
        }

        return (int) $total;
    }

    protected function outputTotals(int $businessId, int $workCenterId, Carbon $start, Carbon $end): array
    {
        $events = ProductionEvent::forBusiness($businessId)
            ->where('work_center_id', $workCenterId)
            ->whereBetween('recorded_at', [$start, $end])
            ->whereIn('event_type', ['complete', 'scrap'])
            ->get();

        $actual = (float) $events->sum('quantity');
        $good = (float) $events->sum('good_quantity');

        if ($actual <= 0) {
            $good = (float) $events->where('event_type', 'complete')->sum('quantity');
            $actual = $good + (float) $events->sum('scrap_quantity');
        }

        return ['actual' => $actual, 'good' => $good];
    }

    protected function idealOutput(WorkCenter $workCenter, int $runMinutes): float
    {
        $capacityPerHour = (float) $workCenter->capacity_per_hour;

        if ($capacityPerHour <= 0 || $runMinutes <= 0) {
            return 0;
        }

        return round(($capacityPerHour / 60) * $runMinutes, 4);
    }
}