Initial commit of SOP Monitoring Dashboard

api/.dockerignore

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+node_modules
+dist
+.env

api/Dockerfile

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+FROM node:20-alpine
+WORKDIR /app
+COPY package*.json ./
+RUN npm install
+RUN npm install -g pm2
+COPY . .
+CMD ["pm2-runtime", "ecosystem.config.js"]

api/ecosystem.config.js

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+module.exports = {
+  apps: [{
+    name: "sop-api",
+    script: "./index.js",
+    instances: "max",
+    exec_mode: "cluster",
+    env: {
+      NODE_ENV: "development",
+    },
+    env_production: {
+      NODE_ENV: "production",
+    }
+  }]
+}

api/index.js

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+const express = require('express');
+const { Pool } = require('pg');
+const cors = require('cors');
+require('dotenv').config();
+
+const app = express();
+app.use(cors());
+app.use(express.json());
+
+const pool = new Pool({
+  user: process.env.DB_USER || 'admin',
+  host: process.env.DB_HOST || 'localhost',
+  database: process.env.DB_NAME || 'sop_monitoring',
+  password: process.env.DB_PASS || 'password',
+  port: process.env.DB_PORT || 5432,
+});
+
+app.get('/api/changeovers', async (req, res) => {
+  try {
+    const result = await pool.query('SELECT DISTINCT changeover_id, changeover_date FROM events ORDER BY changeover_date DESC');
+    res.json(result.rows);
+  } catch (err) {
+    console.error(err);
+    res.status(500).json({ error: 'Internal Server Error' });
+  }
+});
+
+app.get('/api/events', async (req, res) => {
+  try {
+    const { camera_zone, state, changeover_id } = req.query;
+    let query = 'SELECT * FROM events WHERE 1=1';
+    let values = [];
+    
+    if (camera_zone) {
+      values.push(camera_zone);
+      query += ` AND camera_zone = $${values.length}`;
+    }
+    if (state) {
+      values.push(state);
+      query += ` AND state = $${values.length}`;
+    }
+    if (changeover_id) {
+      values.push(changeover_id);
+      query += ` AND changeover_id = $${values.length}`;
+    }
+    query += ' ORDER BY start_time ASC';
+    
+    const result = await pool.query(query, values);
+    res.json(result.rows);
+  } catch (err) {
+    console.error(err);
+    res.status(500).json({ error: 'Internal Server Error' });
+  }
+});
+
+app.get('/api/analytics/idle-time', async (req, res) => {
+  try {
+    const { changeover_id } = req.query;
+    let filter = changeover_id ? `AND changeover_id = $1` : '';
+    let params = changeover_id ? [changeover_id] : [];
+
+    // 1. CO Idle Time: Sum of all events marked Waste in CO
+    const coResult = await pool.query(`
+      SELECT SUM(state_duration_seconds) as total_idle
+      FROM events
+      WHERE camera_zone = 'CO' AND state = 'Waste' ${filter}
+    `, params);
+    const coIdle = parseInt(coResult.rows[0].total_idle || 0);
+
+    // 2. Mill Idle Time: Sum of Waste in Mill + specific Mill gap/idle
+    const millResult = await pool.query(`
+      SELECT SUM(state_duration_seconds) as total_idle
+      FROM events
+      WHERE camera_zone = 'Mill' AND (state = 'Waste' OR state = 'Idle') ${filter}
+    `, params);
+    const millIdle = parseInt(millResult.rows[0].total_idle || 0);
+
+    // 3. Conveyor Idle Time: Sum of No Load (Waste) + Load waiting before start
+    const conveyorResult = await pool.query(`
+      SELECT SUM(state_duration_seconds) as total_idle
+      FROM events
+      WHERE camera_zone = 'Conveyor' AND (state = 'Waste' OR state = 'Load waiting') ${filter}
+    `, params);
+    const conveyorIdle = parseInt(conveyorResult.rows[0].total_idle || 0);
+
+    res.json({
+      CO: coIdle,
+      Mill: millIdle,
+      Conveyor: conveyorIdle
+    });
+  } catch (err) {
+    console.error(err);
+    res.status(500).json({ error: 'Internal Server Error' });
+  }
+});
+
+app.get('/api/analytics/bottlenecks', async (req, res) => {
+  try {
+    const { changeover_id } = req.query;
+    let filter = changeover_id ? `AND changeover_id = $1` : '';
+    let params = changeover_id ? [changeover_id] : [];
+
+    const result = await pool.query(`
+      SELECT event_description, camera_zone, SUM(state_duration_seconds) as total_duration, COUNT(*) as occurrences
+      FROM events
+      WHERE state IN ('Waste', 'Idle', 'Load waiting') ${filter}
+      GROUP BY event_description, camera_zone
+      ORDER BY total_duration DESC
+      LIMIT 10
+    `, params);
+    res.json(result.rows);
+  } catch (err) {
+    console.error(err);
+    res.status(500).json({ error: 'Internal Server Error' });
+  }
+});
+
+app.get('/api/analytics/sop-compliance', async (req, res) => {
+  try {
+    const { changeover_id } = req.query;
+    let filter = changeover_id ? `AND changeover_id = $1` : '';
+    let params = changeover_id ? [changeover_id] : [];
+
+    // 1. Conveyor must be started 15 mins before changeover
+    const coStartResult = await pool.query(`SELECT start_time FROM events WHERE camera_zone = 'CO' ${filter} ORDER BY start_time ASC LIMIT 1`, params);
+    const convStartResult = await pool.query(`SELECT start_time FROM events WHERE camera_zone = 'Conveyor' AND (event_description ILIKE '%Started%' OR event_description ILIKE '%Active%') ${filter} ORDER BY start_time ASC LIMIT 1`, params);
+    
+    let conveyorCompliance = { rule: "Conveyor started 15 min before CO", status: "Unknown", detail: "" };
+    if (coStartResult.rows.length > 0 && convStartResult.rows.length > 0) {
+      const coTime = coStartResult.rows[0].start_time;
+      const convTime = convStartResult.rows[0].start_time;
+      // Compare times (assuming same day)
+      const coDate = new Date(`1970-01-01T${coTime}Z`);
+      const convDate = new Date(`1970-01-01T${convTime}Z`);
+      const diffMins = (coDate - convDate) / 60000;
+      
+      if (diffMins >= 15) {
+        conveyorCompliance.status = "Pass";
+        conveyorCompliance.detail = `Started ${diffMins.toFixed(1)} mins before CO`;
+      } else {
+        conveyorCompliance.status = "Fail";
+        if (diffMins > 0) conveyorCompliance.detail = `Started only ${diffMins.toFixed(1)} mins before CO`;
+        else conveyorCompliance.detail = `Started ${Math.abs(diffMins).toFixed(1)} mins AFTER CO`;
+      }
+    }
+
+    // 2. Mill should be completed within 15 mins after pushout rubber collection
+    const pushoutResult = await pool.query(`SELECT end_time FROM events WHERE event_description ILIKE '%Pushout of Rubber - 4%' ${filter} ORDER BY end_time DESC LIMIT 1`, params);
+    const millCompleteResult = await pool.query(`SELECT end_time FROM events WHERE camera_zone = 'Mill' AND event_description ILIKE '%Sheeting Out - 3%' ${filter} ORDER BY end_time DESC LIMIT 1`, params);
+    
+    let millCompliance = { rule: "Mill completed within 15 min of Pushout", status: "Unknown", detail: "" };
+    if (pushoutResult.rows.length > 0 && millCompleteResult.rows.length > 0) {
+      const pushoutTime = pushoutResult.rows[0].end_time;
+      const millTime = millCompleteResult.rows[0].end_time;
+      const pushoutDate = new Date(`1970-01-01T${pushoutTime}Z`);
+      const millDate = new Date(`1970-01-01T${millTime}Z`);
+      const diffMins = (millDate - pushoutDate) / 60000;
+      
+      if (diffMins <= 15 && diffMins >= 0) {
+        millCompliance.status = "Pass";
+        millCompliance.detail = `Completed in ${diffMins.toFixed(1)} mins`;
+      } else {
+        millCompliance.status = "Fail";
+        millCompliance.detail = `Completed in ${diffMins.toFixed(1)} mins (limit 15)`;
+      }
+    }
+
+    res.json([conveyorCompliance, millCompliance]);
+  } catch (err) {
+    console.error(err);
+    res.status(500).json({ error: 'Internal Server Error' });
+  }
+});
+
+const PORT = process.env.PORT || 3000;
+app.listen(PORT, () => {
+  console.log(`Server running on port ${PORT}`);
+});

api/package.json

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+{
+  "name": "api",
+  "version": "1.0.0",
+  "description": "",
+  "main": "index.js",
+  "scripts": {
+    "test": "echo \"Error: no test specified\" && exit 1"
+  },
+  "keywords": [],
+  "author": "",
+  "license": "ISC",
+  "dependencies": {
+    "cors": "^2.8.6",
+    "dotenv": "^17.4.2",
+    "express": "^5.2.1",
+    "pg": "^8.22.0",
+    "pm2": "^7.0.3"
+  }
+}