264 lines
7.2 KiB
Markdown
264 lines
7.2 KiB
Markdown
# Müller Production System - Implementation Summary
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## Project Overview
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A comprehensive Next.js application for managing milk bottle production at Müller, tracking shifts, operators, machines, and detailed production reports.
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## Core Technologies
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- **Framework**: Next.js 16 (App Router)
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- **Language**: TypeScript
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- **Database**: PostgreSQL with Prisma ORM
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- **Authentication**: NextAuth.js v5
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- **Styling**: Tailwind CSS
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- **Charts**: Recharts
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- **Password Hashing**: bcryptjs
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## Database Schema (8 Tables)
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### 1. Admin
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- System administrators who manage the entire system
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- Fields: id, firstName, surname, email, password, phone, authLevel
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### 2. ShiftManager
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- Managers who create and oversee shifts
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- Fields: id, empNo, firstName, surname, email, phone, status
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### 3. Worker
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- Operators, Level 2 supervisors, and engineers
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- Fields: id, empNo, firstName, surname, email, phone, jobPosition, status
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### 4. Team
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- 4 teams: Red, Green, Blue, Yellow
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- Fields: id, name, shiftManagerId
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### 5. Machine
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- 7 blow moulding machines (T1-T7)
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- Fields: id, name, status, machineType, bottlesPerMin
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### 6. Shift
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- Shift records (AM: 7am-7pm, PM: 8pm-7am)
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- Fields: id, name, shiftManagerId, startTime, endTime, shiftDate, status
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### 7. ShiftTeamMember
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- Assignment of workers to specific shifts and machines
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- Fields: id, shiftId, teamId, workerId, shiftRole, machineId
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### 8. MachineShiftReport
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- Comprehensive production reports with JSON fields for:
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- wallThickness, sectionWeights, station1Weights
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- safetyChecklist
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- filmDetails
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- bottleWeightTracking
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- hourlyQualityChecks
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- seamLeakTest
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- productionParameters
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- productionTracking
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- averageWeight, totalBagsMade
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- qualityMetrics, outputMetrics
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## Application Structure
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### Authentication Flow
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1. User selects role (Admin/Shift Manager/Operator)
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2. Enters email and password
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3. NextAuth validates credentials
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4. Redirects to role-specific dashboard
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5. Middleware protects all routes except /login
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### Admin Features
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- **Dashboard**: Overview statistics
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- **Teams Page**: View/create/edit teams
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- **Workers Page**: Manage operators and staff
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- **Managers Page**: Manage shift managers
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- **Machines Page**: Manage 7 machines
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### Shift Manager Features
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- **Dashboard**: Shift statistics
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- **Shifts Page**: View all shifts with status
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- **Create Shift Page**:
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- Select shift type (AM/PM)
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- Choose date and team
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- Assign 7 operators to 7 machines
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- Automatically creates MachineShiftReport for each operator
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### Operator Features
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- **Active Shifts Page**:
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- Shows current day's active shifts
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- Displays shift details (date, team, machine, time)
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- Button to open report
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- **Report Page** (9 sections):
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1. **Basic Info**: Date, operator name, machine, team, shift
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2. **Safety Checklist**: 6 safety items to check
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3. **Production Pre-Checks**: Wall thickness, section weights, station weights
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4. **Production Parameters**: Hourly temperature tracking
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5. **Bottle Weight Tracking**: Weight chart with 4 bottles per hour
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6. **Hourly Quality Checks**: Comprehensive quality inspection
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7. **Production Tracking**: Hourly production numbers
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8. **Seam Leak Test**: Mould testing (every 3 hours)
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9. **Film Details**: Film replacement tracking
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10. **Production Data**: Final metrics and output
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- **Archive Page**: View closed shifts (read-only)
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## Key Features Implemented
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### 1. Responsive Design
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- Mobile-friendly layouts
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- Responsive tables and forms
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- Touch-friendly buttons and inputs
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### 2. Real-time Data Visualization
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- Line charts for bottle weight tracking
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- Shows average, upper/lower limits, target weight
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- Updates dynamically as data is added
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### 3. Modal Forms
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- Clean UX for adding hourly data
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- Prevents page clutter
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- Easy to use on mobile
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### 4. Automatic Calculations
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- Average bottle weight from 4 bottles
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- Upper/lower limits calculation
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- Auto-populated timestamps
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### 5. Data Persistence
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- All form data saved via API routes
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- JSON fields for flexible data structures
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- Real-time updates without page refresh
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## API Routes
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### Authentication
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- `POST /api/auth/[...nextauth]` - NextAuth handlers
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### Data Management
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- `GET /api/teams` - Fetch all teams
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- `GET /api/workers` - Fetch all workers
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- `GET /api/machines` - Fetch all machines
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- `POST /api/shifts` - Create new shift
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- `PATCH /api/reports/[id]` - Update report data
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## Component Architecture
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### Layout Components
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- `DashboardLayout` - Main layout with sidebar
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- `Sidebar` - Navigation menu (role-specific)
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- `Modal` - Reusable modal component
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### Report Sections (9 components)
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- `SafetyChecklistSection`
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- `ProductionPreChecksSection`
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- `ProductionParametersSection`
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- `BottleWeightTrackingSection`
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- `HourlyQualityChecksSection`
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- `ProductionTrackingSection`
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- `SeamLeakTestSection`
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- `FilmDetailsSection`
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- `ProductionDataSection`
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## Workflow
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### Complete Shift Lifecycle
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1. **Admin Setup** (One-time)
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- Creates teams
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- Adds workers
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- Adds shift managers
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- Configures machines
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2. **Shift Creation** (Shift Manager)
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- Selects date and shift type
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- Chooses team
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- Assigns 7 operators to 7 machines
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- System creates shift and 7 blank reports
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3. **Shift Execution** (Operator)
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- Logs in and sees active shift
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- Opens report for their machine
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- Fills out safety checklist
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- Enters pre-check measurements
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- Adds hourly data throughout shift:
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- Temperature parameters
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- Bottle weights
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- Quality checks
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- Production numbers
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- Performs seam leak tests (every 3 hours)
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- Records film changes
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- Enters final production data
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4. **Shift Closure** (Shift Manager)
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- Reviews shift completion
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- Closes shift
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- Shift moves to archive
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## Security Features
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- Password hashing with bcryptjs
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- Role-based access control
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- Protected API routes
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- Session management with NextAuth
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- Middleware route protection
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## Data Integrity
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- Required fields validation
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- Type safety with TypeScript
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- Prisma schema validation
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- Foreign key relationships
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- Status tracking (active/inactive/closed)
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## Scalability Considerations
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- JSON fields for flexible report data
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- Indexed database fields
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- Efficient queries with Prisma
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- Component-based architecture
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- API route separation
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## Future Enhancements (Not Implemented)
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- Email notifications
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- PDF report generation
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- Advanced analytics dashboard
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- Multi-language support
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- Mobile app
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- Real-time collaboration
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- Automated quality alerts
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- Integration with production machines
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## Testing Recommendations
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1. Test all three user roles
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2. Create multiple shifts
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3. Fill out complete reports
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4. Test shift closure
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5. Verify archive functionality
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6. Test on mobile devices
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7. Verify data persistence
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8. Test concurrent users
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## Deployment Checklist
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- [ ] Set strong AUTH_SECRET
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- [ ] Configure production DATABASE_URL
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- [ ] Set up PostgreSQL database
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- [ ] Run migrations
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- [ ] Seed initial data
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- [ ] Configure NEXTAUTH_URL
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- [ ] Test all user flows
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- [ ] Set up backup strategy
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- [ ] Configure monitoring
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- [ ] Set up error tracking
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## Maintenance Notes
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- Regular database backups recommended
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- Monitor report data growth
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- Archive old shifts periodically
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- Update dependencies regularly
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- Review security patches
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- Monitor API performance
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---
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**Total Development Time**: Single session
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**Lines of Code**: ~3000+
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**Components**: 20+
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**API Routes**: 6
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**Database Tables**: 8
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**Pages**: 15+
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