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