WFDASH-WEBAPP/src/lib/server/repairs-service.ts

/**
 * Server-side repairs service.
 *
 * Owns the write surface for the `repairs` collection (the legacy
 * `pb-helpers.ts` only has the bare `getRepairs` / `createRepair`
 * client-side helpers — they're fine for the list page, but every
 * write that needs admin credentials + cross-collection writes
 * belongs here).
 *
 * The repair lifecycle:
 *
 *   new  →  assessing  →  quoted  →  approved  →  in_progress  →  completed
 *     └────►  cancelled (from any pre-completed state)
 *
 *   ‑ "new"        : booked in, machine physically received
 *   ‑ "assessing"  : office sent the machine to a supplier for analysis
 *                    (a delivery-note PDF is on file under
 *                    `repairs.delivery_note`)
 *   ‑ "quoted"     : supplier returned a quote (uploaded to
 *                    `repairs.quote`)
 *   ‑ "approved"   : customer approved the supplier's quote (and the
 *                    office cut a supplier PO — uploaded to
 *                    `repairs.purchase_order`)
 *   ‑ "in_progress": supplier is working on the repair
 *   ‑ "completed"  : machine is back with the customer
 *
 * Side-channel data lives in the file fields (`photos`, `quote`,
 * `purchase_order`, `delivery_note`) — the service exposes thin
 * `upload*` helpers that re-PATCH the row with the new file list,
 * mirroring the multi-file pattern PocketBase uses everywhere else.
 */

import { getAdminPocketBase } from "./pocketbase-admin";
import { renderDeliveryNotePdf } from "@/lib/pdf/render";
import {
  deliveryNoteLetterheadCode,
  fetchLetterhead,
  loadLetterheadLogoDataUri,
} from "@/lib/letterhead";
import type {
  Customer,
  Repair,
  Supplier,
  User,
} from "@/lib/types";

const REPAIRS = "repairs";
const CUSTOMERS = "customers";
const SUPPLIERS = "suppliers";
const USERS = "users";
const DELIVERY_NOTES = "delivery_notes";
const ORDER_ITEMS = "order_items";

export type RepairStatus =
  | "new"
  | "assessing"
  | "quoted"
  | "approved"
  | "in_progress"
  | "completed"
  | "cancelled";

/** Allowed manual transitions. Centralised so the route + UI agree. */
const ALLOWED_TRANSITIONS: Record<RepairStatus, RepairStatus[]> = {
  new: ["assessing", "quoted", "cancelled"],
  assessing: ["quoted", "cancelled"],
  quoted: ["approved", "in_progress", "cancelled"],
  approved: ["in_progress", "cancelled"],
  in_progress: ["completed", "cancelled"],
  completed: [],
  cancelled: [],
};

function rejectTransition(from: RepairStatus, to: RepairStatus): never {
  const allowed = ALLOWED_TRANSITIONS[from] ?? [];
  const list = allowed.length > 0 ? allowed.join(", ") : "none";
  throw new Error(
    `Cannot transition repair from "${from}" to "${to}" (allowed: ${list}).`,
  );
}

function assertTransition(from: RepairStatus, to: RepairStatus): void {
  if (!ALLOWED_TRANSITIONS[from].includes(to)) rejectTransition(from, to);
}

/* ============================================================================
 * List + read
 * ========================================================================== */

export interface ListRepairsOptions {
  page?: number;
  perPage?: number;
  search?: string;
  status?: RepairStatus | "";
  sort?: string;
}

export interface ListRepairsResult {
  items: Repair[];
  totalItems: number;
  totalPages: number;
  page: number;
  perPage: number;
}

/**
 * Searchable columns on the `repairs` collection. Mirrors the
 * legacy `getRepairs` filter in `pb-helpers.ts:1485` but expanded
 * with the new fields (serial_no, notes) so the operator can find
 * a repair by typing any of the human-readable bits. PB's `~`
 * operator is case-insensitive substring.
 */
const SEARCHABLE_COLUMNS = [
  "repair_number",
  "item_description",
  "fault_description",
  "notes",
  "serial_no",
];

function buildSearchFilter(search: string): string | null {
  const trimmed = search.trim();
  if (!trimmed) return null;
  const escaped = trimmed.replace(/"/g, '\\"');
  return SEARCHABLE_COLUMNS.map((c) => `${c} ~ "${escaped}"`).join(" || ");
}

export async function listRepairs(
  options: ListRepairsOptions = {},
): Promise<ListRepairsResult> {
  const pb = await getAdminPocketBase();
  const page = options.page ?? 1;
  const perPage = options.perPage ?? 20;
  const sort = options.sort ?? "-created";

  const clauses: string[] = [];
  const searchClause = buildSearchFilter(options.search ?? "");
  if (searchClause) clauses.push(searchClause);
  if (options.status) {
    clauses.push(`status = "${options.status}"`);
  }
  const filter = clauses.join(" && ");

  const result = await pb.collection(REPAIRS).getList<Repair>(page, perPage, {
    filter,
    sort,
    expand: "customer,company,order,supplier",
  });
  return {
    items: result.items,
    totalItems: result.totalItems,
    totalPages: result.totalPages,
    page: result.page,
    perPage: result.perPage,
  };
}

export async function getRepair(id: string): Promise<Repair> {
  const pb = await getAdminPocketBase();
  return pb.collection(REPAIRS).getOne<Repair>(id, {
    expand: "customer,company,order,supplier",
  });
}

/* ============================================================================
 * Create / update
 * ========================================================================== */

export interface CreateRepairInput {
  customer?: string | null;
  company?: string | null;
  order?: string | null;
  supplier?: string | null;
  item_description: string;
  fault_description: string;
  notes?: string | null;
  serial_no?: string | null;
  photos?: string[];
}

export async function createRepair(
  input: CreateRepairInput,
): Promise<Repair> {
  const pb = await getAdminPocketBase();

  if (!input.item_description?.trim()) {
    throw new Error("item_description is required.");
  }
  if (!input.fault_description?.trim()) {
    throw new Error("fault_description is required.");
  }

  const repairNumber = await generateRepairNumberServer();

  const create: Record<string, unknown> = {
    repair_number: repairNumber,
    status: "new",
    item_description: input.item_description.trim(),
    fault_description: input.fault_description.trim(),
    notes: input.notes ?? "",
    customer: input.customer || null,
    company: input.company || null,
    order: input.order || null,
    supplier: input.supplier || null,
    serial_no: input.serial_no ?? "",
  };
  if (input.photos && input.photos.length > 0) {
    create.photos = input.photos;
  }
  return pb.collection(REPAIRS).create<Repair>(create);
}

export interface UpdateRepairInput {
  status?: RepairStatus;
  notes?: string | null;
  fault_description?: string;
  item_description?: string;
  serial_no?: string | null;
  customer?: string | null;
  company?: string | null;
  order?: string | null;
  supplier?: string | null;
}

export async function updateRepair(
  id: string,
  input: UpdateRepairInput,
): Promise<Repair> {
  const pb = await getAdminPocketBase();
  const existing = await pb.collection(REPAIRS).getOne<Repair>(id);
  const patch: Record<string, unknown> = {};

  if (input.status !== undefined) {
    assertTransition(existing.status, input.status);
    patch.status = input.status;
  }
  if (input.notes !== undefined) patch.notes = input.notes ?? "";
  if (input.item_description !== undefined)
    patch.item_description = input.item_description;
  if (input.fault_description !== undefined)
    patch.fault_description = input.fault_description;
  if (input.serial_no !== undefined) patch.serial_no = input.serial_no ?? "";
  if (input.customer !== undefined) patch.customer = input.customer || null;
  if (input.company !== undefined) patch.company = input.company || null;
  if (input.order !== undefined) patch.order = input.order || null;
  if (input.supplier !== undefined) patch.supplier = input.supplier || null;

  return pb.collection(REPAIRS).update<Repair>(id, patch);
}

/* ============================================================================
 * Repair number generator (server-side, atomic-ish)
 * ========================================================================== */

export async function generateRepairNumberServer(
  now: Date = new Date(),
): Promise<string> {
  const pb = await getAdminPocketBase();
  const year = now.getFullYear();
  const month = String(now.getMonth() + 1).padStart(2, "0");
  const prefix = `REP-${year}-${month}-`;

  const existing = await pb.collection(REPAIRS).getList<Repair>(1, 1, {
    filter: `repair_number ~ "${prefix}"`,
    sort: "-repair_number",
  });
  let seq = 1;
  if (existing.items.length > 0) {
    const last = existing.items[0].repair_number ?? "";
    const lastSeq = parseInt(last.split("-").pop() || "0", 10);
    if (Number.isFinite(lastSeq) && lastSeq > 0) seq = lastSeq + 1;
  }
  return `${prefix}${String(seq).padStart(3, "0")}`;
}

/* ============================================================================
 * "Send to supplier" — generate the DN PDF and attach to repair
 * ========================================================================== */

const REPAIR_DN_PREFIX = "RDN";

/**
 * Generate a server-side daily sequence for repair DNs. Distinct
 * from the customer-DN sequence so a repair DN never shadows a
 * customer-DN number (operator can tell them apart at a glance).
 */
async function generateRepairDeliveryNoteNumber(now: Date = new Date()): Promise<string> {
  const pb = await getAdminPocketBase();
  const yy = String(now.getFullYear()).slice(-2);
  const mm = String(now.getMonth() + 1).padStart(2, "0");
  const dd = String(now.getDate()).padStart(2, "0");
  const prefix = `${REPAIR_DN_PREFIX}${yy}${mm}${dd}`;
  // We use the created order's `delivery_note_number` to find the
  // last sequence. The same `delivery_note_number` field is shared
  // with customer DNs, so we constrain to the repair prefix.
  const existing = await pb
    .collection(ORDER_ITEMS)
    .getList(1, 1, {
      filter: `delivery_note_number ~ "${prefix}"`,
      sort: "-delivery_note_number",
    })
    .catch(() => null);
  let seq = 1;
  if (existing && existing.items.length > 0) {
    const last = (existing.items[0] as { delivery_note_number?: string }).delivery_note_number ?? "";
    const lastSeq = parseInt(last.slice(prefix.length), 10);
    if (Number.isFinite(lastSeq) && lastSeq > 0) seq = lastSeq + 1;
  }
  return `${prefix}${String(seq).padStart(2, "0")}`;
}

export interface GenerateRepairDeliveryNoteResult {
  deliveryNoteId: string;
  deliveryNoteNumber: string;
  filename: string;
}

/**
 * Generate a delivery note for sending the machine to the supplier
 * for analysis. Three steps:
 *
 *   1. Resolve the supplier name + address (for the PDF's "DELIVER TO"
 *      block) and the customer name (for the "FROM" reference line).
 *   2. Create a `delivery_notes` header row + one `order_items` row
 *      with the repair's item description. The order_items row is
 *      what the driver app and the order-completion flows look at;
 *      one row is enough for "send this machine to supplier X".
 *   3. Render the DN PDF and stamp it on the repair's
 *      `delivery_note` file field so the operator can download it
 *      from the repair detail page.
 *
 * The repair's status is bumped to `assessing` (with the standard
 * transition guard). The supplier must already be set on the repair
 * — we don't auto-resolve it.
 */
export async function generateRepairDeliveryNote(
  repairId: string,
): Promise<GenerateRepairDeliveryNoteResult> {
  const pb = await getAdminPocketBase();

  const repair = await pb.collection(REPAIRS).getOne<Repair>(repairId, {
    expand: "supplier,customer,company",
  });

  if (!repair.supplier) {
    throw new Error(
      "Repair has no supplier set. Set a supplier on the repair before generating a delivery note.",
    );
  }
  const supplier = await pb.collection(SUPPLIERS).getOne<Supplier>(repair.supplier);

  // Resolve the customer name (for the PDF reference line) — the
  // "DELIVER TO" block uses the supplier as destination.
  let customerName = "";
  if (repair.customer) {
    try {
      const c = await pb.collection(CUSTOMERS).getOne<Customer>(repair.customer);
      customerName = c.customer ?? "";
    } catch {
      // Customer lookup is best-effort; the PDF falls back to the
      // repair.customer relation name if the lookup fails.
      customerName = repair.expand?.customer?.customer ?? "";
    }
  }

  const deliveryNoteNumber = await generateRepairDeliveryNoteNumber();
  const now = new Date().toISOString();

  // ── 1. delivery_notes header ─────────────────────────────────
  // We use the same `delivery_notes` collection as customer DNs;
  // the kind is distinguished by the `notes` field (which we
  // stamp with a leading "[Repair send-to-supplier]" tag) and by
  // the `RDN` number prefix. Customer-DN queries don't filter
  // by number, so this doesn't pollute the customer-DN list.
  const header = await pb.collection(DELIVERY_NOTES).create({
    delivery_note_number: deliveryNoteNumber,
    customer: repair.customer || null,
    company: repair.company || null,
    order: null,
    status: "draft",
    notes:
      `[Repair send-to-supplier] ${repair.repair_number} — ${repair.item_description}` +
      (repair.notes ? `\n\n${repair.notes}` : ""),
    created_by: null,
  });

  // ── 2. order_items row ───────────────────────────────────────
  const itemDescription = `[Repair ${repair.repair_number}] ${repair.item_description}${repair.serial_no ? ` (S/N: ${repair.serial_no})` : ""}`;
  const item = await pb.collection(ORDER_ITEMS).create({
    order: null,
    delivery_note_number: deliveryNoteNumber,
    description: itemDescription,
    quantity: 1,
    order_qty: 1,
    supplier: repair.supplier,
    cost_price: 0,
    selling_price: 0,
    sku: "",
    notes: repair.fault_description,
    item_status: "delivery_note",
  });

  // ── 3. Render + upload the DN PDF ─────────────────────────────
  const letterheadCode = deliveryNoteLetterheadCode();
  const letterhead = await fetchLetterhead(letterheadCode);
  const logoDataUri = await loadLetterheadLogoDataUri(letterheadCode);

  const pdfBuffer = await renderDeliveryNotePdf({
    header: {
      deliveryNoteNumber,
      dateIso: now,
      orderNumber: repair.repair_number,
      companyName: supplier.suppliername ?? "",
      customerName: customerName,
    },
    lines: [
      {
        id: item.id,
        description: itemDescription,
        qty: 1,
      },
    ],
    letterhead,
    logoDataUri,
  });

  const filename = `${deliveryNoteNumber}.pdf`;
  const blob = new Blob([new Uint8Array(pdfBuffer)], { type: "application/pdf" });

  // Attach to the item's multi-file field (so the rest of the
  // existing DN-download flow works) AND to the repair's
  // `delivery_note` field (so the operator finds it on the
  // repair detail page).
  const itemForm = new FormData();
  itemForm.append("order_item_attachements", blob, filename);
  await pb.collection(ORDER_ITEMS).update(item.id, itemForm);

  // For the repair, we need to preserve the existing file list
  // (field is multi-file, maxSelect 10) and append the new file.
  const previousFiles = Array.isArray(repair.delivery_note)
    ? repair.delivery_note
    : [];
  const repairForm = new FormData();
  for (const f of previousFiles) repairForm.append("delivery_note", f);
  repairForm.append("delivery_note", blob, filename);
  await pb.collection(REPAIRS).update(repairId, repairForm);

  // ── 4. Status flip: new → assessing ──────────────────────────
  if (repair.status === "new") {
    assertTransition("new", "assessing");
    await pb.collection(REPAIRS).update(repairId, { status: "assessing" });
  }

  return {
    deliveryNoteId: header.id,
    deliveryNoteNumber,
    filename,
  };
}

/* ============================================================================
 * File upload helpers (photos / quote / purchase_order)
 * ========================================================================== */

export type RepairFileField = "photos" | "quote" | "purchase_order";

export async function uploadRepairFile(
  repairId: string,
  field: RepairFileField,
  file: File | Blob,
  filename: string,
): Promise<Repair> {
  const pb = await getAdminPocketBase();
  const existing = await pb.collection(REPAIRS).getOne<Repair>(repairId);
  const previousFiles = Array.isArray(existing[field])
    ? (existing[field] as string[])
    : [];

  const form = new FormData();
  for (const f of previousFiles) form.append(field, f);
  form.append(field, file, filename);

  const updated = await pb.collection(REPAIRS).update<Repair>(repairId, form);

  // Auto-bump status: uploading a quote moves new/assessing → quoted.
  if (field === "quote" && (existing.status === "new" || existing.status === "assessing")) {
    assertTransition(existing.status, "quoted");
    await pb.collection(REPAIRS).update(repairId, { status: "quoted" });
  }

  return updated;
}

/**
 * Remove a single file from a multi-file field (PB stores the
 * field as a string[] of filenames). Used by the detail page's
 * "delete" button on each attachment thumbnail.
 */
export async function removeRepairFile(
  repairId: string,
  field: RepairFileField,
  filename: string,
): Promise<Repair> {
  const pb = await getAdminPocketBase();
  const existing = await pb.collection(REPAIRS).getOne<Repair>(repairId);
  const files = Array.isArray(existing[field]) ? (existing[field] as string[]) : [];
  const filtered = files.filter((f) => f !== filename);
  if (filtered.length === files.length) {
    // Nothing to delete — return the row unchanged.
    return existing;
  }
  const form = new FormData();
  for (const f of filtered) form.append(field, f);
  return pb.collection(REPAIRS).update<Repair>(repairId, form);
}

/* ============================================================================
 * Read helpers for the UI (small)
 * ========================================================================== */

/**
 * Lightweight list of customers for the "New Repair" dropdown.
 * Distinct from the full customer lookup — just enough to show the
 * name + company in the combobox. Pulled via the admin client; the
 * where-used UI is the office-side repairs page (server-authenticated).
 *
 * The `customer.expand.company` expand is required so the
 * `<CustomerSearch>` combobox can render its "{Company} · {Customer}"
 * triplet. Without this expand the company column falls back to
 * "(no company)" for every row and the picker becomes useless on
 * mobile (the operator can't disambiguate "John Smith at Acme" from
 * "John Smith at Globex").
 */
export async function listCustomersForRepairForm(): Promise<Customer[]> {
  const pb = await getAdminPocketBase();
  const result = await pb.collection(CUSTOMERS).getList<Customer>(1, 500, {
    fields: "id,customer,email,number,company,expand",
    sort: "customer",
    expand: "company",
  });
  return result.items;
}

export async function listSuppliersForRepairForm(): Promise<
  Array<{ id: string; suppliername: string }>
> {
  const pb = await getAdminPocketBase();
  const result = await pb.collection(SUPPLIERS).getList<Supplier>(1, 500, {
    fields: "id,suppliername",
    sort: "suppliername",
  });
  return result.items.map((s) => ({
    id: s.id,
    suppliername: s.suppliername,
  }));
}

/**
 * Order lookup used by the OrderSearch combobox. Mirrors the
 * /api/v1/quotes/lookup shape — search by order_number / customer /
 * company. We only return the fields the picker renders, with the
 * customer + company expanded so the dropdown shows
 * "{Company} · {Customer} · {order #}" (matches the sprint modal's
 * QuoteSearch shape).
 */
export async function searchOrdersForRepairForm(
  q: string,
  page = 1,
  perPage = 25,
): Promise<{
  items: Array<{
    id: string;
    order_number: string;
    customer_name: string;
    company_name: string;
  }>;
  totalItems: number;
  totalPages: number;
  page: number;
  perPage: number;
}> {
  const pb = await getAdminPocketBase();
  const trimmed = q.trim();
  const filters: string[] = [];
  if (trimmed.length > 0) {
    const safe = trimmed.replace(/["()*]/g, "").slice(0, 64);
    if (safe.length > 0) {
      const escaped = safe.replace(/\\/g, "\\\\");
      const ors = [
        `order_number ~ "${escaped}"`,
        `expand.customer.customer ~ "${escaped}"`,
        `expand.company.company ~ "${escaped}"`,
      ];
      filters.push(`(${ors.join(" || ")})`);
    }
  }
  const result = await pb
    .collection("orders")
    .getList(page, perPage, {
      filter: filters.join(" && "),
      sort: "-created",
      fields: "id,order_number,customer,company,expand",
      expand: "customer,company",
    })
    .catch((err) => {
      console.error("[searchOrdersForRepairForm] failed:", err);
      return { items: [], page: 1, perPage, totalItems: 0, totalPages: 0 };
    });

  const items = result.items.map((o) => {
    const expand = (o as { expand?: { customer?: { customer?: string }; company?: { company?: string } } }).expand;
    return {
      id: o.id,
      order_number: (o as { order_number?: string }).order_number ?? "",
      customer_name: expand?.customer?.customer ?? "",
      company_name: expand?.company?.company ?? "",
    };
  });

  return {
    items,
    totalItems: result.totalItems,
    totalPages: result.totalPages,
    page: result.page,
    perPage: result.perPage,
  };
}

/* ============================================================================
 * Misc helpers
 * ========================================================================== */

/** Resolve the user id of the operator (for the audit stamp). */
export async function getMe(): Promise<{ id: string; name?: string } | null> {
  const pb = await getAdminPocketBase();
  try {
    const me = await pb.collection(USERS).getAuthRecord();
    return me ? { id: (me as User).id, name: (me as User).name } : null;
  } catch {
    return null;
  }
}