mega-plant/lib/job-card-pdf.ts

import { formatMinutes, jobTypeLabel } from "./job-cards";

/** Everything the printed job card shows. All optional except the card number: a blank form prints too. */
export type JobCardPdfData = {
  jcNo?: number | null;
  plantNo?: string;
  plantName?: string;
  site?: string;
  mechanic?: string;
  machineHours?: string;
  date?: string;
  startedAt?: string;
  endedAt?: string;
  type?: string;
  minutes?: number;
  note?: string;
  /** Oil booked out to this job, e.g. "Hydraulic 68 - 5 L" — its own block above Spares. */
  oil?: string[];
  /** Parts used — written in by hand today, so empty unless supplied. */
  spares?: string[];
};

const A4: [number, number] = [595.28, 841.89];

const dmy = (stamp: string | undefined) => {
  if (!stamp) return "";
  const d = new Date(stamp.replace(" ", "T"));
  if (Number.isNaN(d.getTime())) return "";
  const p = new Intl.DateTimeFormat("en-ZA", { timeZone: "Africa/Johannesburg", day: "2-digit", month: "2-digit", year: "numeric" }).formatToParts(d);
  const g = (t: string) => p.find((x) => x.type === t)?.value ?? "";
  return `${g("day")}/${g("month")}/${g("year")}`;
};
const hm = (stamp: string | undefined) => {
  if (!stamp) return "";
  const d = new Date(stamp.replace(" ", "T"));
  return Number.isNaN(d.getTime()) ? "" : new Intl.DateTimeFormat("en-ZA", { timeZone: "Africa/Johannesburg", hour: "2-digit", minute: "2-digit", hourCycle: "h23" }).format(d);
};

/** Break text into lines no wider than `max` points. */
function wrap(text: string, widthOf: (s: string) => number, max: number): string[] {
  const out: string[] = [];
  for (const para of text.split(/\r?\n/)) {
    let line = "";
    for (const word of para.split(/\s+/).filter(Boolean)) {
      const next = line ? `${line} ${word}` : word;
      if (widthOf(next) <= max) line = next;
      else { if (line) out.push(line); line = word; }
    }
    out.push(line);
  }
  return out;
}

/**
 * The Machine Service job card, laid out like the paper pad the mechanics fill in by hand
 * (Section 07, Plant Moving Equipment Record). A real vector PDF, built in the browser with
 * pdf-lib. Fields we do not hold (Doc No, Next Service Due, signatures …) print as empty
 * boxes to be completed by hand.
 */
export async function buildJobCardPdf(data: JobCardPdfData = {}): Promise<Uint8Array> {
  const { PDFDocument, StandardFonts, rgb } = await import("pdf-lib");
  const doc = await PDFDocument.create();
  const page = doc.addPage(A4);
  const reg = await doc.embedFont(StandardFonts.Helvetica);
  const bold = await doc.embedFont(StandardFonts.HelveticaBold);

  const NAVY = rgb(0.16, 0.2, 0.35);
  const INK = rgb(0.08, 0.08, 0.1);
  const GOLD = rgb(0.93, 0.68, 0.29);
  const RED = rgb(0.78, 0.2, 0.3);
  const LINE = rgb(0.25, 0.28, 0.4);
  const RULE = rgb(0.72, 0.74, 0.8);

  const X = 34, W = A4[0] - 68;
  const H = A4[1];
  const box = (x: number, y: number, w: number, h: number, width = 0.9) =>
    page.drawRectangle({ x, y, width: w, height: h, borderColor: LINE, borderWidth: width });
  const text = (s: string, x: number, y: number, size = 9, font = reg, color = INK) =>
    page.drawText(s, { x, y, size, font, color });
  const hline = (y: number, x1 = X, x2 = X + W, color = RULE) =>
    page.drawLine({ start: { x: x1, y }, end: { x: x2, y }, thickness: 0.5, color });

  // ---- Header: logo, title, document box
  let y = H - 34;
  const headH = 62;
  box(X, y - headH, W, headH, 1);
  const titleX = X + 215, docX = X + W - 150;
  page.drawLine({ start: { x: titleX, y }, end: { x: titleX, y: y - headH }, thickness: 1, color: LINE });
  page.drawLine({ start: { x: docX, y }, end: { x: docX, y: y - headH }, thickness: 1, color: LINE });
  try {
    const res = await fetch("/brand/logo.png");
    if (res.ok) {
      const img = await doc.embedPng(new Uint8Array(await res.arrayBuffer()));
      page.drawImage(img, { x: X + 8, y: y - headH + 12, width: 38, height: 38 });
    }
  } catch { /* the wordmark below still identifies the form */ }
  const megaW = bold.widthOfTextAtSize("MEGA", 15), plantW = bold.widthOfTextAtSize("PLANT", 15);
  text("MEGA", X + 54, y - 34, 15, bold, GOLD);
  text("PLANT", X + 54 + megaW + 5, y - 34, 15, bold, INK);
  text("(Pty) Ltd", X + 54 + megaW + 5 + plantW + 3, y - 34, 7, bold, INK);
  const title = "Machine Service";
  text(title, titleX + (docX - titleX - bold.widthOfTextAtSize(title, 15)) / 2, y - 36, 15, bold);
  ["Doc. No.", "Page No.", "Rev.", "Date:"].forEach((l, i) => {
    const ry = y - (i + 1) * (headH / 4);
    if (i) page.drawLine({ start: { x: docX, y: ry + headH / 4 }, end: { x: X + W, y: ry + headH / 4 }, thickness: 0.6, color: LINE });
    text(l, docX + 6, ry + 5, 8, bold);
  });
  page.drawLine({ start: { x: docX + 62, y }, end: { x: docX + 62, y: y - headH }, thickness: 0.6, color: LINE });

  // ---- Job Card strip
  y -= headH + 10;
  box(X, y - 26, W, 26, 1);
  text("Job Card", X + W / 2 - 60, y - 17, 13, bold);
  text("JC No:", X + W - 140, y - 17, 11, bold);
  text(data.jcNo != null ? String(data.jcNo).padStart(4, "0") : "", X + W - 90, y - 17, 13, bold, RED);

  // ---- Details grid
  y -= 36;
  const gridH = 104;
  box(X, y - gridH, W, gridH, 1);
  const midX = X + W * 0.52;
  page.drawLine({ start: { x: midX - 8, y }, end: { x: midX - 8, y: y - gridH }, thickness: 0.6, color: LINE });
  const row = (label: string, value: string, x: number, ry: number, lw: number, maxW: number) => {
    text(label, x, ry, 8.5, bold);
    hline(ry - 3, x + lw, x + lw + maxW, RULE);
    let v = value, size = 10.5;
    while (v && reg.widthOfTextAtSize(v, size) > maxW - 4 && size > 6.5) size -= 0.5;
    if (v) text(v, x + lw + 3, ry, size, reg);
  };
  const lx = X + 8, rx = midX;
  const rowGap = 26;
  const r1 = y - 20;
  row("Plant No:", [data.plantNo, data.plantName].filter(Boolean).join("  ·  "), lx, r1, 70, midX - lx - 80);
  row("Plant Location / Site:", data.site ?? "", lx, r1 - rowGap, 105, midX - lx - 115);
  row("Mechanic:", data.mechanic ?? "", lx, r1 - rowGap * 2, 55, midX - lx - 65);
  row("Last Service Date:", "", lx, r1 - rowGap * 3, 90, midX - lx - 100);
  const rw = X + W - rx - 14;
  row("Machine Hours:", data.machineHours ?? "", rx, r1, 80, rw - 80);
  row("Date:", data.date ?? dmy(data.startedAt), rx, r1 - rowGap, 80, rw - 80);
  row("Next Service Due:", "", rx, r1 - rowGap * 2, 80, rw - 80);
  row("Last Service Hours:", "", rx, r1 - rowGap * 3, 80, rw - 80);

  // ---- Work done table
  y -= gridH + 10;
  const colDate = X + W - 160, colTime = X + W - 75;
  const workH = 190;
  box(X, y - workH, W, workH, 1);
  text("Work Done / Hours / KM", X + 6, y - 14, 9, bold);
  text("Date", colDate + 28, y - 14, 9, bold);
  text("Time", colTime + 24, y - 14, 9, bold);
  page.drawLine({ start: { x: colDate, y }, end: { x: colDate, y: y - workH }, thickness: 0.7, color: LINE });
  page.drawLine({ start: { x: colTime, y }, end: { x: colTime, y: y - workH }, thickness: 0.7, color: LINE });
  hline(y - 20, X, X + W, LINE);
  const lineGap = 19;
  for (let ly = y - 20 - lineGap; ly > y - workH + 2; ly -= lineGap) hline(ly);

  // Type + note, written on the ruled lines.
  const entries: string[] = [];
  if (data.type) entries.push(`${jobTypeLabel(data.type) || data.type}${data.minutes ? ` — ${formatMinutes(data.minutes)} on the job` : ""}`);
  if (data.note) entries.push(...wrap(data.note, (s) => reg.widthOfTextAtSize(s, 10), colDate - X - 14));
  entries.slice(0, 8).forEach((line, i) => text(line, X + 6, y - 20 - lineGap * (i + 1) + 5, 10));
  if (data.startedAt) {
    text(dmy(data.startedAt), colDate + 6, y - 20 - lineGap + 5, 9);
    const t = [hm(data.startedAt), hm(data.endedAt)].filter(Boolean).join("–");
    if (t) text(t, colTime + 4, y - 20 - lineGap + 5, 9);
  }

  // ---- Spares / Charges
  const section = (label: string, top: number, h: number, lines: string[]) => {
    box(X, top - h, W, h, 1);
    text(label, X + 6, top - 14, 9, bold);
    page.drawLine({ start: { x: colDate, y: top }, end: { x: colDate, y: top - h }, thickness: 0.7, color: LINE });
    page.drawLine({ start: { x: colTime, y: top }, end: { x: colTime, y: top - h }, thickness: 0.7, color: LINE });
    hline(top - 20, X, X + W, LINE);
    for (let ly = top - 20 - lineGap; ly > top - h + 2; ly -= lineGap) hline(ly);
    lines.slice(0, 5).forEach((l, i) => text(l, X + 6, top - 20 - lineGap * (i + 1) + 5, 10));
  };
  y -= workH + 8;
  section("Oil:", y, 78, data.oil ?? []);
  y -= 78 + 8;
  section("Spares:", y, 90, data.spares ?? []);
  y -= 90 + 8;
  section("Charges:", y, 66, []);

  // ---- Signatures
  y -= 66 + 10;
  box(X, y - 62, W, 62, 1);
  hline(y - 31, X, X + W, LINE);
  const sigX = X + W * 0.58;
  text("Mechanic Signature:", X + 6, y - 19, 9, bold);
  text("Date:", sigX, y - 19, 9, bold);
  text("Manager Checked:", X + 6, y - 50, 9, bold);
  text("Date:", sigX, y - 50, 9, bold);
  hline(y - 22, X + 100, sigX - 14);
  hline(y - 53, X + 100, sigX - 14);
  hline(y - 22, sigX + 28, X + W - 10);
  hline(y - 53, sigX + 28, X + W - 10);

  // ---- Footer
  y -= 62 + 10;
  box(X, y - 22, W, 22, 1);
  page.drawLine({ start: { x: X + 120, y }, end: { x: X + 120, y: y - 22 }, thickness: 0.8, color: LINE });
  text("Section 07", X + 38, y - 14, 9, bold);
  text("SHEQ System documentation: Operations - Plant Moving Equipment Record", X + 128, y - 14, 8.5, bold);
  void NAVY;

  return doc.save();
}