import { useEffect, useCallback, useRef } from "react";
import { useSceneContext } from "../../scene/sceneContext";
import { useAnimationPlaySpeed, usePlayButtonStore } from "../../../store/ui/usePlayButtonStore";

function Analyzer() {
    const { isPlaying } = usePlayButtonStore();
    const { conveyorStore, machineStore, armBotStore, humanStore, vehicleStore, craneStore, storageUnitStore, materialStore, analysisStore, humanEventManagerRef } = useSceneContext();

    const { conveyors } = conveyorStore();
    const { machines } = machineStore();
    const { armBots } = armBotStore();
    const { humans } = humanStore();
    const { vehicles } = vehicleStore();
    const { cranes } = craneStore();
    const { storageUnits } = storageUnitStore();
    const { materials, getMaterialsByModel } = materialStore();
    const { speed } = useAnimationPlaySpeed();

    const { setAnalysis, setAnalyzing, analysis } = analysisStore();

    // ============================================================================
    // COMPREHENSIVE TRACKING REFS FOR PERFORMANCE METRICS
    // ============================================================================

    // Historical data tracking
    const historicalDataRef = useRef<Record<string, any[]>>({});
    const materialHistoryRef = useRef<MaterialHistoryEntry[]>([]);
    const queueLengthsRef = useRef<Record<string, { timestamp: number; length: number }[]>>({});

    // Timing and intervals
    const analysisIntervalRef = useRef<NodeJS.Timeout | null>(null);
    const startTimeRef = useRef<string>(new Date().toISOString());

    // Error and action tracking
    const errorCountsRef = useRef<Record<string, number>>({});
    const completedActionsRef = useRef<Record<string, number>>({});
    const stateTransitionsRef = useRef<Record<string, any[]>>({});

    // Material flow tracking - tracks materials added/removed per asset
    const materialAdditionsRef = useRef<
        Record<
            string,
            {
                materialId: string;
                materialType: string;
                timestamp: number;
                fromAsset?: string;
            }[]
        >
    >({});

    const materialRemovalsRef = useRef<
        Record<
            string,
            {
                materialId: string;
                materialType: string;
                timestamp: number;
                toAsset?: string;
                processingTime?: number;
            }[]
        >
    >({});

    // Asset state change tracking with detailed timestamps
    const assetStateChangesRef = useRef<
        Record<
            string,
            {
                fromState: string;
                toState: string;
                timestamp: number;
                duration?: number;
            }[]
        >
    >({});

    // Cycle tracking for each asset
    const assetCyclesRef = useRef<
        Record<
            string,
            {
                cycleId: string;
                startTime: number;
                endTime?: number;
                cycleType: string; // 'processing', 'transport', 'pick-place', etc.
                materialsInvolved: string[];
                success: boolean;
            }[]
        >
    >({});

    // Action completion times for performance analysis
    const actionCompletionTimesRef = useRef<
        Record<
            string,
            {
                actionId: string;
                actionType: string;
                startTime: number;
                endTime: number;
                duration: number;
                success: boolean;
            }[]
        >
    >({});

    // Material processing times per asset
    const materialProcessingTimesRef = useRef<
        Record<
            string,
            {
                materialId: string;
                entryTime: number;
                exitTime?: number;
                processingDuration?: number;
                waitTime?: number;
            }[]
        >
    >({});

    // WIP (Work In Progress) tracking per asset over time
    const wipSnapshotsRef = useRef<
        Record<
            string,
            {
                timestamp: number;
                wipCount: number;
                materialIds: string[];
            }[]
        >
    >({});

    // Throughput snapshots for trend analysis
    const throughputSnapshotsRef = useRef<
        Record<
            string,
            {
                timestamp: number;
                itemsProcessed: number;
                timeWindow: number; // in seconds
                rate: number; // items per hour
            }[]
        >
    >({});

    // Asset performance snapshots
    const performanceSnapshotsRef = useRef<
        Record<
            string,
            {
                timestamp: number;
                utilization: number;
                efficiency: number;
                quality: number;
                oee: number;
            }[]
        >
    >({});

    // Bottleneck detection tracking
    const bottleneckEventsRef = useRef<
        Record<
            string,
            {
                timestamp: number;
                queueLength: number;
                utilizationRate: number;
                waitingMaterials: string[];
            }[]
        >
    >({});

    // Previous state tracking for delta calculations
    const previousAssetStatesRef = useRef<
        Record<
            string,
            {
                state: string;
                isActive: boolean;
                materialCount: number;
                timestamp: number;
            }
        >
    >({});

    // Track previous actions for ArmBots to detect cycle completion
    const previousArmBotActionsRef = useRef<Record<string, string | undefined>>({});

    // Track previous actions for Machines to detect cycle completion
    const previousMachineActionsRef = useRef<Record<string, string | undefined>>({});

    // Track previous action counts for Humans to detect completion from EventManager
    const previousHumanCountsRef = useRef<Record<string, Record<string, number>>>({});

    // Track previous vehicle phases to detect trip completion
    const previousVehiclePhasesRef = useRef<Record<string, string>>({});

    // Track previous crane phases to detect cycle completion
    const previousCranePhasesRef = useRef<Record<string, string>>({});

    // Material lifecycle tracking
    const materialLifecycleRef = useRef<
        Record<
            string,
            {
                materialId: string;
                createdAt: number;
                completedAt?: number;
                path: {
                    assetId: string;
                    assetType: string;
                    entryTime: number;
                    exitTime?: number;
                }[];
                totalProcessingTime?: number;
                totalWaitTime?: number;
            }
        >
    >({});

    const resetAllRefs = () => {
        assetCyclesRef.current = {};
        assetStateChangesRef.current = {};
        materialAdditionsRef.current = {};
        materialRemovalsRef.current = {};
        materialProcessingTimesRef.current = {};
        wipSnapshotsRef.current = {};
        throughputSnapshotsRef.current = {};
        performanceSnapshotsRef.current = {};
        bottleneckEventsRef.current = {};
        previousAssetStatesRef.current = {};
        previousArmBotActionsRef.current = {};
        previousMachineActionsRef.current = {};
        previousHumanCountsRef.current = {};
        previousVehiclePhasesRef.current = {};
        previousCranePhasesRef.current = {};
        materialLifecycleRef.current = {};
        setAnalysis(null);
        setAnalyzing(false);
    };

    useEffect(() => {
        if (!isPlaying) {
            resetAllRefs();
        } else {
            // Reset start time when simulation starts
            startTimeRef.current = new Date().toISOString();
        }
    }, [isPlaying]);

    // ============================================================================
    // ENHANCED UTILITY FUNCTIONS
    // ============================================================================

    const calculateAdvancedTimeMetrics = (idleTime: number, activeTime: number, assetId: string, errorCount: number = 0) => {
        const totalTime = idleTime + activeTime;
        const uptime = totalTime > 0 ? (activeTime / totalTime) * 100 : 0;
        const downtime = idleTime;
        const utilizationRate = uptime / 100;

        // Enhanced reliability calculations
        const mtbf = errorCount > 0 ? totalTime / errorCount : totalTime;
        const mttr = errorCount > 0 ? downtime / errorCount : 0;
        const reliability = Math.exp(-errorCount / Math.max(1, totalTime / 3600)) * 100; // Reliability per hour

        // Calculate schedule adherence if scheduled data exists
        const scheduledTime = totalTime; // Could be enhanced with actual schedule data
        const scheduleAdherence = scheduledTime > 0 ? (activeTime / scheduledTime) * 100 : 100;

        return {
            uptime,
            downtime,
            utilizationRate,
            mtbf,
            mttr,
            reliability,
            totalTime,
            scheduleAdherence,
        };
    };

    const calculateQualityMetrics = (assetId: string, totalOperations: number, defects: number, historicalData: any[] = []) => {
        const errorCount = errorCountsRef.current[assetId] || 0;
        const firstPassYield = totalOperations > 0 ? ((totalOperations - defects) / totalOperations) * 100 : 0;
        const defectRate = totalOperations > 0 ? (defects / totalOperations) * 100 : 0;
        const scrapRate = defects > 0 ? defects * 0.1 : 0; // Assuming 10% scrap rate
        const reworkRate = defects > 0 ? defects * 0.9 : 0; // Assuming 90% rework

        // Calculate defect trends
        let defectTrend = "stable";
        if (historicalData.length > 5) {
            const recentDefects = historicalData.slice(-5).filter((d) => d.defects > 0).length;
            const olderDefects = historicalData.slice(-10, -5).filter((d) => d.defects > 0).length;
            if (recentDefects > olderDefects * 1.5) defectTrend = "increasing";
            else if (recentDefects < olderDefects * 0.5) defectTrend = "decreasing";
        }

        return {
            errorRate: totalOperations > 0 ? (errorCount / totalOperations) * 100 : 0,
            errorFrequency: (errorCount / Math.max(1, totalOperations)) * 1000, // Errors per 1000 operations
            successRate: firstPassYield,
            firstPassYield,
            defectRate,
            scrapRate,
            reworkRate,
            defectTrend,
            defectsPerMillion: totalOperations > 0 ? (defects / totalOperations) * 1000000 : 0,
            stateTransitions: getStateTransitions(assetId),
        };
    };

    const calculateMaterialFlowMetricsForAsset = (assetId: string) => {
        const materialsOnAsset = getMaterialsByModel(assetId).length;

        // Use removals as the history of processed items
        // This fixes the issue where items per hour was 0 because materialHistoryRef was empty
        const removals = materialRemovalsRef.current[assetId] || [];

        // Calculate flow metrics
        const wip = materialsOnAsset;

        // Calculate throughput (items per second)
        // Ensure we don't divide by zero
        const durationMs = Date.now() - new Date(startTimeRef.current).getTime();

        // Normalize by simulation speed to get "simulation time" throughput
        const currentSpeed = Math.max(1, speed);
        const throughput = durationMs > 1000 ? ((removals.length / durationMs) * 1000) / currentSpeed : 0;

        // Calculate lead times (processing times on this asset)
        const leadTimes = removals.map((m) => m.processingTime || 0).filter((t) => t > 0);

        const avgLeadTime = leadTimes.length > 0 ? leadTimes.reduce((sum, t) => sum + t, 0) / leadTimes.length : 0;

        // Calculate velocity (turnover)
        const velocity = removals.length / Math.max(1, wip);

        return {
            wip,
            throughput,
            avgLeadTime,
            totalMaterialsProcessed: removals.length,
            currentMaterials: materialsOnAsset,
            avgCycleTime: avgLeadTime / 1000,
            materialVelocity: velocity,
            inventoryTurns: throughput > 0 ? throughput / Math.max(1, wip) : 0,
        };
    };

    const calculatePerformanceMetrics = (actualOutput: number, idealOutput: number, actualTime: number, idealTime: number, assetType: string) => {
        if (idealTime === 0 || actualTime === 0)
            return {
                performanceRate: 100,
                timeEfficiency: 100,
                productivity: 0,
                outputPerHour: 0,
            };

        const performanceRate = idealOutput > 0 ? Math.min((actualOutput / idealOutput) * 100, 100) : 100;
        const timeEfficiency = idealTime > 0 ? Math.min((idealTime / actualTime) * 100, 100) : 100;
        const productivity = actualTime > 0 ? actualOutput / actualTime : 0;
        const outputPerHour = actualTime > 0 ? (actualOutput / actualTime) * 3600 : 0;

        // Asset type specific adjustments
        const efficiencyAdjustment =
            {
                conveyor: 1.0,
                vehicle: 0.95,
                machine: 0.9,
                roboticArm: 0.92,
                human: 0.85,
                crane: 0.88,
                storage: 0.98,
            }[assetType] || 1.0;

        return {
            performanceRate: performanceRate * efficiencyAdjustment,
            timeEfficiency: timeEfficiency * efficiencyAdjustment,
            productivity,
            outputPerHour,
            efficiencyAdjustment,
        };
    };

    const calculateCostMetrics = (assetId: string, assetType: EventType, activeTime: number, totalOutput: number) => {
        // Cost parameters (hourly rates in $)
        const costParams = {
            conveyor: { hourlyRate: 50, maintenanceCost: 0.5, energyCost: 5 },
            vehicle: { hourlyRate: 75, maintenanceCost: 2, energyCost: 10 },
            machine: { hourlyRate: 100, maintenanceCost: 5, energyCost: 15 },
            roboticArm: { hourlyRate: 120, maintenanceCost: 8, energyCost: 20 },
            human: { hourlyRate: 35, maintenanceCost: 0.1, energyCost: 0 },
            crane: { hourlyRate: 150, maintenanceCost: 10, energyCost: 25 },
            storage: { hourlyRate: 25, maintenanceCost: 1, energyCost: 2 },
        };

        const params = costParams[assetType] || costParams.conveyor;
        const hoursOperated = activeTime / 3600;
        const errorCount = errorCountsRef.current[assetId] || 0;

        const operatingCost = hoursOperated * params.hourlyRate;
        const maintenanceCost = errorCount * params.maintenanceCost;
        const energyCost = hoursOperated * params.energyCost;
        const totalCost = operatingCost + maintenanceCost + energyCost;

        const costPerUnit = totalOutput > 0 ? totalCost / totalOutput : 0;
        const costPerHour = totalCost / Math.max(1, hoursOperated);
        const roi = totalOutput > 0 ? (totalOutput * 10) / totalCost : 0; // Assuming $10 value per unit

        return {
            operatingCost,
            maintenanceCost,
            energyCost,
            totalCost,
            costPerUnit,
            costPerHour,
            roi,
            valueAdded: totalOutput * 10 - totalCost,
        };
    };

    const calculateEnergyMetrics = (assetType: EventType, activeTime: number, distanceTraveled: number = 0) => {
        // Energy consumption rates in kW
        const energyRates = {
            conveyor: 7.5,
            vehicle: 15 + distanceTraveled * 0.1, // Base + distance-based
            machine: 20,
            roboticArm: 10,
            human: 0,
            crane: 25,
            storage: 2,
        };

        const rate = energyRates[assetType] || 5;
        const hoursActive = activeTime / 3600;
        const energyConsumed = hoursActive * rate; // kWh
        const energyEfficiency = 85 - Math.random() * 10; // Simulated efficiency 75-85%
        const carbonFootprint = energyConsumed * 0.5; // kg CO2 per kWh (0.5 kg/kWh average)
        const energyCost = energyConsumed * 0.12; // $0.12 per kWh

        return {
            energyConsumed,
            energyEfficiency,
            carbonFootprint,
            powerUsage: rate,
            energyCost,
            energyPerUnit: 0, // Will be calculated with output
        };
    };

    const calculateOEE = (availability: number, performance: number, quality: number) => {
        return (availability * performance * quality) / 10000;
    };

    const getStateTransitions = (assetId: string) => {
        const transitions = stateTransitionsRef.current[assetId] || [];
        const grouped = transitions.reduce((acc, t) => {
            const key = `${t.fromState}-${t.toState}`;
            if (!acc[key]) {
                acc[key] = { fromState: t.fromState, toState: t.toState, count: 0, totalTime: 0 };
            }
            acc[key].count++;
            acc[key].totalTime += t.duration;
            return acc;
        }, {} as Record<string, any>);

        return Object.values(grouped).map((g: any) => ({
            fromState: g.fromState,
            toState: g.toState,
            count: g.count,
            averageTime: g.totalTime / g.count,
        }));
    };

    // ============================================================================
    // TRACKING HELPER FUNCTIONS
    // ============================================================================

    /**
     * Track material addition to an asset
     */
    const trackMaterialAddition = useCallback((assetId: string, materialId: string, materialType: string, fromAsset?: string) => {
        const timestamp = Date.now();

        if (!materialAdditionsRef.current[assetId]) {
            materialAdditionsRef.current[assetId] = [];
        }

        materialAdditionsRef.current[assetId].push({
            materialId,
            materialType,
            timestamp,
            fromAsset,
        });

        // Track in material processing times
        if (!materialProcessingTimesRef.current[assetId]) {
            materialProcessingTimesRef.current[assetId] = [];
        }

        materialProcessingTimesRef.current[assetId].push({
            materialId,
            entryTime: timestamp,
        });

        // Update material lifecycle
        if (!materialLifecycleRef.current[materialId]) {
            materialLifecycleRef.current[materialId] = {
                materialId,
                createdAt: timestamp,
                path: [],
            };
        }

        materialLifecycleRef.current[materialId].path.push({
            assetId,
            assetType: "", // Will be filled by caller
            entryTime: timestamp,
        });

        // Update WIP snapshot
        updateWIPSnapshot(assetId);
    }, []);

    /**
     * Track material removal from an asset
     */
    const trackMaterialRemoval = useCallback((assetId: string, materialId: string, materialType: string, toAsset?: string) => {
        const timestamp = Date.now();

        if (!materialRemovalsRef.current[assetId]) {
            materialRemovalsRef.current[assetId] = [];
        }

        // Calculate processing time
        const processingTimes = materialProcessingTimesRef.current[assetId] || [];
        const entryRecord = processingTimes.find((p) => p.materialId === materialId && !p.exitTime);
        let processingTime: number | undefined;

        if (entryRecord) {
            processingTime = timestamp - entryRecord.entryTime;
            entryRecord.exitTime = timestamp;
            entryRecord.processingDuration = processingTime;
        }

        materialRemovalsRef.current[assetId].push({
            materialId,
            materialType,
            timestamp,
            toAsset,
            processingTime,
        });

        // Update material lifecycle
        const lifecycle = materialLifecycleRef.current[materialId];
        if (lifecycle && lifecycle.path.length > 0) {
            const lastPathEntry = lifecycle.path[lifecycle.path.length - 1];
            if (lastPathEntry.assetId === assetId) {
                lastPathEntry.exitTime = timestamp;
            }
        }

        // Update WIP snapshot
        updateWIPSnapshot(assetId);

        // Update throughput snapshot
        updateThroughputSnapshot(assetId);
    }, []);

    /**
     * Track asset state change
     */
    const trackStateChange = useCallback((assetId: string, fromState: string, toState: string, context?: { actionName?: string }) => {
        const timestamp = Date.now();

        // Increment error count if entering error state
        if (toState === "error") {
            if (!errorCountsRef.current[assetId]) {
                errorCountsRef.current[assetId] = 0;
            }
            errorCountsRef.current[assetId]++;

            // Granular error tracking based on action type
            if (context?.actionName) {
                const actionName = context.actionName.toLowerCase();
                if (actionName.includes("pick")) {
                    if (!errorCountsRef.current[`${assetId}_pick`]) errorCountsRef.current[`${assetId}_pick`] = 0;
                    errorCountsRef.current[`${assetId}_pick`]++;
                } else if (actionName.includes("place")) {
                    if (!errorCountsRef.current[`${assetId}_place`]) errorCountsRef.current[`${assetId}_place`] = 0;
                    errorCountsRef.current[`${assetId}_place`]++;
                }
            }
        }

        if (!assetStateChangesRef.current[assetId]) {
            assetStateChangesRef.current[assetId] = [];
        }

        // Calculate duration from previous state
        const previousChanges = assetStateChangesRef.current[assetId];
        let duration: number | undefined;

        if (previousChanges.length > 0) {
            const lastChange = previousChanges[previousChanges.length - 1];
            duration = timestamp - lastChange.timestamp;
            lastChange.duration = duration;
        }

        assetStateChangesRef.current[assetId].push({
            fromState,
            toState,
            timestamp,
        });

        // Also track in state transitions ref for compatibility
        if (!stateTransitionsRef.current[assetId]) {
            stateTransitionsRef.current[assetId] = [];
        }

        stateTransitionsRef.current[assetId].push({
            fromState,
            toState,
            timestamp,
            duration: duration || 0,
        });
    }, []);

    /**
     * Start a new cycle for an asset
     */
    const startAssetCycle = useCallback((assetId: string, cycleType: string, materialsInvolved: string[] = []) => {
        const timestamp = Date.now();
        const cycleId = `${assetId}-${timestamp}`;

        if (!assetCyclesRef.current[assetId]) {
            assetCyclesRef.current[assetId] = [];
        }

        assetCyclesRef.current[assetId].push({
            cycleId,
            startTime: timestamp,
            cycleType,
            materialsInvolved,
            success: false,
        });

        return cycleId;
    }, []);

    /**
     * Complete a cycle for an asset
     */
    const completeAssetCycle = useCallback((assetId: string, cycleId: string, success: boolean = true) => {
        const timestamp = Date.now();
        const cycles = assetCyclesRef.current[assetId] || [];
        const cycle = cycles.find((c) => c.cycleId === cycleId);

        if (cycle) {
            cycle.endTime = timestamp;
            cycle.success = success;
        }
    }, []);

    /**
     * Track action completion
     */
    const trackActionCompletion = useCallback((assetId: string, actionId: string, actionType: string, startTime: number, success: boolean = true) => {
        const endTime = Date.now();

        if (!actionCompletionTimesRef.current[assetId]) {
            actionCompletionTimesRef.current[assetId] = [];
        }

        actionCompletionTimesRef.current[assetId].push({
            actionId,
            actionType,
            startTime,
            endTime,
            duration: endTime - startTime,
            success,
        });

        // Limit history to last 100 actions
        if (actionCompletionTimesRef.current[assetId].length > 100) {
            actionCompletionTimesRef.current[assetId] = actionCompletionTimesRef.current[assetId].slice(-100);
        }
    }, []);

    /**
     * Update WIP snapshot for an asset
     */
    const updateWIPSnapshot = useCallback(
        (assetId: string) => {
            const timestamp = Date.now();
            const currentMaterials = getMaterialsByModel(assetId);

            if (!wipSnapshotsRef.current[assetId]) {
                wipSnapshotsRef.current[assetId] = [];
            }

            wipSnapshotsRef.current[assetId].push({
                timestamp,
                wipCount: currentMaterials.length,
                materialIds: currentMaterials.map((m) => m.materialId),
            });

            // Keep only last 100 snapshots
            if (wipSnapshotsRef.current[assetId].length > 100) {
                wipSnapshotsRef.current[assetId] = wipSnapshotsRef.current[assetId].slice(-100);
            }
        },
        [getMaterialsByModel]
    );

    /**
     * Update throughput snapshot for an asset
     */
    const updateThroughputSnapshot = useCallback(
        (assetId: string) => {
            const timestamp = Date.now();
            const timeWindow = 60; // 60 seconds

            if (!throughputSnapshotsRef.current[assetId]) {
                throughputSnapshotsRef.current[assetId] = [];
            }

            // Count items processed in the last time window
            const removals = materialRemovalsRef.current[assetId] || [];
            const recentRemovals = removals.filter((r) => timestamp - r.timestamp <= timeWindow * 1000);
            const itemsProcessed = recentRemovals.length;
            // Normalize by speed
            const currentSpeed = Math.max(1, speed);
            const rate = ((itemsProcessed / timeWindow) * 3600) / currentSpeed; // items per hour

            throughputSnapshotsRef.current[assetId].push({
                timestamp,
                itemsProcessed,
                timeWindow,
                rate,
            });

            // Keep only last 100 snapshots
            if (throughputSnapshotsRef.current[assetId].length > 100) {
                throughputSnapshotsRef.current[assetId] = throughputSnapshotsRef.current[assetId].slice(-100);
            }
        },
        [speed]
    );

    /**
     * Update performance snapshot for an asset
     */
    const updatePerformanceSnapshot = useCallback((assetId: string, utilization: number, efficiency: number, quality: number, oee: number) => {
        const timestamp = Date.now();

        if (!performanceSnapshotsRef.current[assetId]) {
            performanceSnapshotsRef.current[assetId] = [];
        }

        performanceSnapshotsRef.current[assetId].push({
            timestamp,
            utilization,
            efficiency,
            quality,
            oee,
        });

        // Keep only last 100 snapshots
        if (performanceSnapshotsRef.current[assetId].length > 100) {
            performanceSnapshotsRef.current[assetId] = performanceSnapshotsRef.current[assetId].slice(-100);
        }
    }, []);

    /**
     * Track bottleneck event
     */
    const trackBottleneckEvent = useCallback((assetId: string, queueLength: number, utilizationRate: number, waitingMaterials: string[]) => {
        const timestamp = Date.now();

        if (!bottleneckEventsRef.current[assetId]) {
            bottleneckEventsRef.current[assetId] = [];
        }

        // Only track if it's a significant bottleneck
        if (queueLength > 2 || utilizationRate > 0.85) {
            bottleneckEventsRef.current[assetId].push({
                timestamp,
                queueLength,
                utilizationRate,
                waitingMaterials,
            });

            // Keep only last 50 events
            if (bottleneckEventsRef.current[assetId].length > 50) {
                bottleneckEventsRef.current[assetId] = bottleneckEventsRef.current[assetId].slice(-50);
            }
        }
    }, []);

    /**
     * Update previous asset state for delta tracking
     */
    const updatePreviousAssetState = useCallback((assetId: string, state: string, isActive: boolean, materialCount: number) => {
        previousAssetStatesRef.current[assetId] = {
            state,
            isActive,
            materialCount,
            timestamp: Date.now(),
        };
    }, []);

    /**
     * Get enhanced material flow metrics using tracked data
     */
    const getEnhancedMaterialFlowMetrics = useCallback(
        (assetId: string) => {
            const additions = materialAdditionsRef.current[assetId] || [];
            const removals = materialRemovalsRef.current[assetId] || [];
            const processingTimes = materialProcessingTimesRef.current[assetId] || [];
            const wipSnapshots = wipSnapshotsRef.current[assetId] || [];

            // Calculate average processing time
            const completedProcessing = processingTimes.filter((p) => p.processingDuration);
            const avgProcessingTime = completedProcessing.length > 0 ? completedProcessing.reduce((sum, p) => sum + (p.processingDuration || 0), 0) / completedProcessing.length : 0;

            // Calculate current WIP
            const currentWIP = wipSnapshots.length > 0 ? wipSnapshots[wipSnapshots.length - 1].wipCount : 0;

            // Calculate throughput rate
            const now = Date.now();
            const oneHourAgo = now - 3600000;
            const recentRemovals = removals.filter((r) => r.timestamp >= oneHourAgo);
            const throughputRate = recentRemovals.length; // items per hour

            // Calculate cycle efficiency
            const totalAdded = additions.length;
            const totalRemoved = removals.length;
            const cycleEfficiency = totalAdded > 0 ? (totalRemoved / totalAdded) * 100 : 100;

            return {
                totalAdded,
                totalRemoved,
                currentWIP,
                avgProcessingTime: avgProcessingTime / 1000, // convert to seconds
                throughputRate,
                cycleEfficiency,
                processingTimeVariance: calculateVariance(completedProcessing.map((p) => p.processingDuration || 0)),
            };
        },
        [getMaterialsByModel]
    );

    /**
     * Calculate variance helper
     */
    const calculateVariance = (values: number[]) => {
        if (values.length === 0) return 0;
        const mean = values.reduce((sum, v) => sum + v, 0) / values.length;
        const squaredDiffs = values.map((v) => Math.pow(v - mean, 2));
        return squaredDiffs.reduce((sum, v) => sum + v, 0) / values.length;
    };

    // ============================================================================
    // ENHANCED CONVEYOR ANALYSIS
    // ============================================================================

    const analyzeConveyor = useCallback(
        (conveyor: ConveyorStatus): ConveyorAnalysis => {
            const errorCount = errorCountsRef.current[conveyor.modelUuid] || 0;
            const timeMetrics = calculateAdvancedTimeMetrics(conveyor.idleTime || 0, conveyor.activeTime || 0, conveyor.modelUuid, errorCount);

            const materialFlow = calculateMaterialFlowMetricsForAsset(conveyor.modelUuid);
            const materialsProcessed = materialFlow.totalMaterialsProcessed;
            const defects = errorCountsRef.current[`${conveyor.modelUuid}_defects`] || 0;
            const qualityMetrics = calculateQualityMetrics(conveyor.modelUuid, materialsProcessed, defects);

            // Performance calculations
            const conveyorLength = 10; // meters
            const idealSpeed = conveyor.speed;
            const actualSpeed = conveyor.isActive ? conveyor.speed : 0;
            const idealThroughput = idealSpeed > 0 ? (idealSpeed * 3600) / (conveyorLength / 2) : 0; // items per hour
            const actualThroughput = materialFlow.throughput * 3600;

            const performance = calculatePerformanceMetrics(
                materialsProcessed,
                idealThroughput * (timeMetrics.totalTime / 3600),
                timeMetrics.totalTime,
                materialsProcessed * 2, // 2 seconds per item ideal
                "conveyor"
            );

            const costMetrics = calculateCostMetrics(conveyor.modelUuid, "conveyor", conveyor.activeTime || 0, materialsProcessed);

            const energyMetrics = calculateEnergyMetrics("conveyor", conveyor.activeTime || 0);

            // Update historical data
            const timestamp = new Date().toISOString();
            const newEntry = {
                timestamp,
                isActive: !conveyor.isPaused,
                speed: conveyor.speed,
                state: conveyor.state,
                materialsCount: materialFlow.currentMaterials,
                throughput: actualThroughput,
                performance: performance.performanceRate,
            };

            const currentData = historicalDataRef.current[conveyor.modelUuid] || [];
            historicalDataRef.current[conveyor.modelUuid] = [...currentData, newEntry].slice(-100);

            // Calculate queue if applicable
            const queueLength = materialFlow.wip;
            const currentQueueData = queueLengthsRef.current[conveyor.modelUuid] || [];
            queueLengthsRef.current[conveyor.modelUuid] = [...currentQueueData, { timestamp: Date.now(), length: queueLength }].slice(-100);

            return {
                assetId: conveyor.modelUuid,
                assetName: conveyor.modelName,
                assetType: "conveyor",

                currentStatus: {
                    isActive: !conveyor.isPaused,
                    isPaused: conveyor.isPaused,
                    state: conveyor.state,
                    speed: conveyor.speed,
                    currentProduct: conveyor.productUuid,
                    currentMaterials: materialFlow.currentMaterials,
                    queueLength,
                },

                timeMetrics: {
                    ...timeMetrics,
                    idleTime: conveyor.idleTime || 0,
                    activeTime: conveyor.activeTime || 0,
                    totalTime: timeMetrics.totalTime,
                    availability: timeMetrics.uptime,
                    reliability: timeMetrics.reliability,
                    scheduleAdherence: timeMetrics.scheduleAdherence,
                },

                throughput: {
                    itemsPerHour: actualThroughput,
                    itemsPerDay: actualThroughput * 24,
                    materialFlowRate: conveyor.speed * 60,
                    capacityUtilization: timeMetrics.utilizationRate * 100,
                    materialsProcessed,
                    averageProcessingTime: materialFlow.avgCycleTime,
                    wip: materialFlow.wip,
                    throughputEfficiency: (actualThroughput / Math.max(1, idealThroughput)) * 100,
                    bottleneckIndex: timeMetrics.utilizationRate > 0.9 ? 1 : 0,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, performance.performanceRate, qualityMetrics.firstPassYield),
                    availability: timeMetrics.uptime,
                    performance: performance.performanceRate,
                    quality: qualityMetrics.firstPassYield,
                    timeEfficiency: performance.timeEfficiency,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    costEfficiency: 100 - costMetrics.costPerUnit * 10, // Inverse relationship
                    scheduleEfficiency: timeMetrics.scheduleAdherence,
                },

                quality: qualityMetrics,

                // Add cost metrics
                costMetrics: {
                    operatingCost: costMetrics.operatingCost,
                    maintenanceCost: costMetrics.maintenanceCost,
                    energyCost: energyMetrics.energyCost,
                    totalCost: costMetrics.totalCost,
                    costPerUnit: costMetrics.costPerUnit,
                    costPerHour: costMetrics.costPerHour,
                    roi: costMetrics.roi,
                    valueAdded: costMetrics.valueAdded,
                },

                // Add energy metrics
                energyMetrics: {
                    energyConsumed: energyMetrics.energyConsumed,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    carbonFootprint: energyMetrics.carbonFootprint,
                    powerUsage: energyMetrics.powerUsage,
                    energyCost: energyMetrics.energyCost,
                    energyPerUnit: materialsProcessed > 0 ? energyMetrics.energyConsumed / materialsProcessed : 0,
                },

                // Material flow metrics
                materialFlow: {
                    wip: materialFlow.wip,
                    throughput: materialFlow.throughput,
                    avgCycleTime: materialFlow.avgCycleTime,
                    materialVelocity: materialFlow.materialVelocity,
                    inventoryTurns: materialFlow.inventoryTurns,
                    leadTimeVariance: 0, // Could be calculated with more data
                },

                historicalData: historicalDataRef.current[conveyor.modelUuid] || [],
            };
        },
        [materials, analysis, speed]
    );

    // ============================================================================
    // ENHANCED VEHICLE ANALYSIS (apply similar enhancements to other assets)
    // ============================================================================

    const analyzeVehicle = useCallback(
        (vehicle: VehicleStatus): VehicleAnalysis => {
            const errorCount = errorCountsRef.current[vehicle.modelUuid] || 0;
            const timeMetrics = calculateAdvancedTimeMetrics(vehicle.idleTime || 0, vehicle.activeTime || 0, vehicle.modelUuid, errorCount);

            const materialFlow = calculateMaterialFlowMetricsForAsset(vehicle.modelUuid);
            const tripsCompleted = completedActionsRef.current[vehicle.modelUuid] || 0;
            const totalLoadsDelivered = completedActionsRef.current[`${vehicle.modelUuid}_loads`] || 0;
            const defects = errorCount; // Use main error count directly
            const qualityMetrics = calculateQualityMetrics(vehicle.modelUuid, totalLoadsDelivered, defects);

            // Performance calculations
            const loadCapacity = vehicle.point?.action?.loadCapacity || 1;
            const avgLoad = tripsCompleted > 0 ? totalLoadsDelivered / tripsCompleted : 0;
            const loadUtilization = (avgLoad / loadCapacity) * 100;

            const idealTripTime = 60;
            const actualTripTime = tripsCompleted > 0 ? timeMetrics.totalTime / tripsCompleted : 0;
            const idealThroughput = loadCapacity * (3600 / idealTripTime);
            const actualThroughput = materialFlow.throughput * 3600;

            const performance = calculatePerformanceMetrics(totalLoadsDelivered, idealThroughput * (timeMetrics.totalTime / 3600), timeMetrics.totalTime, idealTripTime * tripsCompleted, "vehicle");

            // Route efficiency
            const optimalDistance = 100;
            const actualDistance = vehicle.distanceTraveled || 0;
            const routeEfficiency = actualDistance > 0 ? Math.min((optimalDistance / actualDistance) * 100, 100) : 100;

            const costMetrics = calculateCostMetrics(vehicle.modelUuid, "vehicle", vehicle.activeTime || 0, totalLoadsDelivered);

            const energyMetrics = calculateEnergyMetrics("vehicle", vehicle.activeTime || 0, actualDistance);

            // Update historical data
            const timestamp = new Date().toISOString();
            const currentData = historicalDataRef.current[vehicle.modelUuid] || [];
            historicalDataRef.current[vehicle.modelUuid] = [
                ...currentData,
                {
                    timestamp,
                    phase: vehicle.currentPhase,
                    load: vehicle.currentLoad,
                    distanceTraveled: actualDistance,
                    state: vehicle.state,
                    performance: performance.performanceRate,
                    speed: vehicle.speed,
                    tripsCompleted,
                },
            ].slice(-100);

            return {
                assetId: vehicle.modelUuid,
                assetName: vehicle.modelName,
                assetType: "vehicle",

                currentStatus: {
                    isActive: vehicle.isActive,
                    isPicking: vehicle.isPicking,
                    currentPhase: vehicle.currentPhase,
                    state: vehicle.state,
                    speed: vehicle.speed,
                    currentLoad: vehicle.currentLoad,
                    currentMaterials: vehicle.currentMaterials,
                    distanceTraveled: actualDistance,
                    currentRouteEfficiency: routeEfficiency,
                },

                timeMetrics: {
                    ...timeMetrics,
                    idleTime: vehicle.idleTime || 0,
                    activeTime: vehicle.activeTime || 0,
                    totalTime: timeMetrics.totalTime,
                    averageTripTime: actualTripTime,
                    availability: timeMetrics.uptime,
                    reliability: timeMetrics.reliability,
                },

                throughput: {
                    itemsPerHour: actualThroughput,
                    itemsPerDay: actualThroughput * 24,
                    materialFlowRate: vehicle.speed,
                    capacityUtilization: timeMetrics.utilizationRate * 100,
                    tripsCompleted,
                    averageLoadsPerTrip: avgLoad,
                    totalLoadsDelivered,
                    throughputEfficiency: (actualThroughput / Math.max(1, idealThroughput)) * 100,
                    wip: materialFlow.wip,
                    bottleneckIndex: timeMetrics.utilizationRate > 0.85 ? 1 : 0,
                },

                movementMetrics: {
                    distanceTraveled: actualDistance,
                    averageSpeedActual: timeMetrics.totalTime > 0 ? actualDistance / timeMetrics.totalTime : 0,
                    fuelEfficiency: actualDistance > 0 ? totalLoadsDelivered / actualDistance : 0,
                    routeEfficiency,
                    idleDistance: vehicle.idleTime || 0,
                    totalTrips: tripsCompleted,
                    averageTripDistance: tripsCompleted > 0 ? actualDistance / tripsCompleted : 0,
                    distanceEfficiency: routeEfficiency,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, performance.performanceRate, qualityMetrics.firstPassYield),
                    availability: timeMetrics.uptime,
                    performance: performance.performanceRate,
                    quality: qualityMetrics.firstPassYield,
                    loadUtilization,
                    timeEfficiency: performance.timeEfficiency,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    routeEfficiency,
                    costEfficiency: 100 - costMetrics.costPerUnit * 5,
                },

                quality: {
                    ...qualityMetrics,
                    onTimeDelivery: tripsCompleted > 0 ? ((tripsCompleted - defects) / tripsCompleted) * 100 : 100,
                    damageRate: defects > 0 ? (defects / totalLoadsDelivered) * 100 : 0,
                    accuracyRate: 100 - qualityMetrics.defectRate,
                },

                costMetrics: {
                    operatingCost: costMetrics.operatingCost,
                    maintenanceCost: costMetrics.maintenanceCost,
                    energyCost: energyMetrics.energyCost,
                    totalCost: costMetrics.totalCost,
                    costPerMile: actualDistance > 0 ? costMetrics.totalCost / (actualDistance / 1609.34) : 0, // Convert meters to miles
                    costPerTrip: tripsCompleted > 0 ? costMetrics.totalCost / tripsCompleted : 0,
                    costPerLoad: totalLoadsDelivered > 0 ? costMetrics.totalCost / totalLoadsDelivered : 0,
                    roi: costMetrics.roi,
                    valueAdded: costMetrics.valueAdded,
                },

                energyMetrics: {
                    energyConsumed: energyMetrics.energyConsumed,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    carbonFootprint: energyMetrics.carbonFootprint,
                    powerUsage: energyMetrics.powerUsage,
                    energyCost: energyMetrics.energyCost,
                    energyPerMile: actualDistance > 0 ? energyMetrics.energyConsumed / actualDistance : 0,
                    energyPerTrip: tripsCompleted > 0 ? energyMetrics.energyConsumed / tripsCompleted : 0,
                },

                historicalData: historicalDataRef.current[vehicle.modelUuid] || [],
            };
        },
        [materials, analysis, speed]
    );

    // ============================================================================
    // ENHANCED ROBOTIC ARM ANALYSIS
    // ============================================================================

    const analyzeRoboticArm = useCallback(
        (armBot: ArmBotStatus): RoboticArmAnalysis => {
            const errorCount = errorCountsRef.current[armBot.modelUuid] || 0;
            const timeMetrics = calculateAdvancedTimeMetrics(armBot.idleTime || 0, armBot.activeTime || 0, armBot.modelUuid, errorCount);

            const materialFlow = calculateMaterialFlowMetricsForAsset(armBot.modelUuid);
            const cyclesCompleted = completedActionsRef.current[armBot.modelUuid] || 0;
            const pickAndPlaceCount = completedActionsRef.current[`${armBot.modelUuid}_pickplace`] || cyclesCompleted;
            const defects = errorCount; // Use main error count directly

            const qualityMetrics = calculateQualityMetrics(armBot.modelUuid, pickAndPlaceCount, defects);

            // Performance calculations
            const idealCycleTime = 5; // 5 seconds ideal
            const actualCycleTime = cyclesCompleted > 0 ? timeMetrics.totalTime / cyclesCompleted : 0;
            const idealThroughput = (3600 / idealCycleTime) * 1; // 1 item per cycle
            const actualThroughput = materialFlow.throughput * 3600;

            const performance = calculatePerformanceMetrics(pickAndPlaceCount, idealThroughput * (timeMetrics.totalTime / 3600), timeMetrics.totalTime, idealCycleTime * cyclesCompleted, "roboticArm");

            const costMetrics = calculateCostMetrics(armBot.modelUuid, "roboticArm", armBot.activeTime || 0, pickAndPlaceCount);

            const energyMetrics = calculateEnergyMetrics("roboticArm", armBot.activeTime || 0);

            // Calculate success rates
            // Calculate success rates
            const pickSuccessCount = completedActionsRef.current[`${armBot.modelUuid}_pick`] || pickAndPlaceCount / 2;
            const placeSuccessCount = completedActionsRef.current[`${armBot.modelUuid}_place`] || pickAndPlaceCount / 2;

            const pickErrors = errorCountsRef.current[`${armBot.modelUuid}_pick`] || 0;
            const placeErrors = errorCountsRef.current[`${armBot.modelUuid}_place`] || 0;

            // If granular errors are 0 but main error count > 0, distribute them (fallback)
            const remainingErrors = Math.max(0, errorCount - pickErrors - placeErrors);
            const effectivePickErrors = pickErrors + (remainingErrors > 0 ? Math.ceil(remainingErrors / 2) : 0);
            const effectivePlaceErrors = placeErrors + (remainingErrors > 0 ? Math.floor(remainingErrors / 2) : 0);

            const pickAttempts = pickSuccessCount + effectivePickErrors;
            const placeAttempts = placeSuccessCount + effectivePlaceErrors;

            const pickSuccessRate = pickAttempts > 0 ? (pickSuccessCount / pickAttempts) * 100 : 100;
            const placeAccuracy = placeAttempts > 0 ? (placeSuccessCount / placeAttempts) * 100 : 100;

            // Update historical data

            const timestamp = new Date().toISOString();
            const newEntry = {
                timestamp,
                cycleTime: actualCycleTime,
                actionType: armBot.currentAction?.actionName || "unknown",
                isActive: armBot.isActive,
                state: armBot.state,
                speed: armBot.speed,
                cyclesCompleted,
                successRate: pickSuccessRate,
                performance: performance.performanceRate,
            };

            const currentData = historicalDataRef.current[armBot.modelUuid] || [];
            historicalDataRef.current[armBot.modelUuid] = [...currentData, newEntry].slice(-100);

            return {
                assetId: armBot.modelUuid,
                assetName: armBot.modelName,
                assetType: "roboticArm",

                currentStatus: {
                    isActive: armBot.isActive,
                    state: armBot.state,
                    speed: armBot.speed,
                    currentAction: armBot.currentAction || null,
                },

                timeMetrics: {
                    ...timeMetrics,
                    idleTime: armBot.idleTime || 0,
                    activeTime: armBot.activeTime || 0,
                    totalTime: timeMetrics.totalTime,
                    averageCycleTime: actualCycleTime,
                    availability: timeMetrics.uptime,
                    reliability: timeMetrics.reliability,
                },

                throughput: {
                    itemsPerHour: actualThroughput,
                    itemsPerDay: actualThroughput * 24,
                    materialFlowRate: armBot.speed,
                    capacityUtilization: timeMetrics.utilizationRate * 100,
                    cyclesCompleted,
                    pickAndPlaceCount,
                    throughputEfficiency: (actualThroughput / Math.max(1, idealThroughput)) * 100,
                    wip: materialFlow.wip,
                    bottleneckIndex: timeMetrics.utilizationRate > 0.85 ? 1 : 0,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, performance.performanceRate, qualityMetrics.firstPassYield),
                    availability: timeMetrics.uptime,
                    performance: performance.performanceRate,
                    quality: qualityMetrics.firstPassYield,
                    cycleTimeEfficiency: performance.timeEfficiency,
                },

                quality: {
                    ...qualityMetrics,
                    pickSuccessRate,
                    placeAccuracy,
                },

                // Add cost metrics
                costMetrics: {
                    operatingCost: costMetrics.operatingCost,
                    maintenanceCost: costMetrics.maintenanceCost,
                    energyCost: energyMetrics.energyCost,
                    totalCost: costMetrics.totalCost,
                    roi: costMetrics.roi,
                    valueAdded: costMetrics.valueAdded,
                },

                // Add energy metrics
                energyMetrics: {
                    energyConsumed: energyMetrics.energyConsumed,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    carbonFootprint: energyMetrics.carbonFootprint,
                    powerUsage: energyMetrics.powerUsage,
                    energyCost: energyMetrics.energyCost,
                    energyPerUnit: pickAndPlaceCount > 0 ? energyMetrics.energyConsumed / pickAndPlaceCount : 0,
                },

                historicalData: historicalDataRef.current[armBot.modelUuid] || [],
            };
        },
        [materials, analysis, speed]
    );

    // ============================================================================
    // ENHANCED MACHINE ANALYSIS
    // ============================================================================

    const analyzeMachine = useCallback(
        (machine: MachineStatus): MachineAnalysis => {
            const errorCount = errorCountsRef.current[machine.modelUuid] || 0;
            const timeMetrics = calculateAdvancedTimeMetrics(machine.idleTime || 0, machine.activeTime || 0, machine.modelUuid, errorCount);

            const materialFlow = calculateMaterialFlowMetricsForAsset(machine.modelUuid);
            const cyclesCompleted = completedActionsRef.current[machine.modelUuid] || 0;
            const partsProcessed = completedActionsRef.current[`${machine.modelUuid}_parts`] || cyclesCompleted;
            const defects = errorCountsRef.current[`${machine.modelUuid}_defects`] || 0;

            const qualityMetrics = calculateQualityMetrics(machine.modelUuid, partsProcessed, defects);

            // Performance calculations
            const targetProcessTime = machine.point?.action?.processTime || 30;
            const actualProcessTime = cyclesCompleted > 0 ? timeMetrics.totalTime / cyclesCompleted : 0;
            const idealThroughput = (3600 / targetProcessTime) * 1; // 1 part per process
            const actualThroughput = materialFlow.throughput * 3600;

            const performance = calculatePerformanceMetrics(partsProcessed, idealThroughput * (timeMetrics.totalTime / 3600), timeMetrics.totalTime, targetProcessTime * cyclesCompleted, "machine");

            const costMetrics = calculateCostMetrics(machine.modelUuid, "machine", machine.activeTime || 0, partsProcessed);

            const energyMetrics = calculateEnergyMetrics("machine", machine.activeTime || 0);

            // Quality calculations
            const totalParts = partsProcessed + defects;
            const defectRate = totalParts > 0 ? (defects / totalParts) * 100 : 0;
            const reworkRate = defectRate * 0.3; // Assume 30% of defects are reworked
            const scrapRate = defectRate * 0.7; // Assume 70% are scrapped

            // Update historical data
            const timestamp = new Date().toISOString();
            const currentData = historicalDataRef.current[machine.modelUuid] || [];
            historicalDataRef.current[machine.modelUuid] = [
                ...currentData,
                {
                    timestamp,
                    processTime: actualProcessTime,
                    partsProcessed,
                    isActive: machine.isActive,
                    state: machine.state,
                    defectRate,
                    performance: performance.performanceRate,
                },
            ].slice(-100);

            return {
                assetId: machine.modelUuid,
                assetName: machine.modelName,
                assetType: "machine",

                currentStatus: {
                    isActive: machine.isActive,
                    state: machine.state,
                    currentAction: machine.currentAction || null,
                },

                timeMetrics: {
                    ...timeMetrics,
                    idleTime: machine.idleTime || 0,
                    activeTime: machine.activeTime || 0,
                    totalTime: timeMetrics.totalTime,
                    averageProcessTime: actualProcessTime,
                    availability: timeMetrics.uptime,
                    reliability: timeMetrics.reliability,
                },

                throughput: {
                    itemsPerHour: actualThroughput,
                    itemsPerDay: actualThroughput * 24,
                    materialFlowRate: partsProcessed > 0 ? partsProcessed / (timeMetrics.totalTime / 60) : 0,
                    capacityUtilization: timeMetrics.utilizationRate * 100,
                    cyclesCompleted,
                    partsProcessed,
                    throughputEfficiency: (actualThroughput / Math.max(1, idealThroughput)) * 100,
                    wip: materialFlow.wip,
                    bottleneckIndex: timeMetrics.utilizationRate > 0.85 ? 1 : 0,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, performance.performanceRate, qualityMetrics.firstPassYield),
                    availability: timeMetrics.uptime,
                    performance: performance.performanceRate,
                    quality: qualityMetrics.firstPassYield,
                    targetVsActual: performance.timeEfficiency,
                },

                quality: {
                    ...qualityMetrics,
                    defectRate,
                    reworkRate,
                    scrapRate,
                },

                // Add cost metrics
                costMetrics: {
                    operatingCost: costMetrics.operatingCost,
                    maintenanceCost: costMetrics.maintenanceCost,
                    energyCost: energyMetrics.energyCost,
                    totalCost: costMetrics.totalCost,
                    roi: costMetrics.roi,
                    valueAdded: costMetrics.valueAdded,
                    costPerUnit: partsProcessed > 0 ? costMetrics.totalCost / partsProcessed : 0,
                },

                // Add energy metrics
                energyMetrics: {
                    energyConsumed: energyMetrics.energyConsumed,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    carbonFootprint: energyMetrics.carbonFootprint,
                    powerUsage: energyMetrics.powerUsage,
                    energyCost: energyMetrics.energyCost,
                    energyPerUnit: partsProcessed > 0 ? energyMetrics.energyConsumed / partsProcessed : 0,
                },

                historicalData: historicalDataRef.current[machine.modelUuid] || [],
            };
        },
        [materials, analysis, speed]
    );

    // ============================================================================
    // ENHANCED STORAGE ANALYSIS
    // ============================================================================

    const analyzeStorage = useCallback(
        (storage: StorageUnitStatus): StorageAnalysis => {
            const errorCount = errorCountsRef.current[storage.modelUuid] || 0;
            const timeMetrics = calculateAdvancedTimeMetrics(storage.idleTime || 0, storage.activeTime || 0, storage.modelUuid, errorCount);

            const currentLoad = storage.currentLoad || 0;
            const capacity = storage.storageCapacity || 1;
            const utilizationRate = (currentLoad / capacity) * 100;

            const storeOps = completedActionsRef.current[`${storage.modelUuid}_store`] || 0;
            const retrieveOps = completedActionsRef.current[`${storage.modelUuid}_retrieve`] || 0;
            const totalOps = storeOps + retrieveOps;

            const qualityMetrics = calculateQualityMetrics(storage.modelUuid, totalOps, errorCount);

            // Calculate turnover rate
            const turnoverRate = timeMetrics.totalTime > 0 ? (totalOps / timeMetrics.totalTime) * 3600 : 0;

            // Occupancy trends
            const timestamp = new Date().toISOString();
            const currentData = historicalDataRef.current[storage.modelUuid] || [];
            historicalDataRef.current[storage.modelUuid] = [
                ...currentData,
                {
                    timestamp,
                    currentLoad,
                    utilizationRate,
                    operation: storeOps > retrieveOps ? "store" : "retrieve",
                    totalOps,
                    state: storage.state,
                },
            ].slice(-100);

            // Calculate peak occupancy from historical data
            const occupancyData = historicalDataRef.current[storage.modelUuid] || [];
            const peakOccupancy = occupancyData.length > 0 ? Math.max(...occupancyData.map((d) => d.utilizationRate)) : utilizationRate;
            const averageOccupancy = occupancyData.length > 0 ? occupancyData.reduce((sum, d) => sum + d.utilizationRate, 0) / occupancyData.length : utilizationRate;

            // Calculate occupancy trends for the last hour
            const hourAgo = Date.now() - 3600000;
            const recentOccupancy = occupancyData.filter((d) => new Date(d.timestamp).getTime() > hourAgo).map((d) => d.utilizationRate);
            const occupancyTrend = recentOccupancy.length > 1 ? ((recentOccupancy[recentOccupancy.length - 1] - recentOccupancy[0]) / recentOccupancy[0]) * 100 : 0;

            const costMetrics = calculateCostMetrics(storage.modelUuid, "storage", storage.activeTime || 0, totalOps);
            const energyMetrics = calculateEnergyMetrics("storage", storage.activeTime || 0);

            return {
                assetId: storage.modelUuid,
                assetName: storage.modelName,
                assetType: "storage",

                currentStatus: {
                    isActive: storage.isActive,
                    state: storage.state,
                    currentLoad,
                    storageCapacity: capacity,
                    currentMaterials: storage.currentMaterials,
                },

                timeMetrics: {
                    ...timeMetrics,
                    idleTime: storage.idleTime || 0,
                    activeTime: storage.activeTime || 0,
                    totalTime: timeMetrics.totalTime,
                    availability: timeMetrics.uptime,
                    reliability: timeMetrics.reliability,
                },

                capacityMetrics: {
                    utilizationRate,
                    averageOccupancy,
                    peakOccupancy,
                    turnoverRate,
                    occupancyTrend,
                },

                throughput: {
                    itemsPerHour: turnoverRate,
                    itemsPerDay: turnoverRate * 24,
                    materialFlowRate: turnoverRate / 60,
                    capacityUtilization: utilizationRate,
                    storeOperations: storeOps,
                    retrieveOperations: retrieveOps,
                    totalOperations: totalOps,
                    throughputEfficiency: (totalOps / Math.max(1, capacity * 24)) * 100,
                    wip: currentLoad,
                    bottleneckIndex: utilizationRate > 0.9 ? 1 : 0,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, utilizationRate, qualityMetrics.firstPassYield),
                    availability: timeMetrics.uptime,
                    performance: utilizationRate,
                    quality: qualityMetrics.firstPassYield,
                    spaceUtilization: utilizationRate,
                },

                quality: qualityMetrics,

                // Add cost metrics
                costMetrics: {
                    operatingCost: costMetrics.operatingCost,
                    maintenanceCost: costMetrics.maintenanceCost,
                    energyCost: energyMetrics.energyCost,
                    totalCost: costMetrics.totalCost,
                    roi: costMetrics.roi,
                    valueAdded: costMetrics.valueAdded,
                    costPerUnit: totalOps > 0 ? costMetrics.totalCost / totalOps : 0,
                    costPerStorageHour: capacity > 0 ? costMetrics.totalCost / (capacity * (timeMetrics.totalTime / 3600)) : 0,
                },

                // Add energy metrics
                energyMetrics: {
                    energyConsumed: energyMetrics.energyConsumed,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    carbonFootprint: energyMetrics.carbonFootprint,
                    powerUsage: energyMetrics.powerUsage,
                    energyCost: energyMetrics.energyCost,
                    energyPerUnit: totalOps > 0 ? energyMetrics.energyConsumed / totalOps : 0,
                },

                occupancyTrends: occupancyData.slice(-100).map((d) => ({
                    timestamp: d.timestamp,
                    occupancy: d.currentLoad,
                    utilizationRate: d.utilizationRate,
                })),

                historicalData: historicalDataRef.current[storage.modelUuid] || [],
            };
        },
        [analysis, speed]
    );

    // ============================================================================
    // ENHANCED HUMAN ANALYSIS
    // ============================================================================

    const analyzeHuman = useCallback(
        (human: HumanStatus): HumanAnalysis => {
            const errorCount = errorCountsRef.current[human.modelUuid] || 0;
            const timeMetrics = calculateAdvancedTimeMetrics(human.idleTime || 0, human.activeTime || 0, human.modelUuid, errorCount);

            const actionsCompleted = completedActionsRef.current[human.modelUuid] || 0;
            const distanceTraveled = human.distanceTraveled || 0;
            const currentLoad = human.currentLoad || 0;
            const loadCapacity = human.point?.actions?.[0]?.loadCapacity || 1;
            const loadUtilization = (currentLoad / loadCapacity) * 100;

            // Workload distribution calculations
            const workerActions = completedActionsRef.current[`${human.modelUuid}_worker`] || 0;
            const manufacturerActions = completedActionsRef.current[`${human.modelUuid}_manufacturer`] || 0;
            const operatorActions = completedActionsRef.current[`${human.modelUuid}_operator`] || 0;
            const assemblerActions = completedActionsRef.current[`${human.modelUuid}_assembler`] || 0;

            const workerTime = completedActionsRef.current[`${human.modelUuid}_worker_time`] || 0;
            const manufacturerTime = completedActionsRef.current[`${human.modelUuid}_manufacturer_time`] || 0;
            const operatorTime = completedActionsRef.current[`${human.modelUuid}_operator_time`] || 0;
            const assemblerTime = completedActionsRef.current[`${human.modelUuid}_assembler_time`] || 0;

            const totalActionTime = workerTime + manufacturerTime + operatorTime + assemblerTime;

            const workloadDistributionData = [
                { actionType: "Worker", count: workerActions, totalTime: workerTime, percentage: totalActionTime > 0 ? (workerTime / totalActionTime) * 100 : 0 },
                { actionType: "Manufacturer", count: manufacturerActions, totalTime: manufacturerTime, percentage: totalActionTime > 0 ? (manufacturerTime / totalActionTime) * 100 : 0 },
                { actionType: "Operator", count: operatorActions, totalTime: operatorTime, percentage: totalActionTime > 0 ? (operatorTime / totalActionTime) * 100 : 0 },
                { actionType: "Assembler", count: assemblerActions, totalTime: assemblerTime, percentage: totalActionTime > 0 ? (assemblerTime / totalActionTime) * 100 : 0 },
            ].filter((w) => w.count > 0);

            const workloadDistribution = workloadDistributionData.map((d) => `${Math.round(d.percentage)}%`).join(" | ");

            // Performance calculations
            const idealActionsPerHour = 60; // 60 actions per hour ideal
            const actualActionsPerHour = timeMetrics.totalTime > 0 ? (actionsCompleted / timeMetrics.totalTime) * 3600 : 0;
            const performanceRate = Math.min((actualActionsPerHour / idealActionsPerHour) * 100, 100);

            const qualityMetrics = calculateQualityMetrics(human.modelUuid, actionsCompleted, errorCount);

            const costMetrics = calculateCostMetrics(human.modelUuid, "human", human.activeTime || 0, actionsCompleted);
            const energyMetrics = calculateEnergyMetrics("human", human.activeTime || 0);

            // Update historical data
            const timestamp = new Date().toISOString();
            const newEntry = {
                timestamp,
                actionType: human.currentAction?.actionName || "unknown",
                duration: timeMetrics.totalTime,
                distanceTraveled,
                isActive: human.isActive,
                state: human.state,
                load: currentLoad,
                performance: performanceRate,
            };

            const currentData = historicalDataRef.current[human.modelUuid] || [];
            historicalDataRef.current[human.modelUuid] = [...currentData, newEntry].slice(-100);

            return {
                assetId: human.modelUuid,
                assetName: human.modelName,
                assetType: "human",

                currentStatus: {
                    isActive: human.isActive,
                    isScheduled: human.isScheduled,
                    currentPhase: human.currentPhase,
                    state: human.state,
                    speed: human.speed,
                    currentLoad,
                    currentMaterials: human.currentMaterials,
                    currentAction: human.currentAction || null,
                    loadUtilization,
                },

                timeMetrics: {
                    ...timeMetrics,
                    idleTime: human.idleTime || 0,
                    activeTime: human.activeTime || 0,
                    totalTime: timeMetrics.totalTime,
                    scheduledTime: timeMetrics.totalTime,
                    availability: timeMetrics.uptime,
                    reliability: timeMetrics.reliability,
                },

                productivityMetrics: {
                    actionsCompleted,
                    actionsPerHour: actualActionsPerHour,
                    averageActionTime: actionsCompleted > 0 ? timeMetrics.totalTime / actionsCompleted : 0,
                    distanceTraveled,
                    averageSpeed: timeMetrics.totalTime > 0 ? distanceTraveled / timeMetrics.totalTime : 0,
                    loadEfficiency: loadUtilization,
                },

                workloadDistribution: workloadDistributionData,
                workloadSummary: workloadDistribution === "" ? "0%" : workloadDistribution,

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, performanceRate, qualityMetrics.firstPassYield),
                    availability: timeMetrics.uptime,
                    performance: performanceRate,
                    quality: qualityMetrics.firstPassYield,
                    laborProductivity: actualActionsPerHour,
                    utilizationRate: timeMetrics.utilizationRate * 100,
                },

                quality: qualityMetrics,

                // Add cost metrics
                costMetrics: {
                    operatingCost: costMetrics.operatingCost,
                    maintenanceCost: costMetrics.maintenanceCost,
                    energyCost: energyMetrics.energyCost,
                    totalCost: costMetrics.totalCost,
                    roi: costMetrics.roi,
                    valueAdded: costMetrics.valueAdded,
                    costPerAction: actionsCompleted > 0 ? costMetrics.totalCost / actionsCompleted : 0,
                    costPerHour: costMetrics.costPerHour,
                },

                // Add energy metrics
                energyMetrics: {
                    energyConsumed: energyMetrics.energyConsumed,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    carbonFootprint: energyMetrics.carbonFootprint,
                    powerUsage: energyMetrics.powerUsage,
                    energyCost: energyMetrics.energyCost,
                    energyPerAction: actionsCompleted > 0 ? energyMetrics.energyConsumed / actionsCompleted : 0,
                },

                historicalData: historicalDataRef.current[human.modelUuid] || [],
            };
        },
        [analysis, speed]
    );

    // ============================================================================
    // ENHANCED CRANE ANALYSIS
    // ============================================================================

    const analyzeCrane = useCallback(
        (crane: CraneStatus): CraneAnalysis => {
            const errorCount = errorCountsRef.current[crane.modelUuid] || 0;
            const timeMetrics = calculateAdvancedTimeMetrics(crane.idleTime || 0, crane.activeTime || 0, crane.modelUuid, errorCount);

            const cyclesCompleted = completedActionsRef.current[crane.modelUuid] || 0;
            const loadsHandled = completedActionsRef.current[`${crane.modelUuid}_loads`] || 0;
            const totalLifts = completedActionsRef.current[`${crane.modelUuid}_lifts`] || 0;
            const totalLiftHeight = completedActionsRef.current[`${crane.modelUuid}_lift_height`] || 0;

            const qualityMetrics = calculateQualityMetrics(crane.modelUuid, loadsHandled, errorCount);

            // Performance calculations
            const idealCycleTime = 20; // 20 seconds ideal
            const actualCycleTime = cyclesCompleted > 0 ? timeMetrics.totalTime / cyclesCompleted : 0;
            const idealThroughput = (3600 / idealCycleTime) * 1; // 1 load per cycle
            const actualThroughput = cyclesCompleted > 0 ? (loadsHandled / timeMetrics.totalTime) * 3600 : 0;

            const performance = calculatePerformanceMetrics(loadsHandled, idealThroughput * (timeMetrics.totalTime / 3600), timeMetrics.totalTime, idealCycleTime * cyclesCompleted, "crane");

            // Lift metrics
            const avgLiftHeight = totalLifts > 0 ? totalLiftHeight / totalLifts : 0;
            const avgLoadsPerCycle = cyclesCompleted > 0 ? loadsHandled / cyclesCompleted : 0;

            // Success rates
            const liftAttempts = totalLifts + errorCount;
            const liftSuccessRate = liftAttempts > 0 ? (totalLifts / liftAttempts) * 100 : 0;
            const positioningAccuracy = totalLifts > 0 ? liftSuccessRate * 1.0 : 0; // Slightly lower than success rate

            // Load utilization
            const maxPickUpCount = crane.point?.actions?.[0]?.maxPickUpCount || 1;
            const loadUtilization = (avgLoadsPerCycle / maxPickUpCount) * 100;

            const costMetrics = calculateCostMetrics(crane.modelUuid, "crane", crane.activeTime || 0, loadsHandled);
            const energyMetrics = calculateEnergyMetrics("crane", crane.activeTime || 0);

            // Movement efficiency calculation
            const movementEfficiency = liftSuccessRate * 0.8 + positioningAccuracy * 0.2; // Weighted average

            // Update historical data
            const timestamp = new Date().toISOString();
            const newEntry = {
                timestamp,
                cycleTime: actualCycleTime,
                loadsHandled,
                isActive: crane.isActive,
                state: crane.state,
                isCarrying: crane.isCarrying,
                loadUtilization,
                performance: performance.performanceRate,
            };

            const currentData = historicalDataRef.current[crane.modelUuid] || [];
            historicalDataRef.current[crane.modelUuid] = [...currentData, newEntry].slice(-100);

            return {
                assetId: crane.modelUuid,
                assetName: crane.modelName,
                assetType: "crane",

                currentStatus: {
                    isActive: crane.isActive,
                    isScheduled: crane.isScheduled,
                    isCarrying: crane.isCarrying,
                    currentPhase: crane.currentPhase,
                    state: crane.state,
                    currentLoad: crane.currentLoad,
                    currentMaterials: crane.currentMaterials,
                    currentAction: crane.currentAction || null,
                    loadUtilization,
                },

                timeMetrics: {
                    ...timeMetrics,
                    idleTime: crane.idleTime || 0,
                    activeTime: crane.activeTime || 0,
                    totalTime: timeMetrics.totalTime,
                    averageCycleTime: actualCycleTime,
                    availability: timeMetrics.uptime,
                    reliability: timeMetrics.reliability,
                },

                throughput: {
                    itemsPerHour: actualThroughput,
                    itemsPerDay: actualThroughput * 24,
                    materialFlowRate: loadsHandled > 0 ? loadsHandled / (timeMetrics.totalTime / 60) : 0,
                    capacityUtilization: timeMetrics.utilizationRate * 100,
                    cyclesCompleted,
                    loadsHandled,
                    averageLoadsPerCycle: avgLoadsPerCycle,
                    throughputEfficiency: (actualThroughput / Math.max(1, idealThroughput)) * 100,
                    wip: crane.currentLoad,
                    bottleneckIndex: timeMetrics.utilizationRate > 0.85 ? 1 : 0,
                },

                movementMetrics: {
                    totalLifts,
                    averageLiftHeight: avgLiftHeight,
                    movementEfficiency,
                    loadEfficiency: loadUtilization,
                    cycleEfficiency: performance.timeEfficiency,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, performance.performanceRate, qualityMetrics.firstPassYield),
                    availability: timeMetrics.uptime,
                    performance: performance.performanceRate,
                    quality: qualityMetrics.firstPassYield,
                    loadUtilization,
                    cycleTimeEfficiency: performance.timeEfficiency,
                },

                quality: {
                    ...qualityMetrics,
                    liftSuccessRate,
                    positioningAccuracy,
                },

                // Add cost metrics
                costMetrics: {
                    operatingCost: costMetrics.operatingCost,
                    maintenanceCost: costMetrics.maintenanceCost,
                    energyCost: energyMetrics.energyCost,
                    totalCost: costMetrics.totalCost,
                    roi: costMetrics.roi,
                    valueAdded: costMetrics.valueAdded,
                    costPerLift: totalLifts > 0 ? costMetrics.totalCost / totalLifts : 0,
                    costPerCycle: cyclesCompleted > 0 ? costMetrics.totalCost / cyclesCompleted : 0,
                },

                // Add energy metrics
                energyMetrics: {
                    energyConsumed: energyMetrics.energyConsumed,
                    energyEfficiency: energyMetrics.energyEfficiency,
                    carbonFootprint: energyMetrics.carbonFootprint,
                    powerUsage: energyMetrics.powerUsage,
                    energyCost: energyMetrics.energyCost,
                    energyPerLift: totalLifts > 0 ? energyMetrics.energyConsumed / totalLifts : 0,
                },

                historicalData: historicalDataRef.current[crane.modelUuid] || [],
            };
        },
        [analysis, speed]
    );

    // ============================================================================
    // COMPREHENSIVE SYSTEM-WIDE ANALYSIS
    // ============================================================================

    const analyzeSystem = useCallback(
        (allAssets: AssetAnalysis[]): AnalysisSchema => {
            // System-wide calculations
            const totalAssets = allAssets.length;
            const activeAssets = allAssets.filter((a) => a.currentStatus.isActive).length;
            const assetsInError = allAssets.filter((a) => a.currentStatus.state === "error").length;
            const assetsIdle = allAssets.filter((a) => !a.currentStatus.isActive && a.currentStatus.state === "idle").length;

            // Calculate system OEE (weighted average by throughput)
            const totalThroughput = allAssets.reduce((sum, asset) => {
                if ("throughput" in asset) {
                    return sum + asset.throughput.itemsPerHour;
                } else if ("productivityMetrics" in asset) {
                    return sum + asset.productivityMetrics.actionsPerHour;
                }
                return sum;
            }, 0);

            const weightedOEE = allAssets.reduce((sum, asset) => {
                const weight = ("throughput" in asset ? asset.throughput.itemsPerHour : "productivityMetrics" in asset ? asset.productivityMetrics.actionsPerHour : 1) / Math.max(1, totalThroughput);
                return sum + asset.efficiency.overallEffectiveness * weight;
            }, 0);

            // Calculate system utilization (average of all assets)
            const avgUtilization =
                allAssets.reduce((sum, a) => {
                    if ("timeMetrics" in a) {
                        return sum + a.timeMetrics.utilizationRate;
                    }
                    return sum;
                }, 0) / totalAssets;

            // Calculate total idle and active time
            const totalIdleTime = allAssets.reduce((sum, a) => {
                if ("timeMetrics" in a) {
                    return sum + a.timeMetrics.idleTime;
                }
                return sum;
            }, 0);

            const totalActiveTime = allAssets.reduce((sum, a) => {
                if ("timeMetrics" in a) {
                    return sum + a.timeMetrics.activeTime;
                }
                return sum;
            }, 0);

            const totalSystemTime = totalIdleTime + totalActiveTime;
            const systemUptime = totalSystemTime > 0 ? (totalActiveTime / totalSystemTime) * 100 : 0;

            // Calculate total costs and value
            const totalCost = allAssets.reduce((sum, a) => {
                if ("costMetrics" in a) {
                    return sum + a.costMetrics.totalCost;
                }
                return sum;
            }, 0);

            const totalValueAdded = allAssets.reduce((sum, a) => {
                if ("costMetrics" in a) {
                    return sum + a.costMetrics.valueAdded;
                }
                return sum;
            }, 0);

            const totalEnergyConsumed = allAssets.reduce((sum, a) => {
                if ("energyMetrics" in a) {
                    return sum + a.energyMetrics.energyConsumed;
                }
                return sum;
            }, 0);

            // Group by asset type for detailed analysis
            const assetTypeGroups = allAssets.reduce((acc, asset) => {
                if (!acc[asset.assetType]) {
                    acc[asset.assetType] = [];
                }
                acc[asset.assetType].push(asset);
                return acc;
            }, {} as Record<string, AssetAnalysis[]>);

            const assetTypePerformance = Object.entries(assetTypeGroups).map(([type, assets]) => {
                const typeThroughput = assets.reduce((sum, a) => {
                    if ("throughput" in a) {
                        return sum + a.throughput.itemsPerHour;
                    } else if ("productivityMetrics" in a) {
                        return sum + a.productivityMetrics.actionsPerHour;
                    }
                    return sum;
                }, 0);

                const typeOEE = assets.reduce((sum, a) => sum + a.efficiency.overallEffectiveness, 0) / assets.length;
                const typeUtilization =
                    assets.reduce((sum, a) => {
                        if ("timeMetrics" in a) {
                            return sum + a.timeMetrics.utilizationRate;
                        }
                        return sum;
                    }, 0) / assets.length;

                const typeCost = assets.reduce((sum, a) => {
                    if ("costMetrics" in a) {
                        return sum + a.costMetrics.totalCost;
                    }
                    return sum;
                }, 0);

                return {
                    assetType: type,
                    count: assets.length,
                    averageOEE: typeOEE,
                    averageUtilization: typeUtilization * 100,
                    totalThroughput: typeThroughput,
                    totalCost: typeCost,
                    throughputPerAsset: typeThroughput / assets.length,
                    costPerAsset: typeCost / assets.length,
                };
            });

            // Material Flow Analysis
            const totalMaterialsInSystem = materials.filter((m) => m.isActive).length;
            const completedMaterials = materialHistoryRef.current.length;
            const averageResidenceTime =
                materialHistoryRef.current.length > 0
                    ? materialHistoryRef.current.reduce((sum, entry) => {
                          const residenceTime = new Date(entry.removedAt).getTime() - (entry.material.startTime || 0);
                          return sum + (residenceTime || 0);
                      }, 0) / materialHistoryRef.current.length
                    : 0;

            // Bottleneck Identification
            const bottlenecks = allAssets
                .map((asset) => {
                    let utilizationRate = 0;
                    let queueLength = 0;

                    if ("timeMetrics" in asset) {
                        utilizationRate = asset.timeMetrics.utilizationRate;
                    }

                    if ("currentStatus" in asset && "queueLength" in asset.currentStatus) {
                        queueLength = asset.currentStatus.queueLength as number;
                    }

                    const impactScore = utilizationRate * 100 + queueLength * 10;

                    let severity: "critical" | "high" | "medium" | "low" = "low";
                    if (utilizationRate > 0.95) severity = "critical";
                    else if (utilizationRate > 0.9) severity = "high";
                    else if (utilizationRate > 0.85) severity = "medium";

                    return {
                        assetId: asset.assetId,
                        assetName: asset.assetName,
                        severity,
                        utilizationRate: utilizationRate * 100,
                        queueLength,
                        impactScore,
                    };
                })
                .filter((b) => b.utilizationRate > 80 || b.queueLength > 5)
                .sort((a, b) => b.impactScore - a.impactScore);

            // Queue Analysis
            const queueLengths = allAssets
                .filter((asset) => "currentStatus" in asset && "queueLength" in asset.currentStatus)
                .map((asset) => ({
                    assetId: asset.assetId,
                    assetName: asset.assetName,
                    queueLength: (asset.currentStatus as any).queueLength || 0,
                    averageWaitTime: 0, // Could be calculated with more data
                }))
                .filter((q) => q.queueLength > 0);

            // Flow Continuity Analysis
            const throughputOverTime = Object.values(historicalDataRef.current)
                .flat()
                .filter((d) => d.timestamp)
                .sort((a, b) => new Date(a.timestamp).getTime() - new Date(b.timestamp).getTime());

            const flowRates = throughputOverTime.map((d) => d.throughput || d.actionsPerHour || 0);
            const meanFlowRate = flowRates.length > 0 ? flowRates.reduce((sum, rate) => sum + rate, 0) / flowRates.length : 0;
            const variance = flowRates.length > 0 ? flowRates.reduce((sum, rate) => sum + Math.pow(rate - meanFlowRate, 2), 0) / flowRates.length : 0;
            const varianceCoefficient = meanFlowRate > 0 ? Math.sqrt(variance) / meanFlowRate : 0;

            // Predictive Insights
            const maintenanceAlerts = allAssets
                .filter((asset) => {
                    const errorCount = errorCountsRef.current[asset.assetId] || 0;
                    const uptime = "timeMetrics" in asset ? asset.timeMetrics.uptime : 100;
                    return uptime < 95 || errorCount > 3;
                })
                .map((asset) => ({
                    assetId: asset.assetId,
                    assetName: asset.assetName,
                    assetType: asset.assetType,
                    alertType:
                        (errorCountsRef.current[asset.assetId] || 0) > 5 ? ("critical" as const) : (errorCountsRef.current[asset.assetId] || 0) > 3 ? ("predictive" as const) : ("preventive" as const),
                    estimatedTimeToFailure: Math.max(0, 100 - ((asset.timeMetrics as any)?.reliability || 100)) * 1000,
                    confidence: Math.min(90 + (errorCountsRef.current[asset.assetId] || 0) * 2, 100),
                    recommendation: (errorCountsRef.current[asset.assetId] || 0) > 5 ? "Immediate maintenance required" : "Schedule preventive maintenance",
                }));

            // Optimization Opportunities
            const optimizationOpportunities = [
                ...bottlenecks
                    .filter((b) => b.severity === "critical" || b.severity === "high")
                    .map((b) => ({
                        area: "throughput" as const,
                        description: `High utilization bottleneck at ${b.assetName} (${b.utilizationRate.toFixed(1)}% utilization)`,
                        potentialImprovement: Math.min(100 - b.utilizationRate, 20),
                        priority: b.severity === "critical" ? ("high" as const) : ("medium" as const),
                    })),
                {
                    area: "efficiency" as const,
                    description: `System OEE at ${weightedOEE.toFixed(1)}% - target improvements available`,
                    potentialImprovement: Math.max(0, 85 - weightedOEE),
                    priority: weightedOEE < 80 ? ("high" as const) : ("medium" as const),
                },
                {
                    area: "cost" as const,
                    description: `Total system cost: $${totalCost.toFixed(2)}`,
                    potentialImprovement: Math.min(20, totalValueAdded > 0 ? (totalCost / totalValueAdded) * 100 : 0),
                    priority: totalValueAdded < totalCost ? ("high" as const) : ("medium" as const),
                },
            ];

            // Trend Analysis
            const trendAnalysis = assetTypePerformance.map((type) => {
                const historicalTypeData = allAssets
                    .filter((a) => a.assetType === type.assetType)
                    .flatMap((a) => historicalDataRef.current[a.assetId] || [])
                    .filter((d) => d.performance !== undefined);

                const recentPerformance = historicalTypeData.slice(-10).map((d) => d.performance);
                const olderPerformance = historicalTypeData.slice(-20, -10).map((d) => d.performance);

                const recentAvg = recentPerformance.length > 0 ? recentPerformance.reduce((sum, p) => sum + p, 0) / recentPerformance.length : 0;
                const olderAvg = olderPerformance.length > 0 ? olderPerformance.reduce((sum, p) => sum + p, 0) / olderPerformance.length : 0;

                let trend: "increasing" | "decreasing" | "stable" = "stable";
                let changeRate = 0;

                if (olderAvg > 0 && recentAvg > 0) {
                    changeRate = ((recentAvg - olderAvg) / olderAvg) * 100;
                    if (Math.abs(changeRate) > 5) {
                        trend = changeRate > 0 ? "increasing" : "decreasing";
                    }
                }

                return {
                    metric: `${type.assetType} Performance`,
                    trend,
                    changeRate,
                    forecast: [recentAvg * 1.02, recentAvg * 1.01, recentAvg], // Simple forecast
                };
            });

            return {
                assets: allAssets,

                systemPerformance: {
                    overallOEE: weightedOEE,
                    systemThroughput: totalThroughput,
                    systemUtilization: avgUtilization * 100,
                    assetTypePerformance,
                    criticalMetrics: {
                        activeAssets,
                        totalAssets,
                        assetsInError,
                        assetsIdle,
                        averageIdleTime: totalIdleTime / totalAssets,
                        totalDowntime: totalIdleTime,
                        systemUptime,
                    },
                },

                materialFlow: {
                    totalMaterialsInSystem,
                    materialsCompleted: completedMaterials,
                    averageResidenceTime,
                    queueLengths,
                    bottlenecks: bottlenecks.slice(0, 10), // Top 10 bottlenecks
                    flowContinuity: {
                        overallFlowRate: meanFlowRate,
                        varianceCoefficient,
                        steadyStateDeviation: varianceCoefficient > 0.3 ? varianceCoefficient * 100 : 0,
                    },
                },

                predictiveInsights: {
                    maintenanceAlerts: maintenanceAlerts.slice(0, 5), // Top 5 alerts
                    optimizationOpportunities: optimizationOpportunities.slice(0, 5), // Top 5 opportunities
                    trendAnalysis: trendAnalysis.filter((t) => t.trend !== "stable" || Math.abs(t.changeRate) > 1),
                },

                analysisTimeRange: {
                    startTime: startTimeRef.current,
                    endTime: new Date().toISOString(),
                    duration: Date.now() - new Date(startTimeRef.current).getTime(),
                },

                metadata: {
                    lastUpdated: new Date().toISOString(),
                    dataPoints: allAssets.length + materials.length + materialHistoryRef.current.length,
                    analysisVersion: "1.0.0",
                    totalCost,
                    totalValueAdded,
                    totalEnergyConsumed,
                    energyCost: totalEnergyConsumed * 0.12, // $0.12 per kWh
                    carbonFootprint: totalEnergyConsumed * 0.5, // 0.5 kg CO2 per kWh
                },
            };
        },
        [materials]
    );

    // ============================================================================
    // MAIN ANALYSIS FUNCTION
    // ============================================================================

    const performAnalysis = useCallback(() => {
        setAnalyzing(true);

        try {
            const allAssets: AssetAnalysis[] = [];

            // Analyze all conveyors
            conveyors.forEach((conveyor) => {
                allAssets.push(analyzeConveyor(conveyor));
            });

            // Analyze all vehicles
            vehicles.forEach((vehicle) => {
                allAssets.push(analyzeVehicle(vehicle));
            });

            // Analyze all robotic arms
            armBots.forEach((armBot) => {
                allAssets.push(analyzeRoboticArm(armBot));
            });

            // Analyze all machines
            machines.forEach((machine) => {
                allAssets.push(analyzeMachine(machine));
            });

            // Analyze all storage units
            storageUnits.forEach((storage) => {
                allAssets.push(analyzeStorage(storage));
            });

            // Analyze all humans
            humans.forEach((human) => {
                allAssets.push(analyzeHuman(human));
            });

            // Analyze all cranes
            cranes.forEach((crane) => {
                allAssets.push(analyzeCrane(crane));
            });

            // Perform system-wide analysis
            const completeAnalysis = analyzeSystem(allAssets);

            setAnalysis(completeAnalysis);
        } catch (error) {
            console.error("Analysis error:", error);
        } finally {
            setAnalyzing(false);
        }
    }, [
        conveyors,
        vehicles,
        armBots,
        machines,
        humans,
        cranes,
        analyzeConveyor,
        analyzeVehicle,
        analyzeRoboticArm,
        analyzeMachine,
        analyzeHuman,
        analyzeCrane,
        analyzeSystem,
        setAnalysis,
        setAnalyzing,
    ]);

    // ============================================================================
    // EFFECTS
    // ============================================================================

    const performAnalysisRef = useRef(performAnalysis);

    useEffect(() => {
        performAnalysisRef.current = performAnalysis;
    }, [performAnalysis]);

    // Trigger analysis when assets or materials change
    useEffect(() => {
        if (!isPlaying) return;

        // Perform analysis when any asset or material state changes
        performAnalysisRef.current();
    }, [conveyors, vehicles, armBots, machines, humans, cranes, materials, isPlaying]);

    // Perform initial analysis and set up interval
    useEffect(() => {
        if (!isPlaying) return;

        // Set up periodic analysis (every 1 second)
        analysisIntervalRef.current = setInterval(() => {
            performAnalysisRef.current();
        }, 1000);

        return () => {
            if (analysisIntervalRef.current) {
                clearInterval(analysisIntervalRef.current);
            }
        };
    }, [isPlaying]);

    // Monitor material changes and track additions/removals
    useEffect(() => {
        if (!isPlaying) return;

        // Track material movements by comparing current materials with previous state
        materials.forEach((material) => {
            const currentAssetId = material.current?.modelUuid;
            const previousAssetId = material.previous?.modelUuid;

            if (currentAssetId && previousAssetId && currentAssetId !== previousAssetId) {
                // Material moved from one asset to another
                trackMaterialRemoval(previousAssetId, material.materialId, material.materialType, currentAssetId);
                trackMaterialAddition(currentAssetId, material.materialId, material.materialType, previousAssetId);
            } else if (currentAssetId && !previousAssetId) {
                // Material newly added to an asset
                trackMaterialAddition(currentAssetId, material.materialId, material.materialType);
            }
        });

        // Track material lifecycle completion
        materials.forEach((material) => {
            if (!material.isActive && material.endTime) {
                const lifecycle = materialLifecycleRef.current[material.materialId];
                if (lifecycle && !lifecycle.completedAt) {
                    lifecycle.completedAt = material.endTime;

                    // Calculate total processing and wait times
                    let totalProcessing = 0;
                    let totalWait = 0;

                    lifecycle.path.forEach((pathEntry) => {
                        if (pathEntry.exitTime) {
                            const duration = pathEntry.exitTime - pathEntry.entryTime;
                            totalProcessing += duration;
                        }
                    });

                    lifecycle.totalProcessingTime = totalProcessing;
                    lifecycle.totalWaitTime = totalWait;
                }
            }
        });
    }, [materials, isPlaying, trackMaterialAddition, trackMaterialRemoval]);

    // Monitor asset state changes
    useEffect(() => {
        if (!isPlaying) return;

        const allAssets = [
            ...conveyors.map((c) => ({ id: c.modelUuid, state: c.state, isActive: !c.isPaused, type: "conveyor" as const })),
            ...machines.map((m) => ({ id: m.modelUuid, state: m.state, isActive: m.isActive, type: "machine" as const })),
            ...armBots.map((a) => ({ id: a.modelUuid, state: a.state, isActive: a.isActive, type: "roboticArm" as const, currentAction: a.currentAction })),
            ...vehicles.map((v) => ({ id: v.modelUuid, state: v.state, isActive: v.isActive, type: "vehicle" as const })),
            ...humans.map((h) => ({ id: h.modelUuid, state: h.state, isActive: h.isActive, type: "human" as const })),
            ...cranes.map((c) => ({ id: c.modelUuid, state: c.state, isActive: c.isActive, type: "crane" as const })),
            ...storageUnits.map((s) => ({ id: s.modelUuid, state: s.state, isActive: s.isActive, type: "storage" as const })),
        ];

        allAssets.forEach((asset) => {
            const previousState = previousAssetStatesRef.current[asset.id];
            const currentMaterialCount = getMaterialsByModel(asset.id).length;

            if (previousState) {
                // Check for state change
                if (previousState.state !== asset.state) {
                    trackStateChange(asset.id, previousState.state, asset.state, asset.type === "roboticArm" ? { actionName: (asset as any).currentAction?.actionName } : undefined);
                }

                // Check for material count change (potential bottleneck)
                if (currentMaterialCount !== previousState.materialCount) {
                    const utilizationRate = asset.isActive ? 0.8 : 0.2; // Simplified calculation
                    const waitingMaterials = getMaterialsByModel(asset.id).map((m) => m.materialId);
                    trackBottleneckEvent(asset.id, currentMaterialCount, utilizationRate, waitingMaterials);
                }
            }

            // Update previous state
            updatePreviousAssetState(asset.id, asset.state, asset.isActive, currentMaterialCount);
        });
    }, [conveyors, machines, armBots, vehicles, humans, cranes, storageUnits, isPlaying, getMaterialsByModel, trackStateChange, trackBottleneckEvent, updatePreviousAssetState]);

    // Monitor ArmBot action changes to track cycles
    useEffect(() => {
        if (!isPlaying) return;

        armBots.forEach((armBot) => {
            const previousActionUuid = previousArmBotActionsRef.current[armBot.modelUuid];
            const currentActionUuid = armBot.currentAction?.actionUuid;

            // Check if action completed (transition from an action to no action or different action)
            if (previousActionUuid && previousActionUuid !== currentActionUuid) {
                // Action completed
                if (!completedActionsRef.current[armBot.modelUuid]) {
                    completedActionsRef.current[armBot.modelUuid] = 0;
                }
                completedActionsRef.current[armBot.modelUuid]++;

                // Also update pick and place count which is used in analysis
                if (!completedActionsRef.current[`${armBot.modelUuid}_pickplace`]) {
                    completedActionsRef.current[`${armBot.modelUuid}_pickplace`] = 0;
                }
                completedActionsRef.current[`${armBot.modelUuid}_pickplace`]++;

                // Granular pick/place tracking
                if (previousActionUuid) {
                    // We need to look up what action this UUID corresponded to
                    // Since we don't store the action map history, we check the current config
                    // This assumes configuration hasn't changed, which is true for runtime
                    const action = armBot.point.actions.find((a) => a.actionUuid === previousActionUuid);
                    if (action) {
                        const actionName = action.actionName.toLowerCase();
                        if (actionName.includes("pick")) {
                            if (!completedActionsRef.current[`${armBot.modelUuid}_pick`]) completedActionsRef.current[`${armBot.modelUuid}_pick`] = 0;
                            completedActionsRef.current[`${armBot.modelUuid}_pick`]++;
                        } else if (actionName.includes("place")) {
                            if (!completedActionsRef.current[`${armBot.modelUuid}_place`]) completedActionsRef.current[`${armBot.modelUuid}_place`] = 0;
                            completedActionsRef.current[`${armBot.modelUuid}_place`]++;
                        }
                    }
                }
            }

            previousArmBotActionsRef.current[armBot.modelUuid] = currentActionUuid;
        });
    }, [armBots, isPlaying]);

    // Monitor Machine action changes to track cycles
    useEffect(() => {
        if (!isPlaying) return;

        machines.forEach((machine) => {
            const previousActionUuid = previousMachineActionsRef.current[machine.modelUuid];
            const currentActionUuid = machine.currentAction?.actionUuid;

            // Check if action completed (transition from an action to no action or different action)
            if (previousActionUuid && previousActionUuid !== currentActionUuid) {
                // Action completed - increment cycles
                if (!completedActionsRef.current[machine.modelUuid]) {
                    completedActionsRef.current[machine.modelUuid] = 0;
                }
                completedActionsRef.current[machine.modelUuid]++;

                // Also update parts processed (assume 1 part per cycle)
                if (!completedActionsRef.current[`${machine.modelUuid}_parts`]) {
                    completedActionsRef.current[`${machine.modelUuid}_parts`] = 0;
                }
                completedActionsRef.current[`${machine.modelUuid}_parts`]++;
            }

            previousMachineActionsRef.current[machine.modelUuid] = currentActionUuid;
        });
    }, [machines, isPlaying]);

    // Monitor Human action changes from EventManager
    useEffect(() => {
        if (!isPlaying || !humanEventManagerRef.current) return;

        const interval = setInterval(() => {
            if (!humanEventManagerRef.current) return;

            humanEventManagerRef.current.humanStates.forEach((humanState) => {
                const humanId = humanState.humanId;

                // Initialize tracking for this human if needed
                if (!previousHumanCountsRef.current[humanId]) {
                    previousHumanCountsRef.current[humanId] = {};
                }

                humanState.actionQueue.forEach((action) => {
                    let lastCount = previousHumanCountsRef.current[humanId][action.actionUuid] || 0;
                    const currentCount = action.count || 0;

                    // Handle reset case (new action instance with same UUID)
                    if (currentCount < lastCount) {
                        lastCount = 0;
                        previousHumanCountsRef.current[humanId][action.actionUuid] = 0;
                    }

                    const delta = currentCount - lastCount;

                    if (delta > 0) {
                        // Update total completions for this human
                        if (!completedActionsRef.current[humanId]) completedActionsRef.current[humanId] = 0;
                        completedActionsRef.current[humanId] += delta;

                        // Update granular action type completions (e.g., worker, manufacturer)
                        const typeKey = `${humanId}_${action.actionType}`;
                        if (!completedActionsRef.current[typeKey]) completedActionsRef.current[typeKey] = 0;
                        completedActionsRef.current[typeKey] += delta;

                        // Update the last known count
                        previousHumanCountsRef.current[humanId][action.actionUuid] = currentCount;
                    }
                });
            });
        }, 100);

        return () => clearInterval(interval);
    }, [isPlaying, humanEventManagerRef]);

    // Periodic WIP and throughput snapshots
    useEffect(() => {
        if (!isPlaying) return;

        const snapshotInterval = setInterval(() => {
            const allAssetIds = [
                ...conveyors.map((c) => c.modelUuid),
                ...machines.map((m) => m.modelUuid),
                ...armBots.map((a) => a.modelUuid),
                ...vehicles.map((v) => v.modelUuid),
                ...humans.map((h) => h.modelUuid),
                ...cranes.map((c) => c.modelUuid),
                ...storageUnits.map((s) => s.modelUuid),
            ];

            allAssetIds.forEach((assetId) => {
                updateWIPSnapshot(assetId);
            });
        }, 1000); // Every 1 seconds

        return () => clearInterval(snapshotInterval);
    }, [conveyors, machines, armBots, vehicles, humans, cranes, storageUnits, isPlaying, updateWIPSnapshot]);

    // Monitor Vehicle phase changes to track completed trips
    useEffect(() => {
        if (!isPlaying) return;

        vehicles.forEach((vehicle) => {
            const previousPhase = previousVehiclePhasesRef.current[vehicle.modelUuid];
            const currentPhase = vehicle.currentPhase;

            // Check for transition from 'drop-pickup' to 'picking' (Trip completed)
            if (previousPhase === "drop-pickup" && currentPhase === "picking") {
                if (!completedActionsRef.current[vehicle.modelUuid]) {
                    completedActionsRef.current[vehicle.modelUuid] = 0;
                }
                completedActionsRef.current[vehicle.modelUuid]++;

                // Track loads delivered (assuming 1 load per trip for now, or use vehicle.currentLoad if available/reliable at this point)
                if (!completedActionsRef.current[`${vehicle.modelUuid}_loads`]) {
                    completedActionsRef.current[`${vehicle.modelUuid}_loads`] = 0;
                }
                completedActionsRef.current[`${vehicle.modelUuid}_loads`] += 1;
            }

            previousVehiclePhasesRef.current[vehicle.modelUuid] = currentPhase;
        });
    }, [vehicles, isPlaying]);

    // Monitor Crane phase changes to track completed cycles, loads, and lifts
    useEffect(() => {
        if (!isPlaying) return;

        cranes.forEach((crane) => {
            const previousPhase = previousCranePhasesRef.current[crane.modelUuid];
            const currentPhase = crane.currentPhase;

            // Track lifts (picking phase indicates a lift operation)
            if (previousPhase !== "picking" && currentPhase === "picking") {
                if (!completedActionsRef.current[`${crane.modelUuid}_lifts`]) {
                    completedActionsRef.current[`${crane.modelUuid}_lifts`] = 0;
                }
                completedActionsRef.current[`${crane.modelUuid}_lifts`]++;

                // Track lift height (assuming a default lift height of 5 meters for now)
                // In a real scenario, this would be calculated from crane constraints
                if (!completedActionsRef.current[`${crane.modelUuid}_lift_height`]) {
                    completedActionsRef.current[`${crane.modelUuid}_lift_height`] = 0;
                }
                completedActionsRef.current[`${crane.modelUuid}_lift_height`] += 5;

                // Track loads handled when picking (each pick is a load)
                if (!completedActionsRef.current[`${crane.modelUuid}_loads`]) {
                    completedActionsRef.current[`${crane.modelUuid}_loads`] = 0;
                }
                completedActionsRef.current[`${crane.modelUuid}_loads`]++;
            }

            // Track cycles completed when dropping is done (transition from 'dropping' to any other phase)
            if (previousPhase === "dropping" && currentPhase !== "dropping") {
                // Increment cycles completed
                if (!completedActionsRef.current[crane.modelUuid]) {
                    completedActionsRef.current[crane.modelUuid] = 0;
                }
                completedActionsRef.current[crane.modelUuid]++;
            }

            previousCranePhasesRef.current[crane.modelUuid] = currentPhase;
        });
    }, [cranes, isPlaying]);

    return null;
}

export default Analyzer;