Dwinzo_Demo/app/src/modules/simulation/analyzer/analyzer.tsx

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

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

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

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

    const historicalDataRef = useRef<Record<string, any[]>>({});
    const materialHistoryRef = useRef<MaterialHistoryEntry[]>([]);
    const eventTimestampsRef = useRef<Record<string, { start: number; end?: number }[]>>({});
    const queueLengthsRef = useRef<Record<string, { timestamp: number; length: number }[]>>({});
    const performanceHistoryRef = useRef<Record<string, number[]>>({});
    const analysisIntervalRef = useRef<NodeJS.Timeout | null>(null);
    const startTimeRef = useRef<string>(new Date().toISOString());
    const errorCountsRef = useRef<Record<string, number>>({});
    const completedActionsRef = useRef<Record<string, number>>({});
    const stateTransitionsRef = useRef<Record<string, any[]>>({});

    // ============================================================================
    // CALCULATION UTILITIES
    // ============================================================================

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

        const errorCount = errorCountsRef.current[assetId] || 0;

        return {
            uptime,
            downtime,
            utilizationRate,
            mtbf: errorCount > 0 ? totalTime / errorCount : totalTime || 0,
            mttr: errorCount > 0 ? downtime / errorCount : 0,
        };
    };

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

    const trackStateTransition = (assetId: string, fromState: string, toState: string, time: number) => {
        if (!stateTransitionsRef.current[assetId]) {
            stateTransitionsRef.current[assetId] = [];
        }
        stateTransitionsRef.current[assetId].push({
            fromState,
            toState,
            timestamp: Date.now(),
            duration: time,
        });
    };

    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,
        }));
    };

    // Count materials currently on an asset
    const getMaterialsOnAsset = (assetId: string) => {
        return materials.filter((m) => m.current.modelUuid === assetId && m.isActive);
    };

    // Calculate actual performance vs ideal
    const calculatePerformanceRate = (actualTime: number, idealTime: number) => {
        if (idealTime === 0 || actualTime === 0) return 100;
        return Math.min((idealTime / actualTime) * 100, 100);
    };

    // ============================================================================
    // 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 : 100;
        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 = getMaterialsOnAsset(assetId);
        const materialHistory = materialHistoryRef.current.filter((m) => m.material.current?.modelUuid === assetId || m.material.previous?.modelUuid === assetId);

        // Calculate flow metrics
        const wip = materialsOnAsset.length;
        const throughput = (materialHistory.length / (Date.now() - new Date(startTimeRef.current).getTime())) * 1000;

        // Calculate lead times
        const leadTimes = materialHistory
            .map((m) => {
                if (m.removedAt && m.material.startTime) {
                    return new Date(m.removedAt).getTime() - m.material.startTime;
                }
                return 0;
            })
            .filter((t) => t > 0);

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

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

        return {
            wip,
            throughput,
            avgLeadTime,
            totalMaterialsProcessed: materialHistory.length,
            currentMaterials: materialsOnAsset.length,
            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
        };
    };

    // ============================================================================
    // 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();
            if (!historicalDataRef.current[conveyor.modelUuid]) {
                historicalDataRef.current[conveyor.modelUuid] = [];
            }
            historicalDataRef.current[conveyor.modelUuid].push({
                timestamp,
                isActive: conveyor.isActive,
                speed: conveyor.speed,
                state: conveyor.state,
                materialsCount: materialFlow.currentMaterials,
                throughput: actualThroughput,
                performance: performance.performanceRate,
            });

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

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

                currentStatus: {
                    isActive: conveyor.isActive,
                    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]
    );

    // ============================================================================
    // 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[`${vehicle.modelUuid}_loads`] || 0;
            const defects = errorCountsRef.current[`${vehicle.modelUuid}_defects`] || 0;
            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();
            if (!historicalDataRef.current[vehicle.modelUuid]) {
                historicalDataRef.current[vehicle.modelUuid] = [];
            }
            historicalDataRef.current[vehicle.modelUuid].push({
                timestamp,
                phase: vehicle.currentPhase,
                load: vehicle.currentLoad,
                distanceTraveled: actualDistance,
                state: vehicle.state,
                performance: performance.performanceRate,
                speed: vehicle.speed,
                tripsCompleted,
            });

            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 : 0,
                    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]
    );
    // ============================================================================
    // ROBOTIC ARM ANALYSIS
    // ============================================================================

    const analyzeRoboticArm = useCallback(
        (armBot: ArmBotStatus): RoboticArmAnalysis => {
            const timeMetrics = calculateTimeMetrics(armBot.idleTime || 0, armBot.activeTime || 0, armBot.modelUuid);

            const totalTime = (armBot.idleTime || 0) + (armBot.activeTime || 0);
            const cyclesCompleted = completedActionsRef.current[armBot.modelUuid] || 0;

            // Calculate cycle time efficiency
            const idealCycleTime = 5; // 5 seconds ideal
            const actualCycleTime = cyclesCompleted > 0 ? totalTime / cyclesCompleted : 0;
            const cycleTimeEfficiency = calculatePerformanceRate(actualCycleTime, idealCycleTime);

            // Pick success rate based on errors
            const pickAttempts = cyclesCompleted + (errorCountsRef.current[armBot.modelUuid] || 0);
            const pickSuccessRate = pickAttempts > 0 ? (cyclesCompleted / pickAttempts) * 100 : 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,
                    averageCycleTime: actualCycleTime,
                },

                throughput: {
                    itemsPerHour: totalTime > 0 ? (cyclesCompleted / totalTime) * 3600 : 0,
                    itemsPerDay: totalTime > 0 ? (cyclesCompleted / totalTime) * 86400 : 0,
                    materialFlowRate: armBot.speed,
                    capacityUtilization: timeMetrics.utilizationRate * 100,
                    cyclesCompleted,
                    pickAndPlaceCount: cyclesCompleted,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, cycleTimeEfficiency, pickSuccessRate),
                    availability: timeMetrics.uptime,
                    performance: cycleTimeEfficiency,
                    quality: pickSuccessRate,
                    cycleTimeEfficiency,
                },

                quality: {
                    errorRate: pickAttempts > 0 ? (errorCountsRef.current[armBot.modelUuid] || 0) / pickAttempts : 0,
                    errorFrequency: totalTime > 0 ? ((errorCountsRef.current[armBot.modelUuid] || 0) / totalTime) * 3600 : 0,
                    successRate: pickSuccessRate,
                    stateTransitions: getStateTransitions(armBot.modelUuid),
                    pickSuccessRate,
                    placeAccuracy: pickSuccessRate,
                },

                historicalData: (analysis?.assets.find((a) => a.assetId === armBot.modelUuid)?.historicalData || []) as RoboticArmAnalysis["historicalData"],
            };
        },
        [analysis]
    );

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

    const analyzeMachine = useCallback(
        (machine: MachineStatus): MachineAnalysis => {
            const timeMetrics = calculateTimeMetrics(machine.idleTime || 0, machine.activeTime || 0, machine.modelUuid);

            const totalTime = (machine.idleTime || 0) + (machine.activeTime || 0);
            const cyclesCompleted = completedActionsRef.current[machine.modelUuid] || 0;
            const defects = errorCountsRef.current[`${machine.modelUuid}_defects`] || 0;

            // Get target process time from action
            const targetProcessTime = machine.point?.action?.processTime || 30;
            const actualProcessTime = cyclesCompleted > 0 ? totalTime / cyclesCompleted : 0;
            const targetVsActual = calculatePerformanceRate(actualProcessTime, targetProcessTime);

            // Quality metrics
            const totalParts = cyclesCompleted + defects;
            const qualityRate = totalParts > 0 ? ((cyclesCompleted - defects) / totalParts) * 100 : 100;
            const defectRate = totalParts > 0 ? (defects / totalParts) * 100 : 0;

            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,
                    averageProcessTime: actualProcessTime,
                },

                throughput: {
                    itemsPerHour: totalTime > 0 ? (cyclesCompleted / totalTime) * 3600 : 0,
                    itemsPerDay: totalTime > 0 ? (cyclesCompleted / totalTime) * 86400 : 0,
                    materialFlowRate: cyclesCompleted > 0 ? cyclesCompleted / (totalTime / 60) : 0,
                    capacityUtilization: timeMetrics.utilizationRate * 100,
                    cyclesCompleted,
                    partsProcessed: cyclesCompleted,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, targetVsActual, qualityRate),
                    availability: timeMetrics.uptime,
                    performance: targetVsActual,
                    quality: qualityRate,
                    targetVsActual,
                },

                quality: {
                    errorRate: totalParts > 0 ? (errorCountsRef.current[machine.modelUuid] || 0) / totalParts : 0,
                    errorFrequency: totalTime > 0 ? ((errorCountsRef.current[machine.modelUuid] || 0) / totalTime) * 3600 : 0,
                    successRate: qualityRate,
                    stateTransitions: getStateTransitions(machine.modelUuid),
                    defectRate,
                    reworkRate: defectRate * 0.3, // Assume 30% of defects are reworked
                },

                historicalData: (analysis?.assets.find((a) => a.assetId === machine.modelUuid)?.historicalData || []) as MachineAnalysis["historicalData"],
            };
        },
        [analysis]
    );

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

    const analyzeStorage = useCallback(
        (storage: StorageUnitStatus): StorageAnalysis => {
            const timeMetrics = calculateTimeMetrics(storage.idleTime || 0, storage.activeTime || 0, storage.modelUuid);

            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;

            // Calculate turnover rate
            const totalTime = (storage.idleTime || 0) + (storage.activeTime || 0);
            const turnoverRate = totalTime > 0 ? (totalOps / totalTime) * 3600 : 0; // Operations per hour

            // Get peak occupancy from previous analysis
            const previousAnalysis = analysis?.assets.find((a) => a.assetId === storage.modelUuid);
            const previousPeak = previousAnalysis && "capacityMetrics" in previousAnalysis ? previousAnalysis.capacityMetrics.peakOccupancy : utilizationRate;
            const peakOccupancy = Math.max(previousPeak, utilizationRate);

            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,
                },

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

                throughput: {
                    itemsPerHour: turnoverRate,
                    itemsPerDay: turnoverRate * 24,
                    materialFlowRate: turnoverRate / 60,
                    capacityUtilization: utilizationRate,
                    storeOperations: storeOps,
                    retrieveOperations: retrieveOps,
                    totalOperations: totalOps,
                },

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, utilizationRate, 100),
                    availability: timeMetrics.uptime,
                    performance: utilizationRate,
                    quality: 100,
                    spaceUtilization: utilizationRate,
                },

                quality: {
                    errorRate: totalOps > 0 ? (errorCountsRef.current[storage.modelUuid] || 0) / totalOps : 0,
                    errorFrequency: totalTime > 0 ? ((errorCountsRef.current[storage.modelUuid] || 0) / totalTime) * 3600 : 0,
                    successRate: 100,
                    stateTransitions: getStateTransitions(storage.modelUuid),
                },

                occupancyTrends: [],
                historicalData: (analysis?.assets.find((a) => a.assetId === storage.modelUuid)?.historicalData || []) as StorageAnalysis["historicalData"],
            };
        },
        [analysis]
    );

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

    const analyzeHuman = useCallback(
        (human: HumanStatus): HumanAnalysis => {
            const timeMetrics = calculateTimeMetrics(human.idleTime || 0, human.activeTime || 0, human.modelUuid);

            const totalTime = (human.idleTime || 0) + (human.activeTime || 0);
            const actionsCompleted = completedActionsRef.current[human.modelUuid] || 0;

            // Calculate workload distribution
            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 workloadDistribution = [
                { actionType: "worker", count: workerActions, totalTime: workerTime, percentage: totalTime > 0 ? (workerTime / totalTime) * 100 : 0 },
                { actionType: "manufacturer", count: manufacturerActions, totalTime: manufacturerTime, percentage: totalTime > 0 ? (manufacturerTime / totalTime) * 100 : 0 },
                { actionType: "operator", count: operatorActions, totalTime: operatorTime, percentage: totalTime > 0 ? (operatorTime / totalTime) * 100 : 0 },
                { actionType: "assembler", count: assemblerActions, totalTime: assemblerTime, percentage: totalTime > 0 ? (assemblerTime / totalTime) * 100 : 0 },
            ].filter((w) => w.count > 0);

            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: human.currentLoad,
                    currentMaterials: human.currentMaterials,
                    currentAction: human.currentAction || null,
                },

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

                productivityMetrics: {
                    actionsCompleted,
                    actionsPerHour: totalTime > 0 ? (actionsCompleted / totalTime) * 3600 : 0,
                    averageActionTime: actionsCompleted > 0 ? totalTime / actionsCompleted : 0,
                    distanceTraveled: human.distanceTraveled || 0,
                },

                workloadDistribution,

                efficiency: {
                    overallEffectiveness: calculateOEE(timeMetrics.uptime, 100, 100),
                    availability: timeMetrics.uptime,
                    performance: 100,
                    quality: 100,
                    laborProductivity: totalTime > 0 ? actionsCompleted / (totalTime / 3600) : 0,
                    utilizationRate: timeMetrics.utilizationRate * 100,
                },

                quality: {
                    errorRate: actionsCompleted > 0 ? (errorCountsRef.current[human.modelUuid] || 0) / actionsCompleted : 0,
                    errorFrequency: totalTime > 0 ? ((errorCountsRef.current[human.modelUuid] || 0) / totalTime) * 3600 : 0,
                    successRate: 100,
                    stateTransitions: getStateTransitions(human.modelUuid),
                },

                historicalData: (analysis?.assets.find((a) => a.assetId === human.modelUuid)?.historicalData || []) as HumanAnalysis["historicalData"],
            };
        },
        [analysis]
    );

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

    const analyzeCrane = useCallback((crane: CraneStatus): CraneAnalysis => {
        const timeMetrics = calculateTimeMetrics(crane.idleTime || 0, crane.activeTime || 0, crane.modelUuid);

        const totalTime = (crane.idleTime || 0) + (crane.activeTime || 0);
        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;

        // Calculate cycle time
        const actualCycleTime = cyclesCompleted > 0 ? totalTime / cyclesCompleted : 0;
        const idealCycleTime = 20; // 20 seconds ideal
        const cycleTimeEfficiency = calculatePerformanceRate(actualCycleTime, idealCycleTime);

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

        // Lift success rate
        const liftAttempts = totalLifts + (errorCountsRef.current[crane.modelUuid] || 0);
        const liftSuccessRate = liftAttempts > 0 ? (totalLifts / liftAttempts) * 100 : 100;

        // Load utilization based on max pick up count
        const maxPickUpCount = crane.point?.actions?.[0]?.maxPickUpCount || 1;
        const loadUtilization = (avgLoadsPerCycle / maxPickUpCount) * 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,
            },

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

            throughput: {
                itemsPerHour: totalTime > 0 ? (loadsHandled / totalTime) * 3600 : 0,
                itemsPerDay: totalTime > 0 ? (loadsHandled / totalTime) * 86400 : 0,
                materialFlowRate: cyclesCompleted > 0 ? cyclesCompleted / (totalTime / 60) : 0,
                capacityUtilization: timeMetrics.utilizationRate * 100,
                cyclesCompleted,
                loadsHandled,
                averageLoadsPerCycle: avgLoadsPerCycle,
            },

            movementMetrics: {
                totalLifts,
                averageLiftHeight: avgLiftHeight,
                movementEfficiency: liftSuccessRate,
            },

            efficiency: {
                overallEffectiveness: calculateOEE(timeMetrics.uptime, cycleTimeEfficiency, liftSuccessRate),
                availability: timeMetrics.uptime,
                performance: cycleTimeEfficiency,
                quality: liftSuccessRate,
                loadUtilization,
                cycleTimeEfficiency,
            },

            quality: {
                errorRate: liftAttempts > 0 ? (errorCountsRef.current[crane.modelUuid] || 0) / liftAttempts : 0,
                errorFrequency: totalTime > 0 ? ((errorCountsRef.current[crane.modelUuid] || 0) / totalTime) * 3600 : 0,
                successRate: 100,
                stateTransitions: getStateTransitions(crane.modelUuid),
                liftSuccessRate: liftSuccessRate,
                positioningAccuracy: liftSuccessRate,
            },

            historicalData: [],
        };
    }, []);

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

    const analyzeSystem = useCallback((allAssets: AssetAnalysis[]): AnalysisSchema => {
        // Calculate system-wide metrics
        const totalAssets = allAssets.length;
        const activeAssets = allAssets.filter((a) => a.currentStatus.isActive).length;
        const assetsInError = allAssets.filter((a) => a.currentStatus.state === "error").length;

        const avgOEE = allAssets.reduce((sum, a) => sum + a.efficiency.overallEffectiveness, 0) / totalAssets;
        const avgUtilization = allAssets.reduce((sum, a) => sum + a.timeMetrics.utilizationRate, 0) / totalAssets;
        const avgIdleTime = allAssets.reduce((sum, a) => sum + a.timeMetrics.idleTime, 0) / totalAssets;
        const totalDowntime = allAssets.reduce((sum, a) => sum + a.timeMetrics.downtime, 0);

        // Helper to get throughput safely
        const getThroughput = (asset: AssetAnalysis): number => {
            if ("throughput" in asset) {
                return asset.throughput.itemsPerHour;
            } else if ("productivityMetrics" in asset) {
                return asset.productivityMetrics.actionsPerHour;
            }
            return 0;
        };

        // Group by asset type
        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]) => ({
            assetType: type,
            count: assets.length,
            averageOEE: assets.reduce((sum, a) => sum + a.efficiency.overallEffectiveness, 0) / assets.length,
            averageUtilization: (assets.reduce((sum, a) => sum + a.timeMetrics.utilizationRate, 0) / assets.length) * 100,
            totalThroughput: assets.reduce((sum, a) => sum + getThroughput(a), 0),
        }));

        // Identify bottlenecks (high utilization + low throughput)
        const bottlenecks = allAssets
            .filter((a) => a.timeMetrics.utilizationRate > 0.8)
            .map((a) => ({
                assetId: a.assetId,
                assetName: a.assetName,
                severity:
                    a.timeMetrics.utilizationRate > 0.95
                        ? ("critical" as const)
                        : a.timeMetrics.utilizationRate > 0.9
                        ? ("high" as const)
                        : a.timeMetrics.utilizationRate > 0.85
                        ? ("medium" as const)
                        : ("low" as const),
                utilizationRate: a.timeMetrics.utilizationRate * 100,
                queueLength: 0,
                impactScore: a.timeMetrics.utilizationRate * 100,
            }))
            .sort((a, b) => b.impactScore - a.impactScore);

        return {
            assets: allAssets,

            systemPerformance: {
                overallOEE: avgOEE,
                systemThroughput: allAssets.reduce((sum, a) => sum + getThroughput(a), 0),
                systemUtilization: avgUtilization * 100,
                assetTypePerformance,
                criticalMetrics: {
                    activeAssets,
                    totalAssets,
                    assetsInError,
                    averageIdleTime: avgIdleTime,
                    totalDowntime,
                },
            },

            materialFlow: {
                totalMaterialsInSystem: 0,
                materialsCompleted: 0,
                averageResidenceTime: 0,
                queueLengths: [],
                bottlenecks,
                flowContinuity: {
                    overallFlowRate: 0,
                    varianceCoefficient: 0,
                    steadyStateDeviation: 0,
                },
            },

            predictiveInsights: {
                maintenanceAlerts: [],
                optimizationOpportunities: [],
                trendAnalysis: [],
            },

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

            metadata: {
                lastUpdated: new Date().toISOString(),
                dataPoints: allAssets.length,
                analysisVersion: "1.0.0",
            },
        };
    }, []);

    // ============================================================================
    // 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
    // ============================================================================

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

        // Set up periodic analysis (every 5 seconds)
        analysisIntervalRef.current = setInterval(() => {
            performAnalysis();
        }, 5000);

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

    return null;
}

export default Analyzer;