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, getMaterialsByModel } = materialStore();

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

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

    // ============================================================================
    // 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 = getMaterialsByModel(assetId).length;
        const materialHistory = materialHistoryRef.current.filter((m) => m.material.current?.modelUuid === assetId || m.material.previous?.modelUuid === assetId);

        // Calculate flow metrics
        const wip = materialsOnAsset;
        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,
            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,
        }));
    };

    // ============================================================================
    // 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.isActive,
                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.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();
            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 : 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]
    );

    // ============================================================================
    // 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[`${armBot.modelUuid}_pickplace`] || cyclesCompleted;
            const defects = errorCountsRef.current[`${armBot.modelUuid}_defects`] || 0;

            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
            const pickAttempts = pickAndPlaceCount + (errorCountsRef.current[armBot.modelUuid] || 0);
            const pickSuccessRate = pickAttempts > 0 ? (pickAndPlaceCount / pickAttempts) * 100 : 100;
            const placeAccuracy = pickSuccessRate * 0.98; // Assuming 98% of successful picks are placed correctly

            // 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]
    );

    // ============================================================================
    // 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]
    );

    // ============================================================================
    // 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();
            if (!historicalDataRef.current[storage.modelUuid]) {
                historicalDataRef.current[storage.modelUuid] = [];
            }
            historicalDataRef.current[storage.modelUuid].push({
                timestamp,
                currentLoad,
                utilizationRate,
                operation: storeOps > retrieveOps ? "store" : "retrieve",
                totalOps,
                state: storage.state,
            });

            // 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]
    );

    // ============================================================================
    // 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 workloadDistribution = [
                { 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);

            // 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,

                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]
    );

    // ============================================================================
    // 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 : 100;
            const positioningAccuracy = liftSuccessRate * 0.98; // 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]
    );

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

    // 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);
            }
        };
    }, [isPlaying, conveyors, vehicles, armBots, machines, humans, cranes, materials]);

    return null;
}

export default Analyzer;