feat: Add core simulation module with detailed type definitions, dashboard editor, and analysis components.

2025-12-22 15:27:20 +05:30
parent 24738e45c8
commit fc5c95d60f
4 changed files with 193 additions and 2 deletions
--- a/app/src/components/SimulationDashboard/components/element/ElementEditor.tsx
+++ b/app/src/components/SimulationDashboard/components/element/ElementEditor.tsx
@@ -235,11 +235,13 @@ const ElementEditor: React.FC<ElementEditorProps> = ({
    const getAssetDropdownItems = useCallback(() => {
        if (!product?.eventDatas) return [];

-        return product.eventDatas.map((asset) => ({
+        const assetItems = product.eventDatas.map((asset) => ({
            id: asset.modelUuid,
            label: asset.modelName,
            icon: <DeviceIcon />,
        }));
+
+        return [{ id: "global", label: "Global System", icon: <DeviceIcon /> }, ...assetItems];
    }, [product?.eventDatas]);

    const getLableValueDropdownItems = useCallback(
@@ -258,6 +260,41 @@ const ElementEditor: React.FC<ElementEditorProps> = ({
                        { id: "global.materialFlow.averageResidenceTime", label: "Average Residence Time", icon: <ParametersIcon /> },
                    ],
                },
+                {
+                    title: "Financial Metrics",
+                    items: [
+                        { id: "global.advancedAnalytics.financials.totalRevenue", label: "Total Revenue", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.financials.grossProfit", label: "Gross Profit", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.financials.netProfitMargin", label: "Net Profit Margin", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.financials.burnRate", label: "Burn Rate", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.financials.breakEvenUnits", label: "Break-even Units", icon: <ParametersIcon /> },
+                    ],
+                },
+                {
+                    title: "Supply Chain Metrics",
+                    items: [
+                        { id: "global.advancedAnalytics.supplyChain.totalInventoryValue", label: "Inventory Value", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.supplyChain.inventoryTurnoverRate", label: "Turnover Rate", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.supplyChain.stockoutRisk", label: "Stockout Risk", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.supplyChain.scrapValue", label: "Scrap Value", icon: <ParametersIcon /> },
+                    ],
+                },
+                {
+                    title: "Sustainability Metrics",
+                    items: [
+                        { id: "global.advancedAnalytics.sustainability.totalCarbonFootprint", label: "Carbon Footprint", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.sustainability.energyIntensity", label: "Energy Intensity", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.sustainability.ecoEfficiencyScore", label: "Eco Efficiency Score", icon: <ParametersIcon /> },
+                    ],
+                },
+                {
+                    title: "Reliability Metrics",
+                    items: [
+                        { id: "global.advancedAnalytics.reliability.systemMTBF", label: "System MTBF", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.reliability.systemMTTR", label: "System MTTR", icon: <ParametersIcon /> },
+                        { id: "global.advancedAnalytics.reliability.systemAvailability", label: "System Availability", icon: <ParametersIcon /> },
+                    ],
+                },
                {
                    title: "Critical System Metrics",
                    items: [
--- a/app/src/modules/simulation/analyzer/analyzer.tsx
+++ b/app/src/modules/simulation/analyzer/analyzer.tsx
@@ -2134,6 +2134,101 @@ function Analyzer() {
                };
            });

+            // Advanced Analytics Calculations
+            const calculateAdvancedAnalytics = (): AdvancedAnalytics => {
+                // Financials
+                // Assume average revenue per completed item is $150 (since cost is ~10-100 range)
+                const revenuePerUnit = 150;
+                const totalRevenue = completedMaterials * revenuePerUnit;
+                const grossProfit = totalRevenue - totalCost;
+                const netProfitMargin = totalRevenue > 0 ? (grossProfit / totalRevenue) * 100 : 0;
+
+                // Categorize costs
+                const laborCost = allAssets.filter((a) => a.assetType === "human").reduce((sum, a) => sum + (a.costMetrics?.totalCost || 0), 0);
+                const energyCosts = allAssets.reduce((sum, a) => sum + (a.energyMetrics?.energyCost || 0), 0);
+                const maintenanceCosts = allAssets.reduce((sum, a) => sum + (a.costMetrics?.maintenanceCost || 0), 0);
+
+                // Fixed vs Variable (Assumption: 40% fixed, 60% variable)
+                const fixedCosts = totalCost * 0.4;
+                const variableCosts = totalCost * 0.6;
+                const breakEvenUnits = revenuePerUnit > variableCosts / Math.max(1, completedMaterials) ? fixedCosts / (revenuePerUnit - variableCosts / Math.max(1, completedMaterials)) : 0;
+
+                // Burn Rate
+                const analysisDurationHours = (Date.now() - new Date(startTimeRef.current).getTime()) / 3600000;
+                const burnRate = analysisDurationHours > 0 ? totalCost / analysisDurationHours : 0;
+
+                const financials: FinancialMetrics = {
+                    totalRevenue,
+                    grossProfit,
+                    netProfitMargin,
+                    burnRate,
+                    laborCostRatio: totalCost > 0 ? laborCost / totalCost : 0,
+                    energyCostRatio: totalCost > 0 ? energyCosts / totalCost : 0,
+                    maintenanceCostRatio: totalCost > 0 ? maintenanceCosts / totalCost : 0,
+                    breakEvenUnits,
+                    fixedCosts,
+                    variableCosts,
+                    revenuePerUnit,
+                    costPerUnit: completedMaterials > 0 ? totalCost / completedMaterials : 0,
+                    profitPerUnit: completedMaterials > 0 ? grossProfit / completedMaterials : 0,
+                };
+
+                // Supply Chain
+                // Assign values to materials
+                const avgMaterialValue = 25;
+                const totalInventoryValue = totalMaterialsInSystem * avgMaterialValue;
+                const inventoryTurnoverRate = totalInventoryValue > 0 ? (totalCost * 0.6) / totalInventoryValue : 0; // standard formula COGS/AvgInv
+                const holdingCostRate = 0.25; // 25% annual holding cost
+                const holdingCost = ((totalInventoryValue * holdingCostRate) / (365 * 24)) * analysisDurationHours; // prorated
+
+                // Scrap value
+                const totalScrap = allAssets.reduce((sum, a) => sum + (a.quality?.scrapRate || 0), 0);
+                const scrapValue = totalScrap * (avgMaterialValue * 0.1); // 10% recovery
+
+                const supplyChain: SupplyChainMetrics = {
+                    totalInventoryValue,
+                    inventoryTurnoverRate,
+                    averageLeadTime: averageResidenceTime / 1000, // seconds
+                    holdingCost,
+                    stockoutRisk: bottlenecks.some((b) => b.severity === "critical") ? 0.8 : 0.2, // Simulated based on bottlenecks
+                    supplierDependence: 0.45, // Constant simulation factor
+                    materialUtilization: completedMaterials > 0 ? (completedMaterials / (completedMaterials + totalScrap)) * 100 : 100,
+                    scrapValue,
+                };
+
+                // Sustainability
+                // CO2 factors
+                const totalWaste = totalScrap * 5; // 5kg per scrap unit (simulated)
+                const wasteGenerationRate = analysisDurationHours > 0 ? totalWaste / analysisDurationHours : 0;
+
+                const sustainability: SustainabilityMetrics = {
+                    totalCarbonFootprint: totalEnergyConsumed * 0.5, // 0.5 kg/kWh
+                    energyIntensity: completedMaterials > 0 ? totalEnergyConsumed / completedMaterials : 0,
+                    carbonIntensity: completedMaterials > 0 ? (totalEnergyConsumed * 0.5) / completedMaterials : 0,
+                    wasteGenerationRate,
+                    recyclableRatio: 0.3, // 30% recyclable (simulated)
+                    waterUsage: completedMaterials * 10, // 10L per unit (simulated)
+                    ecoEfficiencyScore: Math.min(100, Math.max(0, 80 - totalEnergyConsumed * 0.1 + completedMaterials * 0.5)),
+                };
+
+                // Reliability
+                const totalFailures = assetsInError + allAssets.reduce((sum, a) => sum + (errorCountsRef.current[a.assetId] || 0), 0);
+                const systemMTBF = totalFailures > 0 ? totalSystemTime / totalFailures : totalSystemTime;
+                const systemMTTR = totalFailures > 0 ? totalIdleTime / totalFailures : 0;
+
+                const reliability: ReliabilityMetrics = {
+                    systemMTBF: systemMTBF / 3600, // hours
+                    systemMTTR: systemMTTR / 3600, // hours
+                    systemAvailability: systemUptime,
+                    failureFrequency: analysisDurationHours > 0 ? totalFailures / analysisDurationHours : 0,
+                    criticalPathReliability: weightedOEE, // Proxy using OEE
+                };
+
+                return { financials, supplyChain, sustainability, reliability };
+            };
+
+            const advancedAnalytics = calculateAdvancedAnalytics();
+
            return {
                assets: allAssets,

@@ -2166,6 +2261,8 @@ function Analyzer() {
                    },
                },

+                advancedAnalytics,
+
                predictiveInsights: {
                    maintenanceAlerts: maintenanceAlerts.slice(0, 5), // Top 5 alerts
                    optimizationOpportunities: optimizationOpportunities.slice(0, 5), // Top 5 opportunities
--- a/app/src/modules/simulation/simulation.tsx
+++ b/app/src/modules/simulation/simulation.tsx
@@ -26,7 +26,7 @@ function Simulation() {
    const { analysis } = analysisStore();

    useEffect(() => {
-        // console.log("analysis: ", analysis);
+        console.log("analysis: ", analysis);
    }, [analysis]);

    useEffect(() => {
--- a/app/src/types/simulationTypes.d.ts
+++ b/app/src/types/simulationTypes.d.ts
@@ -514,6 +514,8 @@ interface QualityMetrics {
        count: number;
        averageTime: number;
    }[];
+    scrapRate?: number;
+    reworkRate?: number;
 }

 interface CostMetrics {
@@ -1126,6 +1128,58 @@ interface PredictiveInsights {
    }[];
 }

+interface FinancialMetrics {
+    totalRevenue: number;
+    grossProfit: number;
+    netProfitMargin: number; // Percentage
+    burnRate: number; // Cost per hour
+    laborCostRatio: number; // Labor cost / Total cost
+    energyCostRatio: number; // Energy cost / Total cost
+    maintenanceCostRatio: number; // Maintenance cost / Total cost
+    breakEvenUnits: number; // Units needed to cover fixed costs
+    fixedCosts: number; // Estimated fixed overhead
+    variableCosts: number; // Direct production costs
+    revenuePerUnit: number;
+    costPerUnit: number;
+    profitPerUnit: number;
+}
+
+interface SupplyChainMetrics {
+    totalInventoryValue: number; // Current WIP value
+    inventoryTurnoverRate: number; // COGS / Average Inventory (per hour scaled)
+    averageLeadTime: number; // End-to-end processing time
+    holdingCost: number; // Estimated cost to store WIP
+    stockoutRisk: number; // Probability of starvation
+    supplierDependence: number; // External dependency factor (simulated)
+    materialUtilization: number; // % of raw material converting to product
+    scrapValue: number; // Recoverable value from waste
+}
+
+interface SustainabilityMetrics {
+    totalCarbonFootprint: number; // kg CO2e
+    energyIntensity: number; // kWh per unit produced
+    carbonIntensity: number; // kg CO2 per unit produced
+    wasteGenerationRate: number; // kg waste per hour
+    recyclableRatio: number; // Percentage of waste recyclable
+    waterUsage: number; // Estimated water usage (simulated)
+    ecoEfficiencyScore: number; // 0-100 score
+}
+
+interface ReliabilityMetrics {
+    systemMTBF: number; // System Mean Time Between Failures
+    systemMTTR: number; // System Mean Time To Repair
+    systemAvailability: number; // Percentage
+    failureFrequency: number; // Failures per hour
+    criticalPathReliability: number; // Reliability of the bottleneck path
+}
+
+interface AdvancedAnalytics {
+    financials: FinancialMetrics;
+    supplyChain: SupplyChainMetrics;
+    sustainability: SustainabilityMetrics;
+    reliability: ReliabilityMetrics;
+}
+
 // ============================================================================
 // MAIN ANALYSIS SCHEMA
 // ============================================================================
@@ -1142,6 +1196,9 @@ interface AnalysisSchema {
    // Material Flow
    materialFlow: MaterialFlowAnalysis;

+    // Advanced Analytics
+    advancedAnalytics: AdvancedAnalytics;
+
    // Predictive Insights
    predictiveInsights: PredictiveInsights;