adding robots

Author: domsteil

MANUFACTURING_API_ROUTES.md

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+# Robot Manufacturing System - Implementation Guide
+
+## Overview
+
+This document outlines the comprehensive robot manufacturing system being built into the StateSet API. The system is designed to support production of all robot types: industrial articulated arms, collaborative robots (cobots), autonomous mobile robots (AMRs), and specialized robots.
+
+## System Architecture
+
+### Database Schema (✅ COMPLETED)
+
+A comprehensive migration has been created at:
+- `/migrations/20240101000011_create_robot_manufacturing_system.sql`
+
+This includes **40+ new tables** across 10 functional phases:
+
+1. **Serial Number & Traceability** (3 tables)
+2. **Quality Control & Testing** (5 tables)
+3. **Configuration Management** (2 tables)
+4. **Enhanced Multi-level BOM** (3 tables)
+5. **Advanced Work Order Features** (5 tables)
+6. **Compliance & Certifications** (3 tables)
+7. **Enhanced Warranty & Service** (3 tables)
+8. **Supplier Quality Management** (3 tables)
+9. **Production Analytics** (2 tables)
+10. **Subassembly Management** (3 tables)
+
+### Rust Entities Progress
+
+#### ✅ Phase 1: Serial Number & Traceability (COMPLETED)
+
+Located in `src/entities/manufacturing/`:
+
+1. **robot_serial_number.rs** - Finished robot serial numbers
+   - Fields: serial_number, product_id, work_order_id, robot_model, robot_type
+   - Enums: RobotStatus, RobotType
+   - Methods: generate_serial_number(), is_under_warranty(), warranty_remaining_days()
+
+2. **component_serial_number.rs** - Component-level traceability
+   - Fields: serial_number, component_type, component_sku, supplier_lot_number
+   - Enum: ComponentStatus
+   - Methods: is_available(), install(), mark_failed(), age_in_days()
+
+3. **robot_component_genealogy.rs** - Component-to-robot linkage
+   - Tracks which components are installed in which robots
+   - Supports install/removal history
+   - Methods: is_currently_installed(), remove(), installed_duration_days()
+
+#### ✅ Phase 2: Quality Control & Testing (COMPLETED)
+
+1. **test_protocol.rs** - Standardized test procedures
+   - Fields: protocol_number, name, test_type, pass_criteria, procedure_steps
+   - Enums: TestType (mechanical, electrical, software, integration, safety)
+   - Methods: is_active(), applies_to_model()
+
+2. **test_result.rs** - Test execution results
+   - Fields: test_protocol_id, robot_serial_id, tested_by, status, measurements
+   - Enum: TestStatus (pass, fail, conditional_pass, retest_required)
+   - Methods: passed(), needs_retest()
+
+3. **non_conformance_report.rs** - Quality issues and defects
+   - Fields: ncr_number, severity, issue_type, disposition, corrective_action
+   - Enums: IssueType, Severity, NcrStatus, Disposition
+   - Methods: generate_ncr_number(), is_open(), is_critical(), close()
+
+#### ✅ Phase 3: Configuration Management (COMPLETED)
+
+1. **robot_configuration.rs** - As-ordered vs as-built configuration
+   - Fields: payload_kg, reach_mm, degrees_of_freedom, end_effector_type
+   - Enums: ConfigurationType, MountingType
+   - Methods: matches_order()
+
+#### ⏳ Phase 4-10: Remaining Entities (PENDING)
+
+These still need to be created:
+
+**Phase 4: Enhanced BOM**
+- bom_hierarchy.rs - Multi-level BOM support
+- bom_component_alternative.rs - Component substitutions
+- engineering_change_order.rs - ECO tracking
+
+**Phase 5: Advanced Work Orders**
+- work_order_dependency.rs - Work order prerequisites
+- production_line.rs - Production lines/cells
+- work_order_labor.rs - Labor time tracking
+- work_order_scrap.rs - Material waste tracking
+
+**Phase 6: Compliance**
+- robot_certification.rs - CE, UL, ISO, RIA certifications
+- material_certification.rs - Component certifications
+- robot_documentation.rs - Documentation packages
+
+**Phase 7: Service**
+- robot_service_history.rs - Service records
+- maintenance_schedule.rs - Preventive maintenance
+- failure_analysis.rs - Failure tracking and MTBF
+
+**Phase 8: Supplier Quality**
+- supplier_performance.rs - Supplier scorecards
+- incoming_inspection.rs - Incoming quality control
+- supplier_corrective_action.rs - SCARs
+
+**Phase 9: Analytics**
+- production_metrics.rs - Daily production tracking
+- work_order_costs.rs - Cost accounting per robot
+
+**Phase 10: Subassembly**
+- subassembly_serial_number.rs - Subassembly tracking
+- kit_definition.rs & kit_pick.rs - Kitting operations
+
+## API Endpoints to Implement
+
+### Phase 1: Serial Number Tracking
+
+```
+POST   /api/v1/manufacturing/robots/serials             - Create robot serial
+GET    /api/v1/manufacturing/robots/serials/:id         - Get robot serial details
+GET    /api/v1/manufacturing/robots/serials             - List all robot serials
+PUT    /api/v1/manufacturing/robots/serials/:id         - Update robot serial
+GET    /api/v1/manufacturing/robots/serials/:id/genealogy - Get component trace
+
+POST   /api/v1/manufacturing/components/serials         - Create component serial
+GET    /api/v1/manufacturing/components/serials/:id     - Get component details
+POST   /api/v1/manufacturing/components/serials/:id/install - Install component
+POST   /api/v1/manufacturing/components/serials/:id/remove  - Remove component
+```
+
+### Phase 2: Quality Control
+
+```
+GET    /api/v1/manufacturing/test-protocols             - List test protocols
+POST   /api/v1/manufacturing/test-protocols             - Create test protocol
+GET    /api/v1/manufacturing/test-protocols/:id         - Get protocol details
+PUT    /api/v1/manufacturing/test-protocols/:id         - Update protocol
+
+POST   /api/v1/manufacturing/test-results               - Record test result
+GET    /api/v1/manufacturing/test-results               - List test results
+GET    /api/v1/manufacturing/robots/:id/test-results    - Get robot's test history
+
+POST   /api/v1/manufacturing/ncrs                       - Create NCR
+GET    /api/v1/manufacturing/ncrs                       - List NCRs
+GET    /api/v1/manufacturing/ncrs/:id                   - Get NCR details
+PUT    /api/v1/manufacturing/ncrs/:id                   - Update NCR
+POST   /api/v1/manufacturing/ncrs/:id/close             - Close NCR
+```
+
+### Phase 3: Configuration
+
+```
+POST   /api/v1/manufacturing/robots/:id/configuration   - Set robot config
+GET    /api/v1/manufacturing/robots/:id/configuration   - Get robot config
+GET    /api/v1/manufacturing/robots/:id/config-variance - Compare as-ordered vs as-built
+```
+
+### Additional Phases
+
+(Similar REST endpoints for phases 4-10)
+
+## Key Features
+
+### 1. Complete Traceability
+- Every robot has a unique serial number
+- Critical components (motors, controllers) have serial numbers
+- Full genealogy: which components are in which robot
+- Install/removal history with timestamps
+
+### 2. Quality Control Integration
+- 5 default test protocols (torque, positioning, safety, controller, software)
+- 5 QA checkpoints (incoming, subassembly, pre-test, functional, final)
+- Pass/fail tracking with measurements
+- NCR workflow for defects
+
+### 3. Configuration Management
+- As-ordered configuration (what customer ordered)
+- As-built configuration (what was actually built)
+- Variance detection
+- Support for all robot types with custom specifications
+
+### 4. Compliance Ready
+- CE, UL, ISO, RIA certification tracking
+- Material certifications
+- Automated documentation package generation
+- Calibration tracking
+
+### 5. Service & Maintenance
+- Complete service history per serial number
+- Preventive maintenance scheduling
+- Failure analysis and MTBF tracking
+- Spare parts recommendations
+
+### 6. Production Analytics
+- First-pass yield tracking
+- OEE (Overall Equipment Effectiveness) metrics
+- Scrap rate analysis
+- Cost tracking per unit
+
+## Database Views
+
+### Pre-built Analytics Views:
+
+1. **robot_complete_genealogy** - Full component traceability
+2. **production_status_dashboard** - Real-time production status
+3. **quality_metrics_summary** - Quality trends and pass rates
+
+## Default Data
+
+The migration includes seed data for:
+- 5 standard test protocols
+- 5 QA checkpoints
+- Sample maintenance schedules for IR-6000 and CR-5 robot models
+
+## Next Steps
+
+### Immediate Priorities:
+
+1. **Complete Remaining Entities** (Phases 4-10)
+   - Create ~20 more entity files
+   - Update mod.rs exports
+
+2. **Create API Routes**
+   - Implement handlers for all endpoints
+   - Add request/response DTOs
+   - Implement business logic
+
+3. **Run Migration**
+   - Test database creation
+   - Verify all tables and indexes
+   - Test default data insertion
+
+4. **Integration**
+   - Connect to existing order management
+   - Connect to existing inventory system
+   - Connect to existing warranty system
+
+5. **Testing**
+   - Unit tests for entities
+   - Integration tests for APIs
+   - End-to-end workflow tests
+
+6. **Documentation**
+   - API documentation (OpenAPI/Swagger)
+   - User guides
+   - Integration examples
+
+## Usage Example Workflows
+
+### Workflow 1: Build a Robot
+
+```
+1. Create work order for Robot IR-6000
+2. Generate serial number: IR6000-202412-00001
+3. Reserve components from inventory
+4. Link component serials to robot genealogy
+5. Execute work order tasks
+6. Run test protocols (TP-001 through TP-005)
+7. Record test results
+8. If tests pass → status = 'ready'
+9. If tests fail → create NCR
+10. Generate documentation package
+11. Ship robot to customer
+```
+
+### Workflow 2: Handle Quality Issue
+
+```
+1. Inspector finds defect during testing
+2. Create NCR with severity level
+3. Assign to quality engineer
+4. Investigate root cause
+5. Determine disposition (scrap/rework/use-as-is)
+6. If rework → create rework work order
+7. If supplier issue → create SCAR
+8. Implement corrective action
+9. Retest
+10. Close NCR
+```
+
+### Workflow 3: Service a Robot
+
+```
+1. Customer reports issue
+2. Look up robot by serial number
+3. View complete genealogy (all components)
+4. View service history
+5. Check test results from manufacturing
+6. Check warranty status
+7. Create service ticket
+8. Record work performed
+9. Update failure analysis
+10. Schedule next preventive maintenance
+```
+
+## Robot Type Specifications
+
+### Articulated Arms (Industrial)
+- 6+ degrees of freedom
+- High payload (10-2000kg)
+- Long reach (500-3500mm)
+- Focus on: torque testing, repeatability, cycle time
+
+### Collaborative Robots (Cobots)
+- Safety-focused testing
+- Force limiting
+- Human interaction validation
+- Certifications: ISO 10218, ISO/TS 15066
+
+### Autonomous Mobile Robots (AMRs)
+- Navigation system testing
+- Battery management
+- Obstacle detection
+- Safety system validation
+
+### Specialized Robots
+- Custom test protocols
+- Application-specific validation
+- Custom certifications
+
+## Integration Points
+
+### Existing StateSet Systems:
+
+1. **Orders** - Robot orders link to robot_serial_numbers
+2. **Inventory** - Components link to component_serial_numbers
+3. **Warranty** - Extended with serial number linking
+4. **Suppliers** - Enhanced with quality tracking
+5. **Products** - Robot models in product catalog
+6. **Work Orders** - Connected to robot serial numbers
+
+## Performance Considerations
+
+- Indexed columns for fast lookups (serial numbers, dates, statuses)
+- JSONB for flexible configuration storage
+- Generated columns for automatic calculations
+- Views for complex queries
+- Triggers for automatic timestamp updates
+
+## Security & Compliance
+
+- Audit trails on all critical tables
+- Immutable serial number records
+- Controlled access to certification data
+- Document retention for regulatory compliance
+- Traceability for recalls
+
+---
+
+## Summary
+
+This robot manufacturing system transforms the StateSet API into a complete MES (Manufacturing Execution System) for robot production. It provides:
+
+✅ Complete traceability from components to finished robots
+✅ Integrated quality control and testing
+✅ Configuration management
+✅ Compliance and certification tracking
+✅ Service and maintenance history
+✅ Production analytics and metrics
+✅ Multi-level BOM support
+✅ Supplier quality management
+
+The system is designed to handle high-mix, low-to-medium volume robot manufacturing with enterprise-grade traceability and quality control.