tweaks

backend/app/services/client_access_service.py

@@ -20,6 +20,7 @@ MODULE_CATALOG = (
     ("mix_calculator", "Mix Calculator", "production", "Create and review client-specific mix calculation sessions"),
     ("products", "Products", "pricing", "Review finished product pricing"),
     ("scenarios", "Scenarios", "planning", "Run scenario overrides and comparisons"),
+    ("operations_throughput", "Operations Throughput", "production", "Log production throughput and QA checks for grain/feed packing"),
     ("powerbi_export", "Power BI Export", "reporting", "Expose client access data to BI consumers"),
     ("client_access", "Client Access", "administration", "Manage user access, module permissions, and audit history"),
 )
@@ -78,15 +79,15 @@ def has_access_level(access_level: str | None, minimum_level: str) -> bool:
 def default_access_level_for_role(role: str, module_key: str) -> str:
     normalized = role.strip().lower()
     if normalized == "superadmin":
-        return "manage" if module_key in {"client_access", "mix_calculator"} else "edit"
+        return "manage" if module_key in {"client_access", "mix_calculator", "operations_throughput"} else "edit"
     if normalized == "admin":
-        if module_key == "mix_calculator":
+        if module_key in {"mix_calculator", "operations_throughput"}:
             return "manage"
         return "edit" if module_key != "client_access" else "none"
     if normalized == "operator":
-        return "edit" if module_key in {"dashboard", "raw_materials", "mix_master", "mix_calculator", "products", "scenarios"} else "none"
+        return "edit" if module_key in {"dashboard", "raw_materials", "mix_master", "mix_calculator", "products", "scenarios", "operations_throughput"} else "none"
     if normalized == "viewer":
-        return "view" if module_key in {"dashboard", "mix_calculator", "products", "powerbi_export"} else "none"
+        return "view" if module_key in {"dashboard", "mix_calculator", "products", "powerbi_export", "operations_throughput"} else "none"
     return "none"
 
 

backend/app/services/costing_engine.py

@@ -8,7 +8,7 @@ from sqlalchemy.orm import Session, selectinload
 
 from app.models.assumption import FreightCostRule, PackagingCostRule, ProcessCostRule
 from app.models.mix import Mix, MixIngredient
-from app.models.product import Product
+from app.models.product import Product, ProductIngredient
 from app.models.raw_material import RawMaterial, RawMaterialPriceVersion
 
 
@@ -119,6 +119,78 @@ def calculate_mix_cost(db: Session, mix_id: int, overrides: dict | None = None)
     }
 
 
+def _calculate_formula_cost_from_product_ingredients(
+    product_ingredients: list[ProductIngredient],
+    overrides: dict | None = None,
+) -> dict:
+    overrides = overrides or {}
+    total_mix_kg = 0.0
+    total_mix_cost = 0.0
+    warnings: list[str] = []
+    lines: list[dict] = []
+
+    for ingredient in product_ingredients:
+        raw_material = ingredient.raw_material
+        active_price = get_active_price(raw_material)
+        if active_price is None:
+            warnings.append(f"{raw_material.name} has no active price")
+            lines.append(
+                {
+                    "id": ingredient.id,
+                    "raw_material_id": raw_material.id,
+                    "raw_material_name": raw_material.name,
+                    "quantity_kg": ingredient.quantity_kg,
+                    "cost_per_kg": None,
+                    "line_cost": None,
+                    "notes": ingredient.notes,
+                }
+            )
+            total_mix_kg += ingredient.quantity_kg
+            continue
+
+        market_value = overrides.get("raw_material_market_values", {}).get(str(raw_material.id), active_price.market_value)
+        waste_percentage = overrides.get("raw_material_waste_percentages", {}).get(str(raw_material.id), active_price.waste_percentage)
+        price_stub = RawMaterialPriceVersion(
+            raw_material_id=raw_material.id,
+            market_value=market_value,
+            waste_percentage=waste_percentage,
+            effective_date=active_price.effective_date,
+            status=active_price.status,
+        )
+        price_comp = calculate_raw_material_cost(raw_material, price_stub)
+        line_cost = round(ingredient.quantity_kg * price_comp.cost_per_kg, 4)
+        total_mix_kg += ingredient.quantity_kg
+        total_mix_cost += line_cost
+        lines.append(
+            {
+                "id": ingredient.id,
+                "raw_material_id": raw_material.id,
+                "raw_material_name": raw_material.name,
+                "quantity_kg": ingredient.quantity_kg,
+                "cost_per_kg": price_comp.cost_per_kg,
+                "line_cost": line_cost,
+                "notes": ingredient.notes,
+            }
+        )
+
+    if total_mix_kg == 0:
+        warnings.append("Mix total kg is zero")
+        mix_cost_per_kg = None
+    else:
+        mix_cost_per_kg = round(total_mix_cost / total_mix_kg, 4)
+
+    if not product_ingredients:
+        warnings.append("Mix has no ingredients")
+
+    return {
+        "ingredients": lines,
+        "total_mix_kg": round(total_mix_kg, 4),
+        "total_mix_cost": round(total_mix_cost, 4),
+        "mix_cost_per_kg": mix_cost_per_kg,
+        "warnings": warnings,
+    }
+
+
 def _get_process_costs(db: Session, process_name: str | None, overrides: dict) -> tuple[float, float, float, list[str]]:
     if not process_name:
         return 0.0, 0.0, 0.0, ["Missing bagging process"]
@@ -192,12 +264,22 @@ def extract_unit_quantity_kg(unit_of_measure: str) -> float:
 def calculate_product_cost(db: Session, product_id: int, overrides: dict | None = None) -> dict:
     overrides = overrides or {}
     overrides = {**overrides, "tenant_id": overrides.get("tenant_id")}
-    product = db.scalar(select(Product).where(Product.id == product_id).options(selectinload(Product.mix)))
+    product = db.scalar(
+        select(Product)
+        .where(Product.id == product_id)
+        .options(
+            selectinload(Product.mix),
+            selectinload(Product.ingredients).selectinload(ProductIngredient.raw_material).selectinload(RawMaterial.price_versions),
+        )
+    )
     if product is None:
         raise ValueError(f"Product {product_id} not found")
     overrides["tenant_id"] = product.tenant_id
 
-    mix_result = calculate_mix_cost(db, product.mix_id, overrides=overrides)
+    if product.ingredients:
+        mix_result = _calculate_formula_cost_from_product_ingredients(product.ingredients, overrides=overrides)
+    else:
+        mix_result = calculate_mix_cost(db, product.mix_id, overrides=overrides)
     warnings = list(mix_result["warnings"])
     sale_unit_kg = extract_unit_quantity_kg(product.unit_of_measure)
 

backend/app/services/mix_calculator_filenames.py

@@ -3,8 +3,14 @@ from __future__ import annotations
 import re
 
 from app.models.mix_calculator import MixCalculatorSession
+from app.schemas.mix_calculator import MixCalculatorPreviewRead
 
 
 def mix_calculator_pdf_filename(session_record: MixCalculatorSession) -> str:
     raw = f"{session_record.session_number}_{session_record.client_name}_{session_record.product_name}.pdf"
     return re.sub(r"[^\w.\-]+", "_", raw)
+
+
+def mix_calculator_preview_pdf_filename(preview: MixCalculatorPreviewRead) -> str:
+    raw = f"MixCalculator_{preview.client_name}_{preview.product_name}_{preview.mix_date}.pdf"
+    return re.sub(r"[^\w.\-]+", "_", raw)

backend/app/services/mix_calculator_pdf.py

@@ -1,7 +1,8 @@
 from __future__ import annotations
 
 from io import BytesIO
-from math import ceil
+from pathlib import Path
+from types import SimpleNamespace
 
 from app.models.mix_calculator import MixCalculatorSession
 
@@ -24,272 +25,329 @@ def _fractional_bag_warning(session_record: MixCalculatorSession) -> str | None:
     )
 
 
-def build_mix_calculator_pdf(session_record: MixCalculatorSession) -> bytes:
+def _coerce_pdf_source(source):
+    if isinstance(source, dict):
+        lines = [SimpleNamespace(**line) if isinstance(line, dict) else line for line in source.get("lines", [])]
+        return SimpleNamespace(**{**source, "lines": lines})
+    return source
+
+
+def build_mix_calculator_pdf(session_record: MixCalculatorSession | dict) -> bytes:
+    session_record = _coerce_pdf_source(session_record)
     try:
         from reportlab.lib import colors
         from reportlab.lib.pagesizes import A4
-        from reportlab.lib.styles import ParagraphStyle, getSampleStyleSheet
-        from reportlab.lib.units import mm
-        from reportlab.platypus import Paragraph, SimpleDocTemplate, Spacer, Table, TableStyle
+        from reportlab.lib.utils import ImageReader
+        from reportlab.pdfbase.pdfmetrics import stringWidth
+        from reportlab.pdfgen import canvas
     except ModuleNotFoundError as exc:
         raise MixCalculatorPdfUnavailableError(
             "PDF generation is unavailable because 'reportlab' is not installed. "
             "Install backend dependencies again to enable PDF export."
         ) from exc
 
+    page_width, page_height = A4
+    margin = 26
+    gutter = 10
+    content_width = page_width - (margin * 2)
+    page_top = page_height - 40
+
+    palette = {
+        "page": colors.HexColor("#FFFFFF"),
+        "line": colors.HexColor("#000000"),
+        "muted": colors.HexColor("#000000"),
+        "text": colors.HexColor("#000000"),
+        "warning_bg": colors.HexColor("#FFFFFF"),
+        "warning_text": colors.HexColor("#000000"),
+    }
+    logo_path = Path(__file__).resolve().parents[3] / "frontend" / "static" / "logo-hsf.png"
+
+    def clamp(value: float, minimum: float, maximum: float) -> float:
+        return max(minimum, min(maximum, value))
+
+    def fit_text(value: str, font_name: str, font_size: float, max_width: float) -> str:
+        if stringWidth(value, font_name, font_size) <= max_width:
+            return value
+        ellipsis = "..."
+        available = max_width - stringWidth(ellipsis, font_name, font_size)
+        trimmed = value
+        while trimmed and stringWidth(trimmed, font_name, font_size) > available:
+            trimmed = trimmed[:-1]
+        return f"{trimmed.rstrip()}{ellipsis}" if trimmed else ellipsis
+
+    def wrap_text(value: str, font_name: str, font_size: float, max_width: float, max_lines: int) -> list[str]:
+        words = value.split()
+        if not words:
+            return []
+        lines: list[str] = []
+        current = words[0]
+        for word in words[1:]:
+            candidate = f"{current} {word}"
+            if stringWidth(candidate, font_name, font_size) <= max_width:
+                current = candidate
+            else:
+                lines.append(current)
+                current = word
+                if len(lines) == max_lines - 1:
+                    break
+        if len(lines) < max_lines:
+            lines.append(current)
+
+        remaining_words = words[len(" ".join(lines).split()) :]
+        if remaining_words and lines:
+            lines[-1] = fit_text(f"{lines[-1]} {' '.join(remaining_words)}", font_name, font_size, max_width)
+        return lines[:max_lines]
+
+    def draw_box(pdf: canvas.Canvas, x: float, y_top: float, width: float, height: float):
+        pdf.setFillColor(palette["page"])
+        pdf.setStrokeColor(palette["line"])
+        pdf.setLineWidth(1)
+        pdf.rect(x, y_top - height, width, height, fill=1, stroke=1)
+
+    def draw_label_value_card(
+        pdf: canvas.Canvas,
+        x: float,
+        y_top: float,
+        width: float,
+        height: float,
+        label: str,
+        value: str,
+        subtitle: str | None = None,
+        value_font_size: float = 14,
+    ):
+        draw_box(pdf, x, y_top, width, height)
+        inset_x = x + 14
+        label_y = y_top - 16
+        pdf.setFillColor(palette["muted"])
+        pdf.setFont("Helvetica-Bold", 7.5)
+        pdf.drawString(inset_x, label_y, label.upper())
+
+        value_y = y_top - 38
+        pdf.setFillColor(palette["text"])
+        pdf.setFont("Helvetica-Bold", value_font_size)
+        pdf.drawString(inset_x, value_y, fit_text(value, "Helvetica-Bold", value_font_size, width - 28))
+
+        if subtitle:
+            pdf.setFillColor(palette["muted"])
+            pdf.setFont("Helvetica", 8)
+            pdf.drawString(inset_x, y_top - height + 14, fit_text(subtitle, "Helvetica", 8, width - 28))
+
     buffer = BytesIO()
-    document = SimpleDocTemplate(
-        buffer,
-        pagesize=A4,
-        leftMargin=14 * mm,
-        rightMargin=14 * mm,
-        topMargin=14 * mm,
-        bottomMargin=14 * mm,
-        title=f"{session_record.session_number} - {session_record.product_name}",
-        author="Lean 101 Clients",
+    pdf = canvas.Canvas(buffer, pagesize=A4)
+    session_number = getattr(session_record, "session_number", None)
+    document_title = (
+        f"{session_number} - {session_record.product_name}"
+        if session_number
+        else f"Mix Calculator - {session_record.product_name}"
     )
+    pdf.setTitle(document_title)
+    pdf.setAuthor("Lean 101 Clients")
 
-    styles = getSampleStyleSheet()
-    eyebrow = ParagraphStyle(
-        "Eyebrow",
-        parent=styles["BodyText"],
-        fontName="Helvetica-Bold",
-        fontSize=8,
-        leading=10,
-        textColor=colors.HexColor("#62736B"),
-        spaceAfter=5,
-    )
-    title = ParagraphStyle(
-        "Title",
-        parent=styles["Heading1"],
-        fontName="Helvetica-Bold",
-        fontSize=24,
-        leading=26,
-        textColor=colors.HexColor("#21312A"),
-        spaceAfter=6,
-    )
-    subtitle = ParagraphStyle(
-        "Subtitle",
-        parent=styles["BodyText"],
-        fontName="Helvetica",
-        fontSize=10,
-        leading=13,
-        textColor=colors.HexColor("#6B7A73"),
-    )
-    label = ParagraphStyle(
-        "Label",
-        parent=styles["BodyText"],
-        fontName="Helvetica-Bold",
-        fontSize=7,
-        leading=9,
-        textColor=colors.HexColor("#6B7A73"),
-    )
-    value = ParagraphStyle(
-        "Value",
-        parent=styles["BodyText"],
-        fontName="Helvetica-Bold",
-        fontSize=11,
-        leading=13,
-        textColor=colors.HexColor("#21312A"),
-    )
-    card_value = ParagraphStyle(
-        "CardValue",
-        parent=value,
-        fontSize=16,
-        leading=18,
-    )
-    body = ParagraphStyle(
-        "Body",
-        parent=styles["BodyText"],
-        fontName="Helvetica",
-        fontSize=9,
-        leading=12,
-        textColor=colors.HexColor("#304038"),
-    )
-    section_title = ParagraphStyle(
-        "SectionTitle",
-        parent=styles["Heading2"],
-        fontName="Helvetica-Bold",
-        fontSize=13,
-        leading=15,
-        textColor=colors.HexColor("#21312A"),
-    )
+    pdf.setFillColor(palette["page"])
+    pdf.rect(0, 0, page_width, page_height, stroke=0, fill=1)
 
-    warnings = []
-    bag_warning = _fractional_bag_warning(session_record)
-    if bag_warning:
-        warnings.append(bag_warning)
+    current_y = page_top
+    mix_date_label = f"{session_record.mix_date.day} {session_record.mix_date.strftime('%B %Y')}"
 
-    story = [
-        Paragraph(f"Mix Calculator  |  {session_record.session_number}", eyebrow),
-        Paragraph(session_record.product_name, title),
-        Paragraph(f"{session_record.client_name} &nbsp;&middot;&nbsp; {session_record.mix_name}", subtitle),
-        Spacer(1, 8),
-    ]
+    if logo_path.exists():
+        logo_source = str(logo_path)
+        try:
+            from PIL import Image
 
-    header_table = Table(
-        [
-            [
-                [
-                    Paragraph("Mix date", label),
-                    Paragraph(session_record.mix_date.strftime("%d %b %Y"), value),
-                ],
-                [
-                    Paragraph("Prepared by", label),
-                    Paragraph(session_record.prepared_by_name, value),
-                ],
-                [
-                    Paragraph("Status", label),
-                    Paragraph(session_record.status.title(), value),
-                ],
-            ]
-        ],
-        colWidths=[60 * mm, 60 * mm, 52 * mm],
-    )
-    header_table.setStyle(
-        TableStyle(
-            [
-                ("VALIGN", (0, 0), (-1, -1), "TOP"),
-                ("BOX", (0, 0), (-1, -1), 0.8, colors.HexColor("#DBE4DE")),
-                ("INNERGRID", (0, 0), (-1, -1), 0.8, colors.HexColor("#DBE4DE")),
-                ("BACKGROUND", (0, 0), (-1, -1), colors.white),
-                ("LEFTPADDING", (0, 0), (-1, -1), 10),
-                ("RIGHTPADDING", (0, 0), (-1, -1), 10),
-                ("TOPPADDING", (0, 0), (-1, -1), 9),
-                ("BOTTOMPADDING", (0, 0), (-1, -1), 9),
-            ]
+            logo_source = Image.open(logo_path).convert("L")
+        except ModuleNotFoundError:
+            pass
+
+        logo_reader = ImageReader(logo_source)
+        logo_width, logo_height = logo_reader.getSize()
+        aspect_ratio = logo_height / max(logo_width, 1)
+        draw_width = 108
+        draw_height = draw_width * aspect_ratio
+        pdf.drawImage(
+            logo_reader,
+            margin,
+            current_y - draw_height,
+            width=draw_width,
+            height=draw_height,
+            preserveAspectRatio=True,
+            mask="auto",
         )
-    )
-    story.extend([header_table, Spacer(1, 10)])
+        current_y -= draw_height + 20
 
-    summary_table = Table(
-        [
-            [
-                [Paragraph("Batch size", label), Paragraph(f"{_fmt_number(session_record.batch_size_kg)}kg", card_value)],
-                [Paragraph("Total output", label), Paragraph(f"{_fmt_number(session_record.total_kg)}kg", card_value)],
-                [Paragraph("Bags", label), Paragraph(_fmt_number(session_record.total_bags), card_value)],
-                [Paragraph("Unit pack", label), Paragraph(f"{_fmt_number(session_record.product_unit_size_kg)}kg", card_value)],
-            ]
-        ],
-        colWidths=[43 * mm, 43 * mm, 43 * mm, 43 * mm],
-    )
-    summary_table.setStyle(
-        TableStyle(
-            [
-                ("BOX", (0, 0), (-1, -1), 0.8, colors.HexColor("#DBE4DE")),
-                ("INNERGRID", (0, 0), (-1, -1), 0.8, colors.HexColor("#DBE4DE")),
-                ("BACKGROUND", (0, 0), (-1, -1), colors.HexColor("#F9FBFA")),
-                ("VALIGN", (0, 0), (-1, -1), "TOP"),
-                ("LEFTPADDING", (0, 0), (-1, -1), 10),
-                ("RIGHTPADDING", (0, 0), (-1, -1), 10),
-                ("TOPPADDING", (0, 0), (-1, -1), 10),
-                ("BOTTOMPADDING", (0, 0), (-1, -1), 10),
-            ]
-        )
-    )
-    story.extend([summary_table, Spacer(1, 10)])
+    pdf.setFillColor(palette["text"])
+    pdf.setFont("Helvetica-Bold", 15)
+    pdf.drawString(margin, current_y, "Calculated Output")
+    current_y -= 16
 
-    detail_table = Table(
-        [
-            [
-                [Paragraph("Mix source", label), Paragraph(session_record.mix_name, value), Paragraph(f"Saved against {session_record.product_unit_of_measure} units.", body)],
-                [Paragraph("Composition", label), Paragraph(f"{_fmt_number(sum(line.mix_percentage for line in session_record.lines))}%", value), Paragraph(f"{len(session_record.lines)} raw material{'s' if len(session_record.lines) != 1 else ''} in the blend.", body)],
-                [Paragraph("Estimated pages", label), Paragraph(str(max(1, ceil(len(session_record.lines) / 18))), value), Paragraph("Formatted for A4 PDF export.", body)],
-            ]
-        ],
-        colWidths=[60 * mm, 60 * mm, 52 * mm],
+    pdf.setFillColor(palette["muted"])
+    pdf.setFont("Helvetica", 10)
+    pdf.drawString(margin, current_y, "Snapshot of the scaled raw material requirements.")
+    current_y -= 20
+
+    stat_height = 66
+    stat_width = (content_width - (gutter * 2)) / 3
+    draw_label_value_card(
+        pdf,
+        margin,
+        current_y,
+        stat_width,
+        stat_height,
+        "Total kg",
+        _fmt_number(session_record.total_kg),
+        "Scaled batch size",
+        value_font_size=18,
     )
-    detail_table.setStyle(
-        TableStyle(
-            [
-                ("BACKGROUND", (0, 0), (-1, -1), colors.HexColor("#F4F8F5")),
-                ("VALIGN", (0, 0), (-1, -1), "TOP"),
-                ("LEFTPADDING", (0, 0), (-1, -1), 10),
-                ("RIGHTPADDING", (0, 0), (-1, -1), 10),
-                ("TOPPADDING", (0, 0), (-1, -1), 10),
-                ("BOTTOMPADDING", (0, 0), (-1, -1), 10),
-            ]
-        )
+    draw_label_value_card(
+        pdf,
+        margin + stat_width + gutter,
+        current_y,
+        stat_width,
+        stat_height,
+        "Total bags",
+        _fmt_number(session_record.total_bags),
+        session_record.product_unit_of_measure,
+        value_font_size=18,
     )
-    story.extend([detail_table, Spacer(1, 10)])
+    draw_label_value_card(
+        pdf,
+        margin + ((stat_width + gutter) * 2),
+        current_y,
+        stat_width,
+        stat_height,
+        "Prepared by",
+        session_record.prepared_by_name,
+        mix_date_label,
+        value_font_size=10.5,
+    )
+    current_y -= stat_height + 12
+
+    detail_height = 52
+    detail_width = (content_width - gutter) / 2
+    draw_label_value_card(
+        pdf,
+        margin,
+        current_y,
+        detail_width,
+        detail_height,
+        "Client",
+        session_record.client_name,
+        value_font_size=12,
+    )
+    draw_label_value_card(
+        pdf,
+        margin + detail_width + gutter,
+        current_y,
+        detail_width,
+        detail_height,
+        "Product",
+        session_record.product_name,
+        value_font_size=12,
+    )
+    current_y -= detail_height + 8
+
+    draw_label_value_card(
+        pdf,
+        margin,
+        current_y,
+        detail_width,
+        detail_height,
+        "Mix source",
+        session_record.mix_name,
+        value_font_size=11,
+    )
+    draw_label_value_card(
+        pdf,
+        margin + detail_width + gutter,
+        current_y,
+        detail_width,
+        detail_height,
+        "Unit size",
+        f"{_fmt_number(session_record.product_unit_size_kg)}kg",
+        value_font_size=12,
+    )
+    current_y -= detail_height + 10
+
+    warning = _fractional_bag_warning(session_record)
+    note_lines: list[str] = []
+    warning_lines: list[str] = []
+    strip_height = 0
 
     if session_record.notes:
-        notes_table = Table(
-            [[Paragraph("Notes", label)], [Paragraph(session_record.notes.replace("\n", "<br/>"), body)]],
-            colWidths=[172 * mm],
-        )
-        notes_table.setStyle(
-            TableStyle(
-                [
-                    ("BACKGROUND", (0, 0), (-1, 0), colors.HexColor("#F4F8F5")),
-                    ("BOX", (0, 0), (-1, -1), 0.8, colors.HexColor("#DBE4DE")),
-                    ("LEFTPADDING", (0, 0), (-1, -1), 10),
-                    ("RIGHTPADDING", (0, 0), (-1, -1), 10),
-                    ("TOPPADDING", (0, 0), (-1, -1), 8),
-                    ("BOTTOMPADDING", (0, 0), (-1, -1), 8),
-                ]
-            )
-        )
-        story.extend([notes_table, Spacer(1, 10)])
+        note_lines = wrap_text(session_record.notes.replace("\n", " "), "Helvetica", 7.5, content_width - 28, 2)
+        strip_height += 30
+    if warning:
+        warning_lines = wrap_text(warning, "Helvetica", 7.5, content_width - 28, 2)
+        strip_height += 30
+    if strip_height:
+        strip_height += 6
 
-    if warnings:
-        warning_rows = [[Paragraph("Warnings", label)]]
-        warning_rows.extend([[Paragraph(warning, body)] for warning in warnings])
-        warnings_table = Table(warning_rows, colWidths=[172 * mm])
-        warnings_table.setStyle(
-            TableStyle(
-                [
-                    ("BACKGROUND", (0, 0), (-1, 0), colors.HexColor("#FFF5E6")),
-                    ("BACKGROUND", (0, 1), (-1, -1), colors.HexColor("#FFF9EF")),
-                    ("BOX", (0, 0), (-1, -1), 0.8, colors.HexColor("#E8C483")),
-                    ("LEFTPADDING", (0, 0), (-1, -1), 10),
-                    ("RIGHTPADDING", (0, 0), (-1, -1), 10),
-                    ("TOPPADDING", (0, 0), (-1, -1), 8),
-                    ("BOTTOMPADDING", (0, 0), (-1, -1), 8),
-                ]
-            )
-        )
-        story.extend([warnings_table, Spacer(1, 10)])
+    table_header_height = 24
+    table_bottom_padding = 12
+    table_top = current_y
+    available_table_height = table_top - margin - strip_height - table_header_height - table_bottom_padding
+    row_count = max(len(session_record.lines), 1)
+    row_height = clamp(available_table_height / row_count, 16, 32)
+    table_font_size = clamp(row_height * 0.36, 7, 11)
+    table_height = table_header_height + (row_height * row_count)
+    table_bottom = table_top - table_height
 
-    story.extend(
-        [
-            Paragraph("Required Raw Materials", label),
-            Paragraph("Blend composition", section_title),
-            Paragraph(f"{session_record.product_unit_of_measure} · {_fmt_number(session_record.product_unit_size_kg)}kg per unit", subtitle),
-            Spacer(1, 6),
-        ]
-    )
+    pdf.setFillColor(palette["muted"])
+    pdf.setFont("Helvetica-Bold", 7.5)
+    pdf.drawString(margin + 4, table_top - 7, "RAW MATERIAL")
+    pdf.drawString(margin + content_width - 190, table_top - 7, "REQUIRED KG")
+
+    pdf.setStrokeColor(palette["line"])
+    pdf.setLineWidth(0.8)
+    pdf.line(margin, table_top - table_header_height, margin + content_width, table_top - table_header_height)
+
+    left_col_x = margin + 6
+    right_col_x = margin + content_width - 190
+    y_cursor = table_top - table_header_height
 
-    table_rows = [["Raw material", "Mix %", "Required kg", "Unit"]]
     for line in session_record.lines:
-        table_rows.append(
-            [
-                Paragraph(f"<b>{line.raw_material_name}</b>", body),
-                Paragraph(f"{_fmt_number(line.mix_percentage)}%", body),
-                Paragraph(f"{_fmt_number(line.required_kg)}kg", body),
-                Paragraph(line.unit, body),
-            ]
-        )
+        y_cursor -= row_height
+        pdf.setStrokeColor(palette["line"])
+        pdf.setLineWidth(0.6)
+        pdf.line(margin, y_cursor, margin + content_width, y_cursor)
 
-    composition_table = Table(table_rows, colWidths=[88 * mm, 24 * mm, 34 * mm, 26 * mm], repeatRows=1)
-    composition_table.setStyle(
-        TableStyle(
-            [
-                ("BACKGROUND", (0, 0), (-1, 0), colors.HexColor("#EEF4F0")),
-                ("TEXTCOLOR", (0, 0), (-1, 0), colors.HexColor("#4F6158")),
-                ("FONTNAME", (0, 0), (-1, 0), "Helvetica-Bold"),
-                ("FONTSIZE", (0, 0), (-1, 0), 8),
-                ("BOTTOMPADDING", (0, 0), (-1, 0), 8),
-                ("TOPPADDING", (0, 0), (-1, 0), 8),
-                ("LEFTPADDING", (0, 0), (-1, -1), 9),
-                ("RIGHTPADDING", (0, 0), (-1, -1), 9),
-                ("GRID", (0, 0), (-1, -1), 0.6, colors.HexColor("#DBE4DE")),
-                ("VALIGN", (0, 0), (-1, -1), "TOP"),
-                ("ROWBACKGROUNDS", (0, 1), (-1, -1), [colors.white, colors.HexColor("#FBFCFB")]),
-            ]
+        text_y = y_cursor + (row_height / 2) - (table_font_size * 0.35)
+        pdf.setFillColor(palette["text"])
+        pdf.setFont("Helvetica-Bold", table_font_size)
+        pdf.drawString(
+            left_col_x,
+            text_y,
+            fit_text(line.raw_material_name, "Helvetica-Bold", table_font_size, content_width - 210),
         )
-    )
-    story.append(composition_table)
+        pdf.setFont("Helvetica", table_font_size)
+        pdf.drawString(right_col_x, text_y, f"{_fmt_number(line.required_kg)}kg")
 
-    document.build(story)
+    strip_y = table_bottom - 6
+    if note_lines:
+        note_height = 24 if len(note_lines) == 1 else 30
+        pdf.setFillColor(palette["page"])
+        pdf.setStrokeColor(palette["line"])
+        pdf.rect(margin, strip_y - note_height, content_width, note_height, fill=1, stroke=1)
+        pdf.setFillColor(palette["muted"])
+        pdf.setFont("Helvetica-Bold", 7)
+        pdf.drawString(margin + 10, strip_y - 10, "NOTES")
+        pdf.setFillColor(palette["text"])
+        pdf.setFont("Helvetica", 7.5)
+        for idx, text in enumerate(note_lines):
+            pdf.drawString(margin + 10, strip_y - 20 - (idx * 8), text)
+        strip_y -= note_height + 6
+
+    if warning_lines:
+        warning_height = 24 if len(warning_lines) == 1 else 30
+        pdf.setFillColor(palette["warning_bg"])
+        pdf.setStrokeColor(palette["line"])
+        pdf.rect(margin, strip_y - warning_height, content_width, warning_height, fill=1, stroke=1)
+        pdf.setFillColor(palette["warning_text"])
+        pdf.setFont("Helvetica-Bold", 7)
+        pdf.drawString(margin + 10, strip_y - 10, "WARNING")
+        pdf.setFont("Helvetica", 7.5)
+        for idx, text in enumerate(warning_lines):
+            pdf.drawString(margin + 10, strip_y - 20 - (idx * 8), text)
+
+    pdf.showPage()
+    pdf.save()
     return buffer.getvalue()

backend/app/services/mix_calculator_service.py

@@ -8,7 +8,7 @@ from sqlalchemy.orm import Session, joinedload, selectinload
 from app.api.deps import AuthSession
 from app.models.mix import Mix, MixIngredient
 from app.models.mix_calculator import MixCalculatorSession, MixCalculatorSessionLine
-from app.models.product import Product
+from app.models.product import Product, ProductIngredient
 from app.schemas.mix_calculator import MixCalculatorSessionCreate, MixCalculatorSessionUpdate
 from app.services.costing_engine import extract_unit_quantity_kg
 
@@ -28,10 +28,44 @@ def _load_product_for_calculation(db: Session, tenant_id: str, product_id: int)
     return db.scalar(
         select(Product)
         .where(Product.id == product_id, Product.tenant_id == tenant_id, Product.visible.is_(True))
-        .options(selectinload(Product.mix).selectinload(Mix.ingredients).selectinload(MixIngredient.raw_material))
+        .options(
+            selectinload(Product.ingredients).selectinload(ProductIngredient.raw_material),
+            selectinload(Product.mix).selectinload(Mix.ingredients).selectinload(MixIngredient.raw_material),
+        )
     )
 
 
+def _resolved_formula_rows(product: Product) -> tuple[list[dict], float]:
+    if product.ingredients:
+        rows = [
+            {
+                "raw_material_id": ingredient.raw_material_id,
+                "raw_material_name": ingredient.raw_material.name,
+                "quantity_kg": ingredient.quantity_kg,
+                "unit": ingredient.raw_material.unit_of_measure,
+                "sort_order": ingredient.sort_order,
+            }
+            for ingredient in product.ingredients
+            if ingredient.raw_material is not None
+        ]
+    elif product.mix is not None:
+        rows = [
+            {
+                "raw_material_id": ingredient.raw_material_id,
+                "raw_material_name": ingredient.raw_material.name if ingredient.raw_material is not None else f"Raw material {ingredient.raw_material_id}",
+                "quantity_kg": ingredient.quantity_kg,
+                "unit": ingredient.raw_material.unit_of_measure if ingredient.raw_material is not None else "kg",
+                "sort_order": index,
+            }
+            for index, ingredient in enumerate(product.mix.ingredients, start=1)
+        ]
+    else:
+        rows = []
+
+    rows.sort(key=lambda row: (row["sort_order"], row["raw_material_name"]))
+    return rows, round(sum(row["quantity_kg"] for row in rows), 4)
+
+
 def _fractional_bag_warning(batch_size_kg: float, total_bags: float, unit_of_measure: str) -> str | None:
     rounded_bags = round(total_bags)
     if abs(total_bags - rounded_bags) < 1e-9:
@@ -54,12 +88,9 @@ def calculate_mix_calculator_preview(
         raise ValueError("Product not found")
     if product.client_name != values["client_name"]:
         raise ValueError("Selected product does not belong to the chosen client")
-    if product.mix is None:
-        raise ValueError("Product mix is not configured")
-
-    source_total_kg = round(sum(ingredient.quantity_kg for ingredient in product.mix.ingredients), 4)
+    formula_rows, source_total_kg = _resolved_formula_rows(product)
     if source_total_kg <= 0:
-        raise ValueError("Product mix has no source kilograms to scale")
+        raise ValueError("Product has no source kilograms to scale")
 
     batch_size_kg = float(values["batch_size_kg"])
     scale_factor = batch_size_kg / source_total_kg
@@ -72,18 +103,17 @@ def calculate_mix_calculator_preview(
         warnings.append(bag_warning)
 
     lines = []
-    for index, ingredient in enumerate(product.mix.ingredients, start=1):
-        mix_percentage = round((ingredient.quantity_kg / source_total_kg) * 100, 4)
-        required_kg = round(ingredient.quantity_kg * scale_factor, 4)
-        raw_material = ingredient.raw_material
+    for index, ingredient in enumerate(formula_rows, start=1):
+        mix_percentage = round((ingredient["quantity_kg"] / source_total_kg) * 100, 4)
+        required_kg = round(ingredient["quantity_kg"] * scale_factor, 4)
         lines.append(
             {
-                "raw_material_id": raw_material.id if raw_material is not None else ingredient.raw_material_id,
-                "raw_material_name": raw_material.name if raw_material is not None else f"Raw material {ingredient.raw_material_id}",
+                "raw_material_id": ingredient["raw_material_id"],
+                "raw_material_name": ingredient["raw_material_name"],
                 "required_kg": required_kg,
                 "mix_percentage": mix_percentage,
-                "unit": raw_material.unit_of_measure if raw_material is not None else "kg",
-                "sort_order": index,
+                "unit": ingredient["unit"],
+                "sort_order": ingredient["sort_order"] or index,
             }
         )
 
@@ -92,7 +122,7 @@ def calculate_mix_calculator_preview(
         "product_id": product.id,
         "product_name": product.name,
         "mix_id": product.mix_id,
-        "mix_name": product.mix.name,
+        "mix_name": product.mix.name if product.mix else product.name,
         "mix_date": values["mix_date"],
         "batch_size_kg": round(batch_size_kg, 4),
         "total_bags": total_bags,
@@ -108,10 +138,16 @@ def calculate_mix_calculator_preview(
 
 
 def build_mix_calculator_options(db: Session, *, tenant_id: str) -> dict:
-    # Aggregate mix totals in a single query instead of loading every
-    # ingredient row for every product. The previous implementation was the
-    # main slow path on first Mix Calculator open — it streamed the entire
-    # tenant's recipe table just to compute one sum per product.
+    # Prefer product-specific formulas where present; fall back to the shared
+    # mix master for legacy rows that have not been migrated yet.
+    product_totals_rows = db.execute(
+        select(ProductIngredient.product_id, func.coalesce(func.sum(ProductIngredient.quantity_kg), 0.0))
+        .join(Product, Product.id == ProductIngredient.product_id)
+        .where(Product.tenant_id == tenant_id)
+        .group_by(ProductIngredient.product_id)
+    ).all()
+    product_totals: dict[int, float] = {product_id: round(total or 0.0, 4) for product_id, total in product_totals_rows}
+
     mix_totals_rows = db.execute(
         select(MixIngredient.mix_id, func.coalesce(func.sum(MixIngredient.quantity_kg), 0.0))
         .join(Mix, Mix.id == MixIngredient.mix_id)
@@ -137,7 +173,7 @@ def build_mix_calculator_options(db: Session, *, tenant_id: str) -> dict:
             "mix_name": product.mix.name if product.mix else "",
             "unit_of_measure": product.unit_of_measure,
             "unit_size_kg": round(extract_unit_quantity_kg(product.unit_of_measure), 4),
-            "mix_total_kg": mix_totals.get(product.mix_id, 0.0),
+            "mix_total_kg": product_totals.get(product.id, mix_totals.get(product.mix_id, 0.0)),
         }
         for product in products
     ]

backend/app/services/throughput_service.py

@@ -0,0 +1,348 @@
+from __future__ import annotations
+
+import logging
+from datetime import date, datetime
+from pathlib import Path
+from typing import Iterable
+
+from openpyxl import load_workbook
+from sqlalchemy import select
+from sqlalchemy.orm import Session
+
+from app.models.throughput import ProductionThroughput, ThroughputProduct
+
+logger = logging.getLogger("data_entry_app.throughput")
+
+PRODUCTION_SHEET = "Production"
+NAMES_SHEET = "Names"
+
+# Anything at or above this kg/bag is treated as a bulka batch, not a per-bag count.
+_BULKA_BAG_SIZE_THRESHOLD = 100.0
+
+
+def normalise_staff_name(value: object) -> str | None:
+    if value is None:
+        return None
+    text = str(value).strip()
+    if not text:
+        return None
+    # Collapse internal whitespace, title-case for consistency.
+    cleaned = " ".join(text.split())
+    return cleaned
+
+
+def calculate_kg(quantity: float | None, quantity_type: str, bag_size: float | None) -> float:
+    if quantity is None:
+        return 0.0
+    if quantity_type == "kg":
+        return float(quantity)
+    if bag_size is None:
+        return 0.0
+    return float(quantity) * float(bag_size)
+
+
+def qa_passed(entry: ProductionThroughput) -> bool:
+    return bool(entry.scales_checked and entry.label_correct and entry.bag_sealed and entry.pallet_good_condition)
+
+
+def serialize_entry(entry: ProductionThroughput) -> dict:
+    return {
+        "id": entry.id,
+        "tenant_id": entry.tenant_id,
+        "production_date": entry.production_date,
+        "product_id": entry.product_id,
+        "product_name_snapshot": entry.product_name_snapshot,
+        "bag_size": entry.bag_size,
+        "scales_checked": entry.scales_checked,
+        "label_correct": entry.label_correct,
+        "bag_sealed": entry.bag_sealed,
+        "pallet_good_condition": entry.pallet_good_condition,
+        "sample_box_no": entry.sample_box_no,
+        "test_weight_1": entry.test_weight_1,
+        "test_weight_2": entry.test_weight_2,
+        "test_weight_3": entry.test_weight_3,
+        "test_weight_4": entry.test_weight_4,
+        "test_weight_5": entry.test_weight_5,
+        "quantity": entry.quantity,
+        "quantity_type": entry.quantity_type,
+        "calculated_kg": entry.calculated_kg,
+        "staff_name": entry.staff_name,
+        "notes": entry.notes,
+        "qa_passed": qa_passed(entry),
+        "created_by": entry.created_by,
+        "created_at": entry.created_at,
+        "updated_at": entry.updated_at,
+    }
+
+
+def _coerce_bool(value: object) -> bool:
+    if isinstance(value, bool):
+        return value
+    if value is None:
+        return True
+    if isinstance(value, (int, float)):
+        return bool(value)
+    text = str(value).strip().lower()
+    if text in {"yes", "y", "true", "1", "pass", "ok", "x", "checked"}:
+        return True
+    if text in {"no", "n", "false", "0", "fail"}:
+        return False
+    return True
+
+
+def _coerce_float(value: object) -> float | None:
+    if value is None or value == "":
+        return None
+    if isinstance(value, bool):
+        return float(value)
+    if isinstance(value, (int, float)):
+        return float(value)
+    text = str(value).strip().replace(",", "")
+    if not text:
+        return None
+    try:
+        return float(text)
+    except ValueError:
+        return None
+
+
+def _coerce_text(value: object) -> str | None:
+    if value is None:
+        return None
+    text = str(value).strip()
+    if not text or text.lower() in {"#value!", "#n/a", "n/a"}:
+        return None
+    return text
+
+
+def _coerce_date(value: object) -> date | None:
+    if value is None:
+        return None
+    if isinstance(value, datetime):
+        return value.date()
+    if isinstance(value, date):
+        return value
+    text = str(value).strip()
+    if not text:
+        return None
+    for fmt in ("%Y-%m-%d", "%d/%m/%Y", "%m/%d/%Y"):
+        try:
+            return datetime.strptime(text, fmt).date()
+        except ValueError:
+            continue
+    return None
+
+
+def _infer_bulka_default(name: str, bag_size: float | None) -> bool:
+    lowered = name.lower()
+    if "bulka" in lowered:
+        return True
+    if bag_size is None:
+        return False
+    return bag_size >= _BULKA_BAG_SIZE_THRESHOLD
+
+
+def import_names_sheet(db: Session, workbook, tenant_id: str) -> tuple[int, int]:
+    """Upsert product master from the Names sheet. Returns (created, updated)."""
+    if NAMES_SHEET not in workbook.sheetnames:
+        return (0, 0)
+
+    ws = workbook[NAMES_SHEET]
+    existing: dict[tuple[str, str | None], ThroughputProduct] = {}
+    by_item: dict[str, ThroughputProduct] = {}
+    by_name: dict[str, ThroughputProduct] = {}
+    for product in db.scalars(
+        select(ThroughputProduct).where(ThroughputProduct.tenant_id == tenant_id)
+    ).all():
+        if product.item_id:
+            by_item[str(product.item_id)] = product
+        by_name[product.name.lower()] = product
+
+    created = 0
+    updated = 0
+    for row in ws.iter_rows(min_row=2, values_only=True):
+        if not row:
+            continue
+        name = _coerce_text(row[0] if len(row) > 0 else None)
+        if not name:
+            continue
+        item_id_raw = row[1] if len(row) > 1 else None
+        item_id = None
+        if item_id_raw is not None:
+            if isinstance(item_id_raw, float) and item_id_raw.is_integer():
+                item_id = str(int(item_id_raw))
+            else:
+                item_id = _coerce_text(item_id_raw)
+
+        product = (by_item.get(item_id) if item_id else None) or by_name.get(name.lower())
+        if product is None:
+            product = ThroughputProduct(
+                tenant_id=tenant_id,
+                item_id=item_id,
+                name=name,
+                default_bag_size=None,
+                is_bulka_default="bulka" in name.lower(),
+                active=True,
+                notes="Imported from Operations Throughput.xlsx",
+            )
+            db.add(product)
+            created += 1
+            if item_id:
+                by_item[item_id] = product
+            by_name[name.lower()] = product
+        else:
+            if item_id and not product.item_id:
+                product.item_id = item_id
+            if name and product.name != name:
+                product.name = name
+            updated += 1
+
+    db.flush()
+    return (created, updated)
+
+
+def import_production_sheet(db: Session, workbook, tenant_id: str) -> tuple[int, int]:
+    """Import the Production sheet. Returns (imported, skipped)."""
+    if PRODUCTION_SHEET not in workbook.sheetnames:
+        return (0, 0)
+
+    ws = workbook[PRODUCTION_SHEET]
+    # Header row is row 3 in the sheet (rows 1 and 2 are display banners).
+    products_by_name: dict[str, ThroughputProduct] = {
+        product.name.lower(): product
+        for product in db.scalars(
+            select(ThroughputProduct).where(ThroughputProduct.tenant_id == tenant_id)
+        ).all()
+    }
+
+    bag_size_seen: dict[int, list[float]] = {}
+    imported = 0
+    skipped = 0
+
+    for row in ws.iter_rows(min_row=4, values_only=True):
+        if not row or len(row) < 15:
+            skipped += 1
+            continue
+        production_date = _coerce_date(row[0])
+        product_name = _coerce_text(row[1])
+        if production_date is None or not product_name:
+            skipped += 1
+            continue
+
+        bag_size = _coerce_float(row[2])
+        scales = _coerce_bool(row[3])
+        label = _coerce_bool(row[4])
+        sealed = _coerce_bool(row[5])
+        pallet = _coerce_bool(row[6])
+        sample_box = _coerce_text(row[7])
+        tw1 = _coerce_float(row[8])
+        tw2 = _coerce_float(row[9])
+        tw3 = _coerce_float(row[10])
+        tw4 = _coerce_float(row[11])
+        tw5 = _coerce_float(row[12])
+        quantity = _coerce_float(row[13]) or 0.0
+        staff = normalise_staff_name(row[14])
+        notes = _coerce_text(row[15]) if len(row) > 15 else None
+
+        # Infer quantity_type: bulka-style rows have a blank or very large bag size.
+        if bag_size is None or bag_size >= _BULKA_BAG_SIZE_THRESHOLD or "bulka" in product_name.lower():
+            quantity_type = "kg"
+        else:
+            quantity_type = "bags"
+
+        product = products_by_name.get(product_name.lower())
+        if product is None:
+            product = ThroughputProduct(
+                tenant_id=tenant_id,
+                item_id=None,
+                name=product_name,
+                default_bag_size=bag_size,
+                is_bulka_default=_infer_bulka_default(product_name, bag_size),
+                active=True,
+                notes="Auto-created during Operations Throughput import",
+            )
+            db.add(product)
+            db.flush()
+            products_by_name[product_name.lower()] = product
+
+        if product.id is not None and bag_size is not None and bag_size > 0:
+            bag_size_seen.setdefault(product.id, []).append(bag_size)
+
+        calculated = calculate_kg(quantity, quantity_type, bag_size)
+        entry = ProductionThroughput(
+            tenant_id=tenant_id,
+            production_date=production_date,
+            product_id=product.id,
+            product_name_snapshot=product_name,
+            bag_size=bag_size,
+            scales_checked=scales,
+            label_correct=label,
+            bag_sealed=sealed,
+            pallet_good_condition=pallet,
+            sample_box_no=sample_box,
+            test_weight_1=tw1,
+            test_weight_2=tw2,
+            test_weight_3=tw3,
+            test_weight_4=tw4,
+            test_weight_5=tw5,
+            quantity=quantity,
+            quantity_type=quantity_type,
+            calculated_kg=calculated,
+            staff_name=staff,
+            notes=notes,
+            created_by="workbook-import",
+        )
+        db.add(entry)
+        imported += 1
+
+    # Backfill default_bag_size on products that don't have one but appear in entries.
+    for product_id, sizes in bag_size_seen.items():
+        product = db.get(ThroughputProduct, product_id)
+        if product and product.default_bag_size is None:
+            # Use the most common bag size seen.
+            common = max(set(sizes), key=sizes.count)
+            product.default_bag_size = common
+            if not product.is_bulka_default:
+                product.is_bulka_default = _infer_bulka_default(product.name, common)
+
+    db.flush()
+    return (imported, skipped)
+
+
+def import_workbook(db: Session, workbook_path: Path, tenant_id: str) -> dict:
+    workbook = load_workbook(workbook_path, data_only=True)
+    products_created, products_updated = import_names_sheet(db, workbook, tenant_id)
+    entries_imported, entries_skipped = import_production_sheet(db, workbook, tenant_id)
+    return {
+        "products_created": products_created,
+        "products_updated": products_updated,
+        "entries_imported": entries_imported,
+        "entries_skipped": entries_skipped,
+    }
+
+
+def workbook_candidates() -> Iterable[Path]:
+    repo_root = Path(__file__).resolve().parents[3]
+    candidates = [
+        repo_root / "Operations Throughput.xlsx",
+        repo_root.parent / "Operations Throughput.xlsx",
+        Path.cwd() / "Operations Throughput.xlsx",
+        Path("/srv/lean101-clients") / "Operations Throughput.xlsx",
+        Path("/app") / "Operations Throughput.xlsx",
+    ]
+    seen: set[str] = set()
+    ordered: list[Path] = []
+    for candidate in candidates:
+        key = str(candidate)
+        if key in seen:
+            continue
+        seen.add(key)
+        ordered.append(candidate)
+    return ordered
+
+
+def resolve_workbook_path() -> Path | None:
+    for candidate in workbook_candidates():
+        if candidate.exists():
+            return candidate
+    return None