View Code - 20260722

warping_yarn_coverage.php | 20260722_120325.php Initial Domain Snapshot

<?php
require_once __DIR__ . '/modules/auth/page_acl.php';
$ctx = page_require_access('warping_yarn_coverage');

$pdo        = $ctx['pdo'];
$company_id = (int)$ctx['company_id'];

require_once __DIR__ . '/partials/header.php';

function h($s){ return htmlspecialchars((string)$s, ENT_QUOTES, 'UTF-8'); }

/* ================= STOCK ================= */
function get_stock(PDO $pdo, $cid, $den, $col){

$sql = "
    SELECT SUM(weight)
    FROM yarn_stock
    WHERE company_id = :cid
    AND TRIM(LOWER(denier)) = TRIM(LOWER(:den))
    AND TRIM(LOWER(color))  = TRIM(LOWER(:col))
    ";

$st = $pdo->prepare($sql);
    $st->execute([
        ':cid'=>$cid,
        ':den'=>$den,
        ':col'=>$col
    ]);

return (float)($st->fetchColumn() ?? 0);
}

/* ================= BEST PRODUCTION DATE ================= */
$st = $pdo->prepare("
    SELECT DATE(beam_load_date) as d
    FROM company_beam_stock
    WHERE company_id=:cid
    GROUP BY DATE(beam_load_date)
    ORDER BY COUNT(*) DESC
    LIMIT 1
");
$st->execute([':cid'=>$company_id]);
$date = $st->fetchColumn();

/* ================= DATA ================= */
$debug_quality = [];
$debug_yarn = [];
$yarn_req = [];

/* ================= PRODUCTION ================= */
if($date){

$st = $pdo->prepare("
        SELECT 
            cbs.quality_id,
            bq.name AS quality_name,
            wm.machine_no,

SUM(cbs.taka) total_taka,
            MAX(cbs.taka) taka_per_beam

FROM company_beam_stock cbs

LEFT JOIN beam_qualities bq 
            ON bq.id = cbs.quality_id
            AND bq.company_id = cbs.company_id

LEFT JOIN warping_machine wm
            ON wm.operator_id = cbs.warper_id
            AND wm.company_id = cbs.company_id

WHERE cbs.company_id=:cid
        AND DATE(cbs.beam_load_date)=:dt

GROUP BY cbs.quality_id, wm.machine_no
    ");

$st->execute([
        ':cid'=>$company_id,
        ':dt'=>$date
    ]);

$quality_data = $st->fetchAll(PDO::FETCH_ASSOC);

foreach($quality_data as $q){

$qid   = (int)$q['quality_id'];
        $qname = $q['quality_name'] ?? 'Unknown';
        $machine = $q['machine_no'] ?? '-';

$total_meter = $q['total_taka'] * 120;

$debug_quality[] = [
            'qid'=>$qid,
            'name'=>$qname,
            'machine'=>$machine,
            'taka'=>$q['total_taka'],
            'beam'=>$q['total_taka']/$q['taka_per_beam'],
            'meter'=>$total_meter
        ];

/* ===== YARN BREAKDOWN ===== */
        $st2 = $pdo->prepare("
            SELECT denier, color, total_tar, weight
            FROM beam_quality_yarns
            WHERE beam_quality_id=:qid
        ");
        $st2->execute([':qid'=>$qid]);

$yarns = $st2->fetchAll(PDO::FETCH_ASSOC);

$total_ratio = array_sum(array_column($yarns,'total_tar'));
        if($total_ratio <= 0) continue;

foreach($yarns as $y){

$meter = $total_meter * ($y['total_tar'] / $total_ratio);
            $kg = ($meter * $y['weight']) / 100000;

$den = strtoupper(trim($y['denier']));
            $col = strtoupper(trim($y['color']));

$debug_yarn[] = [
                'denier'=>$den,
                'color'=>$col,
                'meter'=>$meter,
                'kg'=>$kg
            ];

$key = $den.'|'.$col;

if(!isset($yarn_req[$key])){
                $yarn_req[$key] = [
                    'denier'=>$den,
                    'color'=>$col,
                    'req'=>0
                ];
            }

$yarn_req[$key]['req'] += $kg;
        }
    }
}

/* ================= FINAL ================= */
$report = [];

foreach($yarn_req as $r){

$stock = get_stock($pdo, $company_id, $r['denier'], $r['color']);

$req = $r['req'];
    $days = ($req>0) ? ($stock / $req) : 0;

$status='SAFE';
    $cls='bg-success';

if($days<3){
        $status='CRITICAL';
        $cls='bg-danger';
    }elseif($days<7){
        $status='LOW';
        $cls='bg-warning';
    }

$report[] = [
        'denier'=>$r['denier'],
        'color'=>$r['color'],
        'req'=>$req,
        'stock'=>$stock,
        'days'=>$days,
        'status'=>$status,
        'cls'=>$cls
    ];
}
?>

<div class="card shadow">
<div class="card-header bg-dark text-white">
Warping Yarn Coverage (Full Plant)
</div>

<div class="mb-3">
<b>All Machines Included</b><br>
Last Production Date: <b><?=h($date)?></b>
</div>

<table class="table table-bordered mb-3">
<tr>
<th>Machine</th>
<th>Quality</th>
<th>Total Taka</th>
<th>Beam</th>
<th>Meter</th>
</tr>

<?php foreach($debug_quality as $d): ?>
<tr>
<td><b><?=$d['machine']?></b></td>
<td><?=h($d['name'])?> (<?=$d['qid']?>)</td>
<td><?=number_format($d['taka'],2)?></td>
<td><?=number_format($d['beam'],2)?></td>
<td><?=number_format($d['meter'],2)?></td>
</tr>
<?php endforeach; ?>
</table>

<table class="table table-bordered mb-3">
<tr>
<th>Denier</th>
<th>Color</th>
<th>Meter</th>
<th>KG</th>
</tr>

<?php foreach($debug_yarn as $d): ?>
<tr>
<td><?=$d['denier']?></td>
<td><?=$d['color']?></td>
<td><?=number_format($d['meter'],2)?></td>
<td><?=number_format($d['kg'],2)?></td>
</tr>
<?php endforeach; ?>
</table>

<h5>Stock Coverage</h5>

<table class="table table-bordered">
<tr>
<th>Denier</th>
<th>Color</th>
<th>Daily Req</th>
<th>Stock</th>
<th>Days</th>
<th>Status</th>
</tr>

<?php foreach($report as $r): ?>
<tr>
<td><?=$r['denier']?></td>
<td><?=$r['color']?></td>
<td><?=number_format($r['req'],2)?></td>
<td><?=number_format($r['stock'],2)?></td>
<td><?=number_format($r['days'],1)?></td>
<td><span class="badge <?=$r['cls']?>"><?=$r['status']?></span></td>
</tr>
<?php endforeach; ?>

</table>

</div>
</div>

</div>

<?php require_once __DIR__ . '/partials/footer.php'; ?>