Update stock status calculations and add restock/overstock qty fields and calculations

inventory-server/db/metrics-schema.sql

@@ -39,6 +39,8 @@ CREATE TABLE IF NOT EXISTS product_metrics (
     weeks_of_inventory INT,
     reorder_point INT,
     safety_stock INT,
+    reorder_qty INT DEFAULT 0,
+    overstocked_amt INT DEFAULT 0,
     -- Financial metrics
     avg_margin_percent DECIMAL(10,3),
     total_revenue DECIMAL(10,3),

inventory-server/scripts/calculate-metrics.js

@@ -760,11 +760,45 @@ async function calculateMetrics() {
                             throw err;
                         });
 
-                        // Get current stock
+                        // Get current stock and stock age
                         const [stockInfo] = await connection.query(`
-                            SELECT stock_quantity, cost_price
+                            SELECT 
-                            FROM products
+                                p.stock_quantity, 
-                            WHERE product_id = ?
+                                p.cost_price,
+                                p.created_at,
+                                p.replenishable,
+                                p.moq,
+                                DATEDIFF(CURDATE(), MIN(po.received_date)) as days_since_first_stock,
+                                DATEDIFF(CURDATE(), COALESCE(
+                                    (SELECT MAX(o2.date) 
+                                     FROM orders o2 
+                                     WHERE o2.product_id = p.product_id 
+                                       AND o2.canceled = false),
+                                    CURDATE()  -- If no sales, use current date
+                                )) as days_since_last_sale,
+                                (SELECT SUM(quantity) 
+                                 FROM orders o3 
+                                 WHERE o3.product_id = p.product_id 
+                                   AND o3.canceled = false) as total_quantity_sold,
+                                CASE 
+                                    WHEN EXISTS (
+                                        SELECT 1 FROM orders o 
+                                        WHERE o.product_id = p.product_id 
+                                        AND o.date >= DATE_SUB(CURDATE(), INTERVAL 30 DAY)
+                                        AND o.canceled = false 
+                                        AND (SELECT SUM(quantity) FROM orders o2 
+                                             WHERE o2.product_id = p.product_id 
+                                             AND o2.date >= o.date 
+                                             AND o2.canceled = false) = 0
+                                    ) THEN true
+                                    ELSE false
+                                END as had_recent_stockout
+                            FROM products p
+                            LEFT JOIN purchase_orders po ON p.product_id = po.product_id 
+                                AND po.status = 'closed' 
+                                AND po.received > 0
+                            WHERE p.product_id = ?
+                            GROUP BY p.product_id
                         `, [product.product_id]).catch(err => {
                             logError(err, `Failed to get stock info for product ${product.product_id}`);
                             throw err;
@@ -787,17 +821,118 @@ async function calculateMetrics() {
                         // Calculate current inventory value
                         const inventory_value = (stock.stock_quantity || 0) * (stock.cost_price || 0);
 
-                        // Calculate stock status using configurable thresholds with proper handling of zero sales
+                        // Calculate stock status with improved handling
-                        const stock_status = daily_sales_avg === 0 ? 'New' :
+                        const stock_status = (() => {
-                            stock.stock_quantity <= Math.max(1, Math.ceil(daily_sales_avg * config.critical_days)) ? 'Critical' :
+                            const days_since_first_stock = stockInfo[0]?.days_since_first_stock || 0;
-                            stock.stock_quantity <= Math.max(1, Math.ceil(daily_sales_avg * config.reorder_days)) ? 'Reorder' :
+                            const days_since_last_sale = stockInfo[0]?.days_since_last_sale || 9999;
-                            stock.stock_quantity > Math.max(1, daily_sales_avg * config.overstock_days) ? 'Overstocked' : 'Healthy';
+                            const total_quantity_sold = stockInfo[0]?.total_quantity_sold || 0;
+                            const had_recent_stockout = stockInfo[0]?.had_recent_stockout || false;
+                            const dq = stock.stock_quantity || 0;
+                            const ds = daily_sales_avg || 0;
+                            const ws = weekly_sales_avg || 0;
+                            const ms = monthly_sales_avg || 0;
+                            
+                            // If no stock, return immediately
+                            if (dq === 0) {
+                                return had_recent_stockout ? 'Critical' : 'Out of Stock';
+                            }
+
+                            // 1. Check if truly "New" (≤30 days and no sales)
+                            if (days_since_first_stock <= 30 && total_quantity_sold === 0) {
+                                return 'New';
+                            }
+
+                            // 2. Handle zero or very low sales velocity cases
+                            if (ds === 0 || (ds < 0.1 && ws < 0.5)) { // Less than 1 sale per 10 days and less than 0.5 per week
+                                if (days_since_first_stock > config.overstock_days) {
+                                    return 'Overstocked';
+                                }
+                                if (days_since_first_stock > 30) {
+                                    return 'At Risk';
+                                }
+                            }
+
+                            // 3. Calculate days of supply and check velocity trends
+                            const days_of_supply = ds > 0 ? dq / ds : 999;
+                            const velocity_trend = ds > 0 ? (ds / (ms || ds) - 1) * 100 : 0; // Percent change from monthly to daily avg
+
+                            // Critical stock level
+                            if (days_of_supply <= config.critical_days) {
+                                return 'Critical';
+                            }
+
+                            // Reorder cases
+                            if (days_of_supply <= config.reorder_days || 
+                                (had_recent_stockout && days_of_supply <= config.reorder_days * 1.5)) {
+                                return 'Reorder';
+                            }
+
+                            // At Risk cases (multiple scenarios)
+                            if (
+                                // Approaching overstock threshold
+                                (days_of_supply >= config.overstock_days * 0.8) ||
+                                // Significant sales decline
+                                (velocity_trend <= -50 && days_of_supply > config.reorder_days * 2) ||
+                                // No recent sales
+                                (days_since_last_sale > 45 && dq > 0) ||
+                                // Very low velocity with significant stock
+                                (ds > 0 && ds < 0.2 && dq > ds * config.overstock_days * 0.5)
+                            ) {
+                                return 'At Risk';
+                            }
+
+                            // Overstock cases
+                            if (days_of_supply >= config.overstock_days) {
+                                return 'Overstocked';
+                            }
+
+                            // If none of the above conditions are met
+                            return 'Healthy';
+                        })();
 
                         // Calculate safety stock using configured values with proper defaults
                         const safety_stock = daily_sales_avg > 0 ? 
                             Math.max(1, Math.ceil(daily_sales_avg * (config.safety_stock_days || 14) * ((config.service_level || 95.0) / 100))) : 
                             null;
 
+                        // Calculate reorder quantity and overstocked amount
+                        let reorder_qty = 0;
+                        let overstocked_amt = 0;
+
+                        // Only calculate reorder quantity for replenishable products
+                        if (stock.replenishable && (stock_status === 'Critical' || stock_status === 'Reorder')) {
+                            const ds = daily_sales_avg || 0;
+                            const lt = purchases.avg_lead_time_days || 14; // Default to 14 days if no lead time data
+                            const sc = config.safety_stock_days || 14;
+                            const ss = safety_stock || 0;
+                            const dq = stock.stock_quantity || 0;
+                            const moq = stock.moq || 1;
+
+                            // Calculate desired stock level based on daily sales, lead time, coverage days, and safety stock
+                            const desired_stock = (ds * (lt + sc)) + ss;
+                            
+                            // Calculate raw reorder amount
+                            const raw_reorder = Math.max(0, desired_stock - dq);
+                            
+                            // Round up to nearest MOQ
+                            reorder_qty = Math.ceil(raw_reorder / moq) * moq;
+                        }
+
+                        // Calculate overstocked amount for overstocked products
+                        if (stock_status === 'Overstocked') {
+                            const ds = daily_sales_avg || 0;
+                            const dq = stock.stock_quantity || 0;
+                            const lt = purchases.avg_lead_time_days || 14;
+                            const sc = config.safety_stock_days || 14;
+                            const ss = safety_stock || 0;
+
+                            // Calculate maximum desired stock based on overstock days configuration
+                            const max_desired_stock = (ds * config.overstock_days) + ss;
+                            
+                            // Calculate excess inventory
+                            overstocked_amt = Math.max(0, dq - max_desired_stock);
+                        }
+
                         // Add to batch update
                         metricsUpdates.push([
                             product.product_id,
@@ -818,7 +953,9 @@ async function calculateMetrics() {
                             purchases.avg_lead_time_days || null,
                             purchases.last_purchase_date || null,
                             purchases.last_received_date || null,
-                            stock_status
+                            stock_status,
+                            reorder_qty,
+                            overstocked_amt
                         ]);
                     } catch (err) {
                         logError(err, `Failed processing product ${product.product_id}`);
@@ -849,7 +986,9 @@ async function calculateMetrics() {
                             avg_lead_time_days,
                             last_purchase_date,
                             last_received_date,
-                            stock_status
+                            stock_status,
+                            reorder_qty,
+                            overstocked_amt
                         ) VALUES ?
                         ON DUPLICATE KEY UPDATE
                             last_calculated_at = NOW(),
@@ -870,7 +1009,9 @@ async function calculateMetrics() {
                             avg_lead_time_days = VALUES(avg_lead_time_days),
                             last_purchase_date = VALUES(last_purchase_date),
                             last_received_date = VALUES(last_received_date),
-                            stock_status = VALUES(stock_status)
+                            stock_status = VALUES(stock_status),
+                            reorder_qty = VALUES(reorder_qty),
+                            overstocked_amt = VALUES(overstocked_amt)
                     `, [metricsUpdates]).catch(err => {
                         logError(err, `Failed to batch update metrics for ${metricsUpdates.length} products`);
                         throw err;

inventory-server/src/routes/products.js

@@ -275,6 +275,8 @@ router.get('/', async (req, res) => {
         pm.current_lead_time,
         pm.target_lead_time,
         pm.lead_time_status,
+        pm.reorder_qty,
+        pm.overstocked_amt,
         COALESCE(pm.days_of_inventory / NULLIF(pt.target_days, 0), 0) as stock_coverage_ratio
       FROM products p
       LEFT JOIN product_metrics pm ON p.product_id = pm.product_id
@@ -323,7 +325,9 @@ router.get('/', async (req, res) => {
       current_lead_time: parseFloat(row.current_lead_time) || 0,
       target_lead_time: parseFloat(row.target_lead_time) || 0,
       lead_time_status: row.lead_time_status || null,
-      stock_coverage_ratio: parseFloat(row.stock_coverage_ratio) || 0
+      stock_coverage_ratio: parseFloat(row.stock_coverage_ratio) || 0,
+      reorder_qty: parseInt(row.reorder_qty) || 0,
+      overstocked_amt: parseInt(row.overstocked_amt) || 0
     }));
 
     res.json({
@@ -507,7 +511,9 @@ router.get('/:id', async (req, res) => {
         avg_lead_time_days: parseInt(rows[0].avg_lead_time_days) || 0,
         current_lead_time: parseInt(rows[0].current_lead_time) || 0,
         target_lead_time: parseInt(rows[0].target_lead_time) || 14,
-        lead_time_status: rows[0].lead_time_status || 'Unknown'
+        lead_time_status: rows[0].lead_time_status || 'Unknown',
+        reorder_qty: parseInt(rows[0].reorder_qty) || 0,
+        overstocked_amt: parseInt(rows[0].overstocked_amt) || 0
       },
       
       // Vendor performance (if available)
@@ -645,7 +651,9 @@ router.get('/:id/metrics', async (req, res) => {
         COALESCE(pm.avg_lead_time_days, 0) as avg_lead_time_days,
         COALESCE(pm.current_lead_time, 0) as current_lead_time,
         COALESCE(pm.target_lead_time, 14) as target_lead_time,
-        COALESCE(pm.lead_time_status, 'Unknown') as lead_time_status
+        COALESCE(pm.lead_time_status, 'Unknown') as lead_time_status,
+        COALESCE(pm.reorder_qty, 0) as reorder_qty,
+        COALESCE(pm.overstocked_amt, 0) as overstocked_amt
       FROM products p
       LEFT JOIN product_metrics pm ON p.product_id = pm.product_id
       LEFT JOIN inventory_status is ON p.product_id = is.product_id
@@ -670,7 +678,9 @@ router.get('/:id/metrics', async (req, res) => {
         avg_lead_time_days: 0,
         current_lead_time: 0,
         target_lead_time: 14,
-        lead_time_status: 'Unknown'
+        lead_time_status: 'Unknown',
+        reorder_qty: 0,
+        overstocked_amt: 0
       });
       return;
     }

inventory/src/components/products/ProductTable.tsx

@@ -26,62 +26,9 @@ import {
   useSortable,
 } from "@dnd-kit/sortable";
 import { CSS } from "@dnd-kit/utilities";
+import { Product } from "@/types/products";
 
-interface Product {
+export type ColumnKey = keyof Product | 'image';
-  product_id: number;
-  title: string;
-  SKU: string;
-  stock_quantity: number;
-  price: number;
-  regular_price: number;
-  cost_price: number;
-  landing_cost_price: number | null;
-  barcode: string;
-  vendor: string;
-  vendor_reference: string;
-  brand: string;
-  categories: string[];
-  tags: string[];
-  options: Record<string, any>;
-  image: string | null;
-  moq: number;
-  uom: number;
-  visible: boolean;
-  managing_stock: boolean;
-  replenishable: boolean;
-  created_at: string;
-  updated_at: string;
-  
-  // Metrics
-  daily_sales_avg?: number;
-  weekly_sales_avg?: number;
-  monthly_sales_avg?: number;
-  avg_quantity_per_order?: number;
-  number_of_orders?: number;
-  first_sale_date?: string;
-  last_sale_date?: string;
-  days_of_inventory?: number;
-  weeks_of_inventory?: number;
-  reorder_point?: number;
-  safety_stock?: number;
-  avg_margin_percent?: number;
-  total_revenue?: number;
-  inventory_value?: number;
-  cost_of_goods_sold?: number;
-  gross_profit?: number;
-  gmroi?: number;
-  avg_lead_time_days?: number;
-  last_purchase_date?: string;
-  last_received_date?: string;
-  abc_class?: string;
-  stock_status?: string;
-  turnover_rate?: number;
-  current_lead_time?: number;
-  target_lead_time?: number;
-  lead_time_status?: string;
-}
-
-type ColumnKey = keyof Product | 'image';
 
 interface ColumnDef {
   key: ColumnKey;
@@ -296,6 +243,12 @@ export function ProductTable({
         ) : (
           <Badge variant="outline">Hidden</Badge>
         );
+      case 'replenishable':
+        return value ? (
+          <Badge variant="secondary">Replenishable</Badge>
+        ) : (
+          <Badge variant="outline">Non-Replenishable</Badge>
+        );
       default:
         if (columnDef?.format && value !== undefined && value !== null) {
           // For numeric formats (those using toFixed), ensure the value is a number

inventory/src/components/products/ProductViews.tsx

@@ -23,14 +23,14 @@ export const PRODUCT_VIEWS: ProductView[] = [
     label: "Critical Stock",
     icon: AlertTriangle,
     iconClassName: "text-destructive",
-    columns: ["image", "title", "SKU", "stock_quantity", "daily_sales_avg", "last_purchase_date", "lead_time_status"]
+    columns: ["image", "title", "SKU", "stock_quantity", "daily_sales_avg", "reorder_qty", "replenishable", "last_purchase_date", "lead_time_status"]
   },
   {
     id: "Reorder",
     label: "Reorder Soon",
     icon: AlertCircle,
     iconClassName: "text-warning",
-    columns: ["image", "title", "SKU", "stock_quantity", "daily_sales_avg", "last_purchase_date", "lead_time_status"]
+    columns: ["image", "title", "SKU", "stock_quantity", "daily_sales_avg", "reorder_qty", "replenishable", "last_purchase_date", "lead_time_status"]
   },
   {
     id: "Healthy",
@@ -44,7 +44,7 @@ export const PRODUCT_VIEWS: ProductView[] = [
     label: "Overstock",
     icon: PackageSearch,
     iconClassName: "text-muted-foreground",
-    columns: ["image", "title", "stock_quantity", "daily_sales_avg", "last_sale_date", "abc_class"]
+    columns: ["image", "title", "stock_quantity", "daily_sales_avg", "overstocked_amt", "replenishable", "last_sale_date", "abc_class"]
   },
   {
     id: "New",

inventory/src/pages/Products.tsx

@@ -6,6 +6,8 @@ import { ProductTableSkeleton } from '@/components/products/ProductTableSkeleton
 import { ProductDetail } from '@/components/products/ProductDetail';
 import { ProductViews } from '@/components/products/ProductViews';
 import { Button } from '@/components/ui/button';
+import { Product } from '@/types/products';
+import type { ColumnKey } from '@/components/products/ProductTable';
 import {
   DropdownMenu,
   DropdownMenuCheckboxItem,
@@ -26,65 +28,9 @@ import {
   PaginationPrevious,
 } from "@/components/ui/pagination"
 
-// Enhanced Product interface with all possible fields
-interface Product {
-  // Basic product info
-  product_id: number;
-  title: string;
-  SKU: string;
-  stock_quantity: number;
-  price: number;
-  regular_price: number;
-  cost_price: number;
-  landing_cost_price: number | null;
-  barcode: string;
-  vendor: string;
-  vendor_reference: string;
-  brand: string;
-  categories: string[];
-  tags: string[];
-  options: Record<string, any>;
-  image: string | null;
-  moq: number;
-  uom: number;
-  visible: boolean;
-  managing_stock: boolean;
-  replenishable: boolean;
-  created_at: string;
-  updated_at: string;
-  
-  // Metrics
-  daily_sales_avg?: number;
-  weekly_sales_avg?: number;
-  monthly_sales_avg?: number;
-  avg_quantity_per_order?: number;
-  number_of_orders?: number;
-  first_sale_date?: string;
-  last_sale_date?: string;
-  days_of_inventory?: number;
-  weeks_of_inventory?: number;
-  reorder_point?: number;
-  safety_stock?: number;
-  avg_margin_percent?: number;
-  total_revenue?: number;
-  inventory_value?: number;
-  cost_of_goods_sold?: number;
-  gross_profit?: number;
-  gmroi?: number;
-  avg_lead_time_days?: number;
-  last_purchase_date?: string;
-  last_received_date?: string;
-  abc_class?: string;
-  stock_status?: string;
-  turnover_rate?: number;
-  current_lead_time?: number;
-  target_lead_time?: number;
-  lead_time_status?: string;
-}
-
 // Column definition type
 interface ColumnDef {
-  key: keyof Product | 'image';
+  key: ColumnKey;
   label: string;
   group: string;
   noLabel?: boolean;
@@ -105,6 +51,10 @@ const AVAILABLE_COLUMNS: ColumnDef[] = [
   { key: 'stock_status', label: 'Stock Status', group: 'Stock' },
   { key: 'days_of_inventory', label: 'Days of Stock', group: 'Stock', format: (v) => v?.toFixed(1) ?? '-' },
   { key: 'abc_class', label: 'ABC Class', group: 'Stock' },
+  { key: 'replenishable', label: 'Replenishable', group: 'Stock' },
+  { key: 'moq', label: 'MOQ', group: 'Stock', format: (v) => v?.toString() ?? '-' },
+  { key: 'reorder_qty', label: 'Reorder Qty', group: 'Stock', format: (v) => v?.toString() ?? '-' },
+  { key: 'overstocked_amt', label: 'Overstock Amt', group: 'Stock', format: (v) => v?.toString() ?? '-' },
   { key: 'price', label: 'Price', group: 'Pricing', format: (v) => v?.toFixed(2) ?? '-' },
   { key: 'regular_price', label: 'Default Price', group: 'Pricing', format: (v) => v?.toFixed(2) ?? '-' },
   { key: 'cost_price', label: 'Cost', group: 'Pricing', format: (v) => v?.toFixed(2) ?? '-' },
@@ -124,7 +74,7 @@ const AVAILABLE_COLUMNS: ColumnDef[] = [
 ];
 
 // Default visible columns
-const DEFAULT_VISIBLE_COLUMNS: (keyof Product | 'image')[] = [
+const DEFAULT_VISIBLE_COLUMNS: ColumnKey[] = [
   'image',
   'title',
   'SKU',
@@ -132,6 +82,8 @@ const DEFAULT_VISIBLE_COLUMNS: (keyof Product | 'image')[] = [
   'vendor',
   'stock_quantity',
   'stock_status',
+  'replenishable',
+  'reorder_qty',
   'price',
   'regular_price',
   'daily_sales_avg',
@@ -141,11 +93,11 @@ const DEFAULT_VISIBLE_COLUMNS: (keyof Product | 'image')[] = [
 
 export function Products() {
   const [filters, setFilters] = useState<Record<string, string | number | boolean>>({});
-  const [sortColumn, setSortColumn] = useState<keyof Product>('title');
+  const [sortColumn, setSortColumn] = useState<ColumnKey>('title');
   const [sortDirection, setSortDirection] = useState<'asc' | 'desc'>('asc');
   const [currentPage, setCurrentPage] = useState(1);
-  const [visibleColumns, setVisibleColumns] = useState<Set<keyof Product | 'image'>>(new Set(DEFAULT_VISIBLE_COLUMNS));
+  const [visibleColumns, setVisibleColumns] = useState<Set<ColumnKey>>(new Set(DEFAULT_VISIBLE_COLUMNS));
-  const [columnOrder, setColumnOrder] = useState<(keyof Product | 'image')[]>([
+  const [columnOrder, setColumnOrder] = useState<ColumnKey[]>([
     ...DEFAULT_VISIBLE_COLUMNS,
     ...AVAILABLE_COLUMNS.map(col => col.key).filter(key => !DEFAULT_VISIBLE_COLUMNS.includes(key))
   ]);
@@ -162,11 +114,6 @@ export function Products() {
     return acc;
   }, {} as Record<string, typeof AVAILABLE_COLUMNS>);
 
-  // Handle column reordering from drag and drop
-  const handleColumnOrderChange = (newOrder: (keyof Product | 'image')[]) => {
-    setColumnOrder(newOrder);
-  };
-
   // Function to fetch products data
   const fetchProducts = async () => {
     const params = new URLSearchParams();

inventory/src/types/products.ts

@@ -32,11 +32,24 @@ export interface Product {
   first_sale_date?: string;
   last_sale_date?: string;
   last_purchase_date?: string;
-  days_of_stock?: number;
+  days_of_inventory?: number;
-  stock_status?: string;
+  weeks_of_inventory?: number;
-  abc_class?: string;
-  profit_margin?: number;
   reorder_point?: number;
-  max_stock?: number;
+  safety_stock?: number;
+  avg_margin_percent?: number;
+  total_revenue?: number;
+  inventory_value?: number;
+  cost_of_goods_sold?: number;
+  gross_profit?: number;
+  gmroi?: number;
+  avg_lead_time_days?: number;
+  last_received_date?: string;
+  abc_class?: string;
+  stock_status?: string;
+  turnover_rate?: number;
+  current_lead_time?: number;
+  target_lead_time?: number;
   lead_time_status?: string;
+  reorder_qty?: number;
+  overstocked_amt?: number;
 }