fix

src/calculation_target_reliability/router.py

@@ -40,7 +40,8 @@ async def get_target_reliability(
     oh_session_id: Optional[str] = Query(None),
     eaf_input: float = Query(99.8),
     duration: int = Query(17520),
-    simulation_id: Optional[str] = Query(None)
+    simulation_id: Optional[str] = Query(None),
+    po_duration = Query(1200)
 ):
     """Get all scope pagination."""
     if not oh_session_id:
@@ -66,7 +67,7 @@ async def get_target_reliability(
             )
             
             simulation_id = simulation.get("data") 
-            await wait_for_workflow(simulation_id=simulation_id.get("data"))
+            await wait_for_workflow(simulation_id=simulation_id)
     else:
         await wait_for_workflow(simulation_id=simulation_id)
         
@@ -82,7 +83,9 @@ async def get_target_reliability(
         db_session=db_session,
         oh_session_id=oh_session_id,
         collector_db=collector_db,
-        simulation_id=simulation_id
+        simulation_id=simulation_id,
+        duration=duration,
+        po_duration=po_duration
     )
 
 

src/calculation_target_reliability/schema.py

@@ -56,9 +56,11 @@ class OptimizationResult(OverhaulBase):
     target_plant_eaf: float
     possible_plant_eaf:float
     eaf_gap: float
+    warning_message:Optional[str]
     asset_contributions: List[dict]
     optimization_success: bool = False
     simulation_id: Optional[str] = None
+    
 
 
 # {

src/calculation_target_reliability/service.py

@@ -1,3 +1,4 @@
+import math
 from typing import Optional, List
 from dataclasses import dataclass
 from sqlalchemy import Delete, Select
@@ -77,57 +78,61 @@ async def get_simulation_results(*, simulation_id: str, token: str):
             "plant_result": plant_data
         }
 
-def calculate_asset_eaf_contributions(plant_result, eq_results, standard_scope, eaf_gap):
+def calculate_asset_eaf_contributions(plant_result, eq_results, standard_scope, eaf_gap, scheduled_outage):
     """
-    Calculate each asset's contribution to plant EAF with realistic improvement potential.
-    Ranking:
-      1. Highest contribution (Birnbaum Importance)
-      2. Tie-breaker: Contribution per downtime (efficiency)
+    Calculate each asset's contribution to plant EAF with realistic, fair improvement allocation.
+    The total EAF gap is distributed among assets proportionally to their contribution potential.
     """
-
     eaf_gap_fraction = eaf_gap / 100.0 if eaf_gap > 1.0 else eaf_gap
+    
+    total_hours = plant_result.get("total_uptime") + plant_result.get("total_downtime")
+    plant_operating_fraction = (total_hours - scheduled_outage) / total_hours
 
-    MIN_BIRNBAUM_IMPORTANCE = 0.0005
-    REALISTIC_MAX_AVAILABILITY = 0.995  # 99.5%
+    REALISTIC_MAX_TECHNICAL = 0.995
+    REALISTIC_MAX_AVAILABILITY = REALISTIC_MAX_TECHNICAL * plant_operating_fraction
     MIN_IMPROVEMENT_PERCENT = 0.0001   
     min_improvement_fraction = MIN_IMPROVEMENT_PERCENT / 100.0
 
     results = []
+    weighted_assets = []
 
+    # Step 1: Collect eligible assets and their weights
     for asset in eq_results:
         asset_name = asset.get("aeros_node").get("node_name")
-        
-        if asset_name not in standard_scope:
+        num_of_events = asset.get("num_events")
+
+        if asset_name not in standard_scope or num_of_events < 2:
             continue
+
+        contribution_factor = asset.get("contribution_factor", 0.0)
+        birbaum = asset.get("contribution", 0.0)
+        current_availability = asset.get("availability", 0.0)
+        downtime = asset.get("total_downtime", 0.0)
+        max_possible_improvement = REALISTIC_MAX_AVAILABILITY - current_availability if REALISTIC_MAX_AVAILABILITY > current_availability else REALISTIC_MAX_TECHNICAL
         
-        
+        raw_weight = birbaum * contribution_factor
+        weight = math.sqrt(raw_weight)
+        weighted_assets.append((asset, weight, max_possible_improvement))
+
+    # Step 2: Compute total weight
+    total_weight = sum(w for _, w, _ in weighted_assets) or 1.0
+
+    # Step 3: Distribute improvement proportionally to weight
+    for asset, weight, max_possible_improvement in weighted_assets:
+        asset_name = asset.get("aeros_node").get("node_name")
         contribution_factor = asset.get("contribution_factor", 0.0)
         birbaum = asset.get("contribution", 0.0)
         current_availability = asset.get("availability", 0.0)
         downtime = asset.get("total_downtime", 0.0)
-            
 
-        # Filter 1: Importance too low
-        if contribution_factor < MIN_BIRNBAUM_IMPORTANCE:
-            continue
+        # Proportional improvement share
+        required_improvement = eaf_gap_fraction * (weight / total_weight)
+        required_improvement = min(required_improvement, max_possible_improvement)
+        required_improvement = max(required_improvement, min_improvement_fraction)
 
-        # Max possible availability improvement
-        max_possible_improvement = REALISTIC_MAX_AVAILABILITY - current_availability
-        if max_possible_improvement <= 0:
-            continue
-        
-        
-        
-        # Inject standard each equipment
-        required_improvement = 0.01
         improvement_impact = required_improvement * contribution_factor
-        
-
-        # Filter 2: Improvement too small
-        if improvement_impact < MIN_IMPROVEMENT_PERCENT:
-            continue
 
-        # Contribution efficiency (secondary metric)
+        # Secondary metric: efficiency
         efficiency = birbaum / downtime if downtime > 0 else birbaum
 
         contribution = AssetWeight(
@@ -138,30 +143,30 @@ def calculate_asset_eaf_contributions(plant_result, eq_results, standard_scope,
             improvement_impact=improvement_impact,
             num_of_failures=asset.get("num_events", 0),
             down_time=downtime,
-            efficiency= efficiency,
+            efficiency=efficiency,
             birbaum=birbaum
         )
-  
 
         results.append(contribution)
 
-    # Sort: 1) contribution (desc), 2) efficiency (desc)
-    results.sort(key=lambda x: (x.birbaum), reverse=True)
+    # Step 4: Sort by Birnbaum importance
+    results.sort(key=lambda x: x.birbaum, reverse=True)
     return results
 
 
 
+
 def project_eaf_improvement(asset: AssetWeight, improvement_factor: float = 0.3) -> float:
     """
     Project EAF improvement after maintenance
     This is a simplified model - you should replace with your actual prediction logic
     """
     current_downtime_pct = 100 - asset.eaf
-    # Assume maintenance reduces downtime by improvement_factor
     improved_downtime_pct = current_downtime_pct * (1 - improvement_factor)
     projected_eaf = 100 - improved_downtime_pct
     return min(projected_eaf, 99.9)  # Cap at 99.9%
 
+
 async def identify_worst_eaf_contributors(
     *,
     simulation_result,
@@ -170,24 +175,56 @@ async def identify_worst_eaf_contributors(
     oh_session_id: str,
     collector_db: CollectorDbSession,
     simulation_id: str,
+    duration:int,
+    po_duration: int
 ):
     """
     Identify equipment that contributes most to plant EAF reduction
-    in order to reach a target EAF.
+    and evaluate if target EAF is physically achievable.
     """
 
     # Extract results
     calc_result = simulation_result["calc_result"]
     plant_result = simulation_result["plant_result"]
 
-    # Ensure list of equipment
     eq_results = calc_result if isinstance(calc_result, list) else [calc_result]
 
     # Current plant EAF and gap
     current_plant_eaf = plant_result.get("eaf", 0)
+    total_hours = duration
+    scheduled_outage = int(po_duration)
+    max_eaf_possible = (total_hours - scheduled_outage) / total_hours * 100
+
+    # Check if target EAF exceeds theoretical maximum
+    warning_message = None
+    if target_eaf > max_eaf_possible:
+        impossible_gap = target_eaf - max_eaf_possible
+        required_scheduled_hours = total_hours * (1 - target_eaf / 100)
+        required_reduction = scheduled_outage - required_scheduled_hours
+
+        warning_message = (
+            f"⚠️ Target EAF {target_eaf:.2f}% exceeds theoretical maximum {max_eaf_possible:.2f}%.\n"
+            f"To achieve it, planned outage must be reduced by approximately "
+            f"{required_reduction:.1f} hours (from {scheduled_outage:.0f}h → {required_scheduled_hours:.0f}h)."
+        )
+
+        # Cap target EAF to max achievable for calculation
+        target_eaf = max_eaf_possible
+
     eaf_gap = (target_eaf - current_plant_eaf) / 100.0
+    if eaf_gap <= 0:
+        return OptimizationResult(
+            current_plant_eaf=current_plant_eaf,
+            target_plant_eaf=target_eaf,
+            possible_plant_eaf=current_plant_eaf,
+            eaf_gap=0,
+            warning_message=warning_message or "Target already achieved or exceeded.",
+            asset_contributions=[],
+            optimization_success=True,
+            simulation_id=simulation_id,
+        )
 
-    # Get standard scope (equipment allowed for overhaul/optimization)
+    # Get standard scope
     standard_scope = await get_standard_scope_by_session_id(
         db_session=db_session,
         overhaul_session_id=oh_session_id,
@@ -197,35 +234,39 @@ async def identify_worst_eaf_contributors(
 
     # Compute contributions
     asset_contributions = calculate_asset_eaf_contributions(
-        plant_result, eq_results, standard_scope_location_tags, eaf_gap=eaf_gap
+        plant_result, 
+        eq_results, 
+        standard_scope_location_tags, 
+        eaf_gap,
+        scheduled_outage
     )
 
-    project_eaf_improvement = 0.0
+    # Greedy selection to fill EAF gap
+    project_eaf_improvement_total = 0.0
     selected_eq = []
 
-    # Greedy select until gap is closed
     for asset in asset_contributions:
-        if project_eaf_improvement >= eaf_gap:
+        if project_eaf_improvement_total >= eaf_gap:
             break
 
-
-        if (project_eaf_improvement + asset.improvement_impact) <= eaf_gap:
+        if (project_eaf_improvement_total + asset.improvement_impact) <= eaf_gap:
             selected_eq.append(asset)
-            project_eaf_improvement += asset.improvement_impact
+            project_eaf_improvement_total += asset.improvement_impact
         else:
-            # allow overshoot tolerance by skipping large ones, continue with smaller ones
             continue
-    
-    possible_eaf_plant = current_plant_eaf + project_eaf_improvement*100
-    
-    selected_eq.sort(key=lambda x: (x.birbaum), reverse=True)
 
-    # Build output with efficiency included
+    possible_eaf_plant = current_plant_eaf + project_eaf_improvement_total * 100
+    possible_eaf_plant = min(possible_eaf_plant, max_eaf_possible)
+
+    selected_eq.sort(key=lambda x: x.birbaum, reverse=True)
+
+    # Final return
     return OptimizationResult(
         current_plant_eaf=current_plant_eaf,
         target_plant_eaf=target_eaf,
         possible_plant_eaf=possible_eaf_plant,
         eaf_gap=eaf_gap,
+        warning_message=warning_message,
         asset_contributions=[
             {
                 "node": asset.node,
@@ -236,10 +277,10 @@ async def identify_worst_eaf_contributors(
                 "system_impact": asset.improvement_impact,
                 "num_of_failures": asset.num_of_failures,
                 "down_time": asset.down_time,
-                "efficiency": asset.efficiency,  
+                "efficiency": asset.efficiency,
             }
             for asset in selected_eq
         ],
-        optimization_success=(current_plant_eaf + project_eaf_improvement) >= target_eaf,
+        optimization_success=(current_plant_eaf + project_eaf_improvement_total * 100) >= target_eaf,
         simulation_id=simulation_id,
     )

src/calculation_time_constrains/service.py

@@ -68,7 +68,7 @@ class OptimumCostModelWithSpareparts:
         self.planned_oh_months = self._get_months_between(last_oh_date, next_oh_date)
         
         # Set analysis time window (default: 1.5x planned interval)
-        self.time_window_months = time_window_months or int(self.planned_oh_months * 1.5)
+        self.time_window_months = time_window_months or int(self.planned_oh_months * 1.3)
         
         # Pre-calculate date range for API calls
         self.date_range = self._generate_date_range()
@@ -174,7 +174,7 @@ class OptimumCostModelWithSpareparts:
 
     def _calculate_equipment_costs_with_spareparts(self, failures_prediction: Dict, birnbaum_importance: float,
                                                  preventive_cost: float, failure_replacement_cost: float, ecs,
-                                                 location_tag: str, planned_overhauls: List = None) -> List[Dict]:
+                                                 location_tag: str, planned_overhauls: List = None, loss_production_permonth=0) -> List[Dict]:
         """Calculate costs for each month including sparepart costs and availability"""
         
         if not failures_prediction:
@@ -349,6 +349,11 @@ class OptimumCostModelWithSpareparts:
                 imp['aeros_node']['node_name']: imp['contribution_factor'] 
                 for imp in importance_results["calc_result"]
             }
+            
+            loss_production_permonth = {
+                imp['aeros_node']['node_name']: (imp['ideal_production'] - imp['production']) / 60
+                for imp in importance_results["calc_result"]
+            }
         except Exception as e:
             self.logger.error(f"Failed to get simulation results: {e}")
             equipment_birnbaum = {}
@@ -376,6 +381,8 @@ class OptimumCostModelWithSpareparts:
             location_tag = equipment.location_tag
             contribution_factor = equipment_birnbaum.get(location_tag, 0.0)
             ecs = ecs_tags.get(location_tag, None)
+            loss_production = loss_production_permonth.get(location_tag, 0) * 960000
+            
             
             # try:
             # # Get failure predictions
@@ -395,7 +402,8 @@ class OptimumCostModelWithSpareparts:
                 failure_replacement_cost=failure_replacement_cost,
                 location_tag=location_tag,
                 planned_overhauls=[] , # Empty in first pass
-                ecs=ecs
+                ecs=ecs,
+                loss_production_permonth=loss_production
             )
             
             if not cost_results:
@@ -696,17 +704,18 @@ async def run_simulation_with_spareparts(*, db_session, calculation, token: str,
     time_window_months = 60
     
     sparepart_manager = await load_sparepart_data_from_db(scope=scope, prev_oh_scope=prev_oh_scope, db_session=collector_db_session, analysis_window_months=time_window_months)
+    
 
     # Initialize optimization model with sparepart management
     optimum_oh_model = OptimumCostModelWithSpareparts(
         token=token,
         last_oh_date=prev_oh_scope.end_date,
         next_oh_date=scope.start_date,
-        time_window_months=time_window_months,
         base_url=RBD_SERVICE_API,
         sparepart_manager=sparepart_manager
     )
 
+
     try:
         # Run fleet optimization with sparepart management
         results = await optimum_oh_model.calculate_cost_all_equipment_with_spareparts(

src/sparepart/service.py

@@ -792,9 +792,11 @@ async def load_sparepart_data_from_db(scope, prev_oh_scope, db_session, analysis
     # prev_oh_scope = await get_prev_oh(db_session=db_session, overhaul_session=scope)
     
     analysis_start_date = prev_oh_scope.end_date
-    analysis_window_months = int(((scope.start_date - prev_oh_scope.end_date).days / 30) * 1.5) if not analysis_window_months else analysis_window_months
+    analysis_window_months = int(((scope.start_date - prev_oh_scope.end_date).days / 30) * 1.3) if not analysis_window_months else analysis_window_months
     
     sparepart_manager = SparepartManager(analysis_start_date, analysis_window_months)
+    start_date = prev_oh_scope.end_date
+    end_date = scope.start_date
     
     # Load sparepart stocks
     # Example query - adjust based on your schema
@@ -832,7 +834,7 @@ async def load_sparepart_data_from_db(scope, prev_oh_scope, db_session, analysis
         wonum,
         asset_location
     FROM public.wo_staging_maximo_2
-    WHERE worktype = 'OH' AND asset_location IS NOT NULL
+    WHERE worktype = 'OH' AND asset_location IS NOT NULL and asset_unit IN ('3', '00')
 ),
 sparepart_usage AS (
     -- Get sparepart usage for OH work orders