private List <ControlChartData> GetPhChartData(List <BatchReport> reports)
{
List <ControlChartData> output = new List <ControlChartData>();
var BatchesGroupedByRecipeType = BatchHelperMethods.GroupBatchesByRecipeType(reports);
List <decimal> values = new List <decimal>();
List <string> xAxisLabels = new List <string>();
foreach (var report in reports.OrderBy(x => x.StartTime.Date).ThenBy(x => x.StartTime.TimeOfDay))
{
values.Add(Convert.ToDecimal(report.Ph));
xAxisLabels.Add($"{report.Campaign}-{report.BatchNo}");
}
ControlChartData data = new ControlChartData
{
Target = 2.6M,
Max = 2.9M,
Min = 2.3M,
Values = values,
XAxisLabels = xAxisLabels,
SeriesName = "Ph",
Title = $"pH Of all Batches",
YAxisSuffix = "pH",
ChartId = "phchart"
};
data.ProcessCpkValues();
output.Add(data);
_xLCreator.AddToWorkBook <decimal>("PH", values, data.Min, data.Max);
return(output);
}
private List <ControlChartData> GetStenolDropChartData(List <BatchReport> reports)
{
List <ControlChartData> output = new List <ControlChartData>();
List <BatchReport> regBatches = reports.Where(x => x.RecipeType == RecipeTypes.Reg).ToList();
List <decimal> values = new List <decimal>();
List <string> xAxisLabels = new List <string>();
string stenolName = _applicationData.ApplicationMode == "demo" ? "Material 21" : "FATTY ALC";
foreach (var report in regBatches)
{
decimal stenol = Convert.ToDecimal(BatchHelperMethods.GetSingleMaterialFromVessel(report, stenolName).ActualWeight);
values.Add(stenol);
xAxisLabels.Add(report.Campaign.ToString() + "-" + report.BatchNo.ToString());
}
ControlChartData data = new ControlChartData
{
Target = 58.5M,
Max = 58.5M + (0.05M * 58.5M),
Min = 58.5M - (0.05M * 58.5M),
Values = values,
XAxisLabels = xAxisLabels,
SeriesName = $"{stenolName} Quantity Kg",
Title = $"{stenolName} Quantity Of Reg Batches",
YAxisSuffix = "Kg",
ChartId = "Reg"
};
data.ProcessCpkValues();
output.Add(data);
_xLCreator.AddToWorkBook <decimal>($"{stenolName}-Regs", values, data.Min, data.Max);
return(output);
}
public void ShouldReturnCorrectWeightOfAllMaterialsInVessel()
{
Vessel vessel = new Vessel();
List <Material> materials = new List <Material>()
{
new Material {
ActualWeight = 11
},
new Material {
ActualWeight = 22
},
new Material {
ActualWeight = 33
},
new Material {
ActualWeight = 44
},
new Material {
ActualWeight = 55
},
new Material {
ActualWeight = 66
}
};
vessel.Materials.AddRange(materials);
double totalWeights = BatchHelperMethods.CountActualWeightOfAllMaterialsInVessel(vessel);
Assert.AreEqual(231, totalWeights);
}
private List <ControlChartData> GetViscoChartData(List <BatchReport> reports)
{
List <ControlChartData> output = new List <ControlChartData>();
var BatchesGroupedByRecipeType = BatchHelperMethods.GroupBatchesByRecipeType(reports);
foreach (var recipeType in BatchesGroupedByRecipeType.Keys)
{
List <decimal> values = new List <decimal>();
List <string> xAxisLabels = new List <string>();
foreach (var report in BatchesGroupedByRecipeType[recipeType].OrderBy(x => x.StartTime.Date).ThenBy(x => x.StartTime.TimeOfDay))
{
values.Add(Convert.ToDecimal(report.Visco));
xAxisLabels.Add($"{report.Campaign}-{report.BatchNo}");
}
RecipeLimits limits = _recipeLimitRepository.GetLimitInfo(recipeType, LimitType.Visco);
ControlChartData data = new ControlChartData
{
Target = limits.Target,
Max = limits.Max,
Min = limits.Min,
Values = values,
XAxisLabels = xAxisLabels,
SeriesName = "Visco cP",
Title = $"Viscos Of {ChangeRecipeTypeNameForDemo(recipeType)} batches",
YAxisSuffix = "cP",
ChartId = recipeType.ToString()
};
data.ProcessCpkValues();
output.Add(data);
_xLCreator.AddToWorkBook <decimal>($"Visco-{recipeType}", values, data.Min, data.Max);
}
return(output);
}
public void StoppageTimeShouldBe4()
{
List <BatchIssue> issues = new List <BatchIssue>
{
new BatchIssue {
BatchIssueId = 1, FaultType = BatchIssue.FaultTypes.Quality, TimeLost = 15, MaterialName = "ANTIFOAM"
},
new BatchIssue {
BatchIssueId = 2, FaultType = BatchIssue.FaultTypes.TemperatureHigh, TimeLost = 15, MaterialName = "ANTIFOAM"
},
new BatchIssue {
BatchIssueId = 3, FaultType = BatchIssue.FaultTypes.AcquireTime, TimeLost = 15, MaterialName = "ANTIFOAM"
},
new BatchIssue {
BatchIssueId = 4, FaultType = BatchIssue.FaultTypes.TemperatureLow, TimeLost = 15, MaterialName = "ANTIFOAM"
},
new BatchIssue {
BatchIssueId = 5, FaultType = BatchIssue.FaultTypes.Quality, TimeLost = 15, MaterialName = "ANTIFOAM"
},
};
double issueCount = BatchHelperMethods.GetTotalQualityIssues(issues);
Assert.AreEqual(4, issueCount);
}
public void StoppageTimeShouldPass()
{
List <BatchIssue> issues = new List <BatchIssue>
{
new BatchIssue {
BatchIssueId = 1, FaultType = BatchIssue.FaultTypes.WaitTime, TimeLost = 15, MaterialName = "ANTIFOAM"
},
new BatchIssue {
BatchIssueId = 2, FaultType = BatchIssue.FaultTypes.WeighTime, TimeLost = 15, MaterialName = "ANTIFOAM"
},
new BatchIssue {
BatchIssueId = 3, FaultType = BatchIssue.FaultTypes.AcquireTime, TimeLost = 15, MaterialName = "ANTIFOAM"
},
new BatchIssue {
BatchIssueId = 4, FaultType = BatchIssue.FaultTypes.Overweigh, TimeLost = 15, MaterialName = "ANTIFOAM"
},
new BatchIssue {
BatchIssueId = 5, FaultType = BatchIssue.FaultTypes.Quality, TimeLost = 15, MaterialName = "ANTIFOAM"
},
};
double timeLost = BatchHelperMethods.GetTotalStoppageTime(issues);
Assert.AreEqual(45, timeLost);
}
public void StoppageTimeShouldReturnWhenEmptyListPassedIn()
{
List <BatchIssue> issues = new List <BatchIssue>();
double timeLost = BatchHelperMethods.GetTotalStoppageTime(issues);
Assert.AreEqual(0, timeLost);
}
public override void ScanForIssues(BatchReport report)
{
var tempSensitiveMaterials = _materialDetailsRepository.GetAllMaterialDetails()
.Where(x => x.MinRawTemp > 0 || x.MaxRawTemp > 0)
.ToList();
foreach (var material in tempSensitiveMaterials)
{
var materialFromBatch = BatchHelperMethods.GetSingleMaterialFromVessel(report, material.Name);
if (materialFromBatch != null)
{
bool overTemp = materialFromBatch.RawMatTemp > material.MaxRawTemp;
bool underTemp = materialFromBatch.RawMatTemp < material.MinRawTemp;
if (overTemp || underTemp)
{
report.BatchIssues.Add(new BatchIssue
{
FaultType = overTemp ? BatchIssue.FaultTypes.TemperatureHigh : BatchIssue.FaultTypes.TemperatureLow,
Message = $"{material.Name} temperature in storage was {UnderOverText(overTemp)} of {GetMaxMinTemp(overTemp, material)}C",
MaterialName = material.Name,
MaterialShortName = material.ShortName,
TimeLost = 0,
ActualReading = materialFromBatch.RawMatTemp,
IssueCreatedBy = IssueDescriptor
});
}
}
}
SetIssueScannedFor(report);
}
public IViewComponentResult Invoke(BatchReport report = null)
{
BatchReport lastBatchMade = _batchRepository.AllBatches.OrderByDescending(x => x.StartTime).FirstOrDefault();;
if (lastBatchMade == null)
{
lastBatchMade = BatchHelperMethods.CreateBlankBatchReport();
}
ViewData["QualityIssues"] = BatchHelperMethods.GetTotalQualityIssues(lastBatchMade.BatchIssues);
ViewData["StoppagesTime"] = BatchHelperMethods.GetTotalStoppageTime(lastBatchMade.BatchIssues);
ViewData["MatVarCost"] = BatchHelperMethods.GetTotalMatVarCost(lastBatchMade.BatchIssues, _materialDetailsRepository);
return(View(lastBatchMade));
}
private string AddAdditionalInfoToJson(string batchJson, BatchReport report, bool sync)
{
batchJson = batchJson.Substring(0, batchJson.Length - 1);
StringBuilder sb = new StringBuilder();
var qualityIssues = BatchHelperMethods.GetTotalQualityIssues(report.BatchIssues);
var stoppageTime = BatchHelperMethods.GetTotalStoppageTime(report.BatchIssues);
var matVarCost = BatchHelperMethods.GetTotalMatVarCost(report.BatchIssues, _materialDetailsRepository);
sb.Append(@"," + Convert.ToChar(34) + "QualityIssues" + Convert.ToChar(34) + ":" + Convert.ToChar(34) + qualityIssues + Convert.ToChar(34));
sb.Append(@"," + Convert.ToChar(34) + "Stoppages" + Convert.ToChar(34) + ":" + Convert.ToChar(34) + stoppageTime + Convert.ToChar(34));
sb.Append(@"," + Convert.ToChar(34) + "MatVarCost" + Convert.ToChar(34) + ":" + Convert.ToChar(34) + matVarCost + Convert.ToChar(34));
sb.Append(@"," + Convert.ToChar(34) + "Sync" + Convert.ToChar(34) + ":" + Convert.ToChar(34) + sync + Convert.ToChar(34) + "}");
batchJson += sb.ToString();
return(batchJson);
}
private List <ControlChartData> GetSoftquatChartData(List <BatchReport> reports)
{
List <ControlChartData> output = new List <ControlChartData>();
var BatchesGroupedByRecipeType = BatchHelperMethods.GroupBatchesByRecipeType(reports);
foreach (var recipeType in BatchesGroupedByRecipeType.Keys)
{
List <decimal> values = new List <decimal>();
List <string> xAxisLabels = new List <string>();
string quatName = _applicationData.ApplicationMode == "demo" ? "Material 51" : "SOFTQUAT";
foreach (var report in BatchesGroupedByRecipeType[recipeType].OrderBy(x => x.StartTime.Date).ThenBy(x => x.StartTime.TimeOfDay))
{
double softquatWeight = BatchHelperMethods.GetSingleMaterialFromVessel(report, quatName).ActualWeight;
values.Add(Convert.ToDecimal(softquatWeight));
xAxisLabels.Add($"{report.Campaign}-{report.BatchNo}");
}
RecipeLimits limits = _recipeLimitRepository.GetLimitInfo(recipeType, LimitType.Softquat);
ControlChartData data = new ControlChartData
{
Target = limits.Target,
Max = limits.Target + (0.05M * limits.Target),
Min = limits.Target - (0.05M * limits.Target),
Values = values,
XAxisLabels = xAxisLabels,
SeriesName = quatName + " Quantity Kg",
Title = $"{quatName} Quantity Of {recipeType} Batches",
YAxisSuffix = "Kg",
ChartId = recipeType.ToString()
};
data.ProcessCpkValues();
output.Add(data);
_xLCreator.AddToWorkBook <decimal>($"{quatName}-{recipeType}", values, data.Min, data.Max);
}
return(output);
}
private Material CalculateWaterDetails(string nameOfMaterial, BatchReport report)
{
Vessel mainMixer = report.AllVessels.Where(x => x.VesselType == Vessel.VesselTypes.MainMixer).FirstOrDefault();
double totalWeightsOfMaterials = BatchHelperMethods.CountActualWeightOfAllMaterialsInVessel(mainMixer);
double totalVesselWeight = report.TotalActualWeight * 1000;
double weightOfMissingWater = totalVesselWeight - totalWeightsOfMaterials;
double rawMatTemp = nameOfMaterial == "Material 63" ? 80.0 : 20;
double vesselTemp = nameOfMaterial == "Material 63" ? 77 : 44;
DateTime StartTimeOfHCL = BatchHelperMethods.GetSingleMaterialFromVessel(report, "Material 59").StartTime;
return(new Material
{
Name = nameOfMaterial,
ActualWeight = weightOfMissingWater,
StartTime = StartTimeOfHCL.Subtract(new TimeSpan(0, 0, 6, 0, 0)),
AgitatorSpeed = 11,
RawMatTemp = rawMatTemp,
TargetWeight = weightOfMissingWater,
WeighTime = 5,
VesselTemp = vesselTemp,
WaitTime = 0.1
});
}
private List <ControlChartData> GetActiveDropChartData(List <BatchReport> reports)
{
List <ControlChartData> output = new List <ControlChartData>();
List <BatchReport> reportsToCheck = new List <BatchReport>();
var batchesGroupedByRecipeType = BatchHelperMethods.GroupBatchesByRecipeType(reports);
foreach (var recipeType in batchesGroupedByRecipeType.Keys)
{
List <decimal> values = new List <decimal>();
List <string> xAxisLabels = new List <string>();
PcsTempTargets limits = new PcsTempTargets();
string nameOfRecipe = "";
foreach (var report in batchesGroupedByRecipeType[recipeType].OrderBy(x => x.StartTime.Date).ThenBy(x => x.StartTime.TimeOfDay))
{
if (recipeType == RecipeTypes.Conc)
{
if (report.Recipe == "WHTCON" || report.Recipe == "Recipe 38")
{
limits = _pcsActiveTempParameters.GetTargetsFor(report.Recipe);
limits.UpperLimit = limits.Target + 1.5M;
limits.LowerLimit = limits.Target - 1.5M;
decimal tempValue = Convert.ToDecimal(_helperMethods.GetTemperatureOfActiveDrop(report.AllVessels.Where(x => x.VesselType == Vessel.VesselTypes.MainMixer).First()));
values.Add(CheckTemperatureForAdjustments(tempValue, limits.UpperLimit, limits.LowerLimit));
xAxisLabels.Add($"{report.Campaign}-{report.BatchNo}");
nameOfRecipe = report.Recipe;
}
}
if (recipeType == RecipeTypes.Reg)
{
if (report.Recipe == "WHTREG" || report.Recipe == "RE-Recipe 39")
{
limits = _pcsActiveTempParameters.GetTargetsFor(report.Recipe);
limits.UpperLimit = limits.Target + 1M;
limits.LowerLimit = limits.Target - 1M;
decimal tempValue = Convert.ToDecimal(_helperMethods.GetTemperatureOfActiveDrop(report.AllVessels.Where(x => x.VesselType == Vessel.VesselTypes.MainMixer).First()));
values.Add(CheckTemperatureForAdjustments(tempValue, limits.UpperLimit, limits.LowerLimit));
xAxisLabels.Add($"{report.Campaign}-{report.BatchNo}");
nameOfRecipe = report.Recipe;
}
}
if (recipeType == RecipeTypes.BigBang)
{
if (report.Recipe == "BB-SKY" || report.Recipe == "BB-Recipe 15")
{
limits = _pcsActiveTempParameters.GetTargetsFor(report.Recipe);
limits.UpperLimit = limits.Target + 1.5M;
limits.LowerLimit = limits.Target - 1.5M;
decimal tempValue = Convert.ToDecimal(_helperMethods.GetTemperatureOfActiveDrop(report.AllVessels.Where(x => x.VesselType == Vessel.VesselTypes.MainMixer).First()));
values.Add(CheckTemperatureForAdjustments(tempValue, limits.UpperLimit, limits.LowerLimit));
xAxisLabels.Add($"{report.Campaign}-{report.BatchNo}");
nameOfRecipe = report.Recipe;
}
}
}
ControlChartData data = new ControlChartData
{
Target = limits.Target,
Max = limits.UpperLimit,
Min = limits.LowerLimit,
Values = values,
XAxisLabels = xAxisLabels,
SeriesName = "Active Drop Temp",
Title = $"Active Drop Temps Of {nameOfRecipe} Batches",
YAxisSuffix = " C",
ChartId = recipeType.ToString()
};
data.ProcessCpkValues();
output.Add(data);
_xLCreator.AddToWorkBook <decimal>($"Active-temp-{nameOfRecipe}", values, data.Min, data.Max);
}
return(output);
}
public void CountShouldReturn0WhenNullPassedIn()
{
double issueCount = BatchHelperMethods.GetTotalQualityIssues(null);
Assert.AreEqual(0, issueCount);
}
public void StoppageTimeShouldReturn0WhenNullPassedIn()
{
double timeLost = BatchHelperMethods.GetTotalStoppageTime(null);
Assert.AreEqual(0, timeLost);
}
