apex/server/services/packingEngine.js

/**
 * Packing Engine — APEX 4.0
 * Layer-based bin packing algorithm (per Dossier Technique Maître §3.1).
 *
 * Strategy:
 *   Level 1 — Côtés empilés (side panels stacked flat)
 *   Level 2 — Dessus + Fond côte à côte (top & bottom side by side)
 *   Level 3 — Étagères + Renforts groupés par épaisseur (shelves & reinforcements)
 *
 * Within each level, pieces are packed using First-Fit-Decreasing by weight,
 * respecting a 28 kg max per box.
 */

import { PACKING, PANEL } from '../../shared/manufacturing.js';

/**
 * Estimate the weight of a single piece in kg.
 * Uses approximate melamine panel density by thickness.
 * @param {number} widthMm
 * @param {number} heightMm
 * @param {number} thicknessMm
 * @returns {number} weight in kg for ONE piece
 */
function estimatePieceWeight(widthMm, heightMm, thicknessMm) {
  const volumeM3 = (widthMm / 1000) * (heightMm / 1000) * (thicknessMm / 1000);

  let density;
  if (thicknessMm >= PANEL.structure) {
    density = PACKING.densityKgM3.melamine19;
  } else if (thicknessMm >= PANEL.reinforcement) {
    density = PACKING.densityKgM3.melamine16;
  } else {
    density = PACKING.densityKgM3.melamine8;
  }

  return volumeM3 * density;
}

/**
 * Expand cutting list pieces into individual packable items.
 * Each piece with quantity > 1 becomes multiple single items.
 * @param {Array} pieces - pieces from cutting list
 * @returns {Array} flat array of single items with weight
 */
function expandPieces(pieces) {
  const items = [];

  for (const piece of pieces) {
    // Skip non-physical items (edge banding, etc.)
    if (piece.unit === 'ml' || piece.widthMm === 0 || piece.heightMm === 0) continue;

    const weightPerPiece = estimatePieceWeight(piece.widthMm, piece.heightMm, piece.thicknessMm);

    for (let i = 0; i < piece.quantity; i++) {
      items.push({
        pieceId: piece.id,
        elementType: piece.elementType,
        description: piece.description,
        widthMm: piece.widthMm,
        heightMm: piece.heightMm,
        thicknessMm: piece.thicknessMm,
        quantity: 1,
        weightKg: Math.round(weightPerPiece * 100) / 100,
        index: i,
      });
    }
  }

  return items;
}

/**
 * Classify expanded items into packing layers per APEX 4.0 §3.1.
 *
 * Level 1: cotes (side panels) — stacked
 * Level 2: dessus + fond (top & bottom) — side by side
 * Level 3: everything else grouped by thickness (etageres, renforts, panneauxInterieurs, dos, etc.)
 *
 * @param {Array} items - expanded single-piece items
 * @returns {Object} { level1, level2, level3 } arrays
 */
function classifyByLayer(items) {
  const level1 = []; // Côtés
  const level2 = []; // Dessus + Fond
  const level3 = []; // Étagères, Renforts, Séparateurs, Dos, Portes, etc.

  for (const item of items) {
    switch (item.elementType) {
      case 'cotes':
      case 'cotesDoublage':
        level1.push(item);
        break;
      case 'dessus':
      case 'fond':
        level2.push(item);
        break;
      default:
        level3.push(item);
        break;
    }
  }

  // Sort level 3 by thickness (group same thickness together) then by weight desc
  level3.sort((a, b) => {
    if (a.thicknessMm !== b.thicknessMm) return b.thicknessMm - a.thicknessMm;
    return b.weightKg - a.weightKg;
  });

  return { level1, level2, level3 };
}

/**
 * First-Fit-Decreasing bin packing for a set of items.
 * Sort items by weight (heaviest first), then assign each to the
 * first box that still has capacity.
 *
 * @param {Array} items - items to pack
 * @param {number} startBoxId - starting box ID
 * @param {string} levelLabel - label for these boxes (e.g. "Niveau 1")
 * @returns {{ boxes: Array, nextBoxId: number }}
 */
function firstFitDecreasing(items, startBoxId = 1, levelLabel = '') {
  if (items.length === 0) return { boxes: [], nextBoxId: startBoxId };

  const sorted = [...items].sort((a, b) => b.weightKg - a.weightKg);
  const maxWeight = PACKING.maxWeightKg;
  const boxes = [];

  for (const item of sorted) {
    // If the single item exceeds max weight, it gets its own box
    if (item.weightKg > maxWeight) {
      boxes.push({
        id: startBoxId + boxes.length,
        level: levelLabel,
        pieces: [item],
        totalWeightKg: item.weightKg,
      });
      continue;
    }

    // Try to fit in an existing box
    let placed = false;
    for (const box of boxes) {
      if (box.totalWeightKg + item.weightKg <= maxWeight) {
        box.pieces.push(item);
        box.totalWeightKg = Math.round((box.totalWeightKg + item.weightKg) * 100) / 100;
        placed = true;
        break;
      }
    }

    // Open a new box
    if (!placed) {
      boxes.push({
        id: startBoxId + boxes.length,
        level: levelLabel,
        pieces: [item],
        totalWeightKg: item.weightKg,
      });
    }
  }

  return { boxes, nextBoxId: startBoxId + boxes.length };
}

/**
 * Generate packing list from a cutting list result.
 * Uses the APEX 4.0 layer-based strategy:
 *   Level 1 → sides stacked
 *   Level 2 → top + bottom side by side
 *   Level 3 → shelves + reinforcements grouped by thickness
 *
 * Each level is independently bin-packed with FFD, then all boxes
 * are merged into a single sequential list.
 *
 * @param {Object} cuttingList - output of generateCuttingList()
 * @returns {Object} packing summary
 */
export function generatePackingList(cuttingList) {
  if (!cuttingList || !cuttingList.pieces || cuttingList.pieces.length === 0) {
    return {
      boxes: [],
      totalBoxes: 0,
      maxWeightKg: PACKING.maxWeightKg,
      heaviestBoxKg: 0,
      totalWeightKg: 0,
      strategy: 'layer-based (APEX 4.0)',
    };
  }

  const items = expandPieces(cuttingList.pieces);
  const { level1, level2, level3 } = classifyByLayer(items);

  // Pack each level independently
  const pack1 = firstFitDecreasing(level1, 1, 'Niveau 1 — Côtés');
  const pack2 = firstFitDecreasing(level2, pack1.nextBoxId, 'Niveau 2 — Dessus/Fond');
  const pack3 = firstFitDecreasing(level3, pack2.nextBoxId, 'Niveau 3 — Étagères/Renforts');

  const allBoxes = [...pack1.boxes, ...pack2.boxes, ...pack3.boxes];

  const heaviestBoxKg = allBoxes.reduce((max, b) => Math.max(max, b.totalWeightKg), 0);
  const totalWeightKg = allBoxes.reduce((sum, b) => sum + b.totalWeightKg, 0);

  return {
    boxes: allBoxes,
    totalBoxes: allBoxes.length,
    maxWeightKg: PACKING.maxWeightKg,
    heaviestBoxKg: Math.round(heaviestBoxKg * 10) / 10,
    totalWeightKg: Math.round(totalWeightKg * 10) / 10,
    strategy: 'layer-based (APEX 4.0)',
    layerSummary: {
      level1: { label: 'Côtés empilés', boxes: pack1.boxes.length, items: level1.length },
      level2: { label: 'Dessus + Fond', boxes: pack2.boxes.length, items: level2.length },
      level3: { label: 'Étagères + Renforts', boxes: pack3.boxes.length, items: level3.length },
    },
  };
}

export default { generatePackingList };