step 9 and cleanup

app/admin/audit/page.tsx

@@ -0,0 +1,241 @@
+import Link from "next/link";
+import { getAuditLog, getAuditFacets, formatRelative } from "@/lib/reports";
+
+export const dynamic = "force-dynamic";
+
+/**
+ * Audit log viewer. Cursor-paginated, with action / entity / actor filters
+ * driven by the GET query string. Server-rendered so the URL is the source
+ * of truth — bookmarking a filtered view just works, and page reloads don't
+ * drop state.
+ *
+ * The JSON `before`/`after` payloads can be long; we render them lazily
+ * inside a <details> block so the table stays scannable.
+ */
+export default async function AuditPage({
+  searchParams,
+}: {
+  searchParams: Promise<{
+    action?: string;
+    entity?: string;
+    actorId?: string;
+    cursor?: string;
+  }>;
+}) {
+  const { action, entity, actorId, cursor } = await searchParams;
+  const [facets, { rows, nextCursor }] = await Promise.all([
+    getAuditFacets(),
+    getAuditLog({
+      limit: 50,
+      action: action || null,
+      entity: entity || null,
+      actorId: actorId || null,
+      cursor: cursor || null,
+    }),
+  ]);
+  const now = new Date();
+
+  // Build a filter-preserving URL for the "Next page" link.
+  const nextHref = nextCursor
+    ? `/admin/audit?${new URLSearchParams({
+        ...(action ? { action } : {}),
+        ...(entity ? { entity } : {}),
+        ...(actorId ? { actorId } : {}),
+        cursor: nextCursor,
+      }).toString()}`
+    : null;
+
+  const filtersActive = !!(action || entity || actorId);
+
+  return (
+    <div className="mx-auto max-w-7xl px-4 py-8">
+      <div className="flex items-start justify-between gap-6 mb-6">
+        <div>
+          <h1 className="text-2xl font-semibold tracking-tight">Audit log</h1>
+          <p className="text-slate-500 mt-1 text-sm">
+            Every write — claim, release, close, create, update, delete, login — lands here.
+            Newest first.
+          </p>
+        </div>
+      </div>
+
+      {/* ─── Filter bar ──────────────────────────────────────────── */}
+      <form method="get" className="mb-6 rounded-xl bg-white border border-slate-200 p-4">
+        <div className="grid gap-3 md:grid-cols-4">
+          <label className="block text-sm">
+            <span className="text-slate-700">Action</span>
+            <select
+              name="action"
+              defaultValue={action ?? ""}
+              className="mt-1 w-full rounded-md border border-slate-300 px-3 py-2 text-sm bg-white"
+            >
+              <option value="">Any action</option>
+              {facets.actions.map((a) => (
+                <option key={a} value={a}>
+                  {a}
+                </option>
+              ))}
+            </select>
+          </label>
+          <label className="block text-sm">
+            <span className="text-slate-700">Entity</span>
+            <select
+              name="entity"
+              defaultValue={entity ?? ""}
+              className="mt-1 w-full rounded-md border border-slate-300 px-3 py-2 text-sm bg-white"
+            >
+              <option value="">Any entity</option>
+              {facets.entities.map((e) => (
+                <option key={e} value={e}>
+                  {e}
+                </option>
+              ))}
+            </select>
+          </label>
+          <label className="block text-sm">
+            <span className="text-slate-700">Actor</span>
+            <select
+              name="actorId"
+              defaultValue={actorId ?? ""}
+              className="mt-1 w-full rounded-md border border-slate-300 px-3 py-2 text-sm bg-white"
+            >
+              <option value="">Any user</option>
+              {facets.actors.map((u) => (
+                <option key={u.id} value={u.id}>
+                  {u.name} ({u.role})
+                </option>
+              ))}
+            </select>
+          </label>
+          <div className="flex items-end gap-2">
+            <button
+              type="submit"
+              className="h-10 rounded-md bg-slate-900 text-white text-sm font-medium px-4"
+            >
+              Filter
+            </button>
+            {filtersActive ? (
+              <Link
+                href="/admin/audit"
+                className="h-10 inline-flex items-center rounded-md border border-slate-300 text-sm font-medium px-4 text-slate-700 hover:bg-slate-50"
+              >
+                Clear
+              </Link>
+            ) : null}
+          </div>
+        </div>
+      </form>
+
+      {/* ─── Results ─────────────────────────────────────────────── */}
+      <div className="rounded-xl bg-white border border-slate-200 overflow-hidden">
+        {rows.length === 0 ? (
+          <p className="px-4 py-10 text-center text-slate-500 text-sm">
+            No events match. Clear filters or widen your search.
+          </p>
+        ) : (
+          <table className="w-full text-sm">
+            <thead className="bg-slate-50 text-left text-slate-600 border-b border-slate-200">
+              <tr>
+                <th className="px-4 py-2 font-medium w-[140px]">When</th>
+                <th className="px-4 py-2 font-medium w-[150px]">Actor</th>
+                <th className="px-4 py-2 font-medium w-[150px]">Action</th>
+                <th className="px-4 py-2 font-medium w-[220px]">Entity</th>
+                <th className="px-4 py-2 font-medium">Payload</th>
+                <th className="px-4 py-2 font-medium w-[100px]">IP</th>
+              </tr>
+            </thead>
+            <tbody>
+              {rows.map((row) => (
+                <tr key={row.id} className="border-b border-slate-100 last:border-0 align-top">
+                  <td className="px-4 py-2 text-slate-600 whitespace-nowrap">
+                    <div>{formatRelative(row.at, now)}</div>
+                    <div className="text-xs text-slate-400">{row.at.toLocaleString()}</div>
+                  </td>
+                  <td className="px-4 py-2">
+                    {row.actor ? (
+                      <>
+                        <div className="text-slate-900">{row.actor.name}</div>
+                        <div className="text-xs text-slate-500">{row.actor.role}</div>
+                      </>
+                    ) : (
+                      <span className="text-slate-400 italic">system</span>
+                    )}
+                  </td>
+                  <td className="px-4 py-2">
+                    <span className="inline-flex rounded-full bg-slate-100 text-slate-700 text-xs px-2 py-0.5 font-mono">
+                      {row.action}
+                    </span>
+                  </td>
+                  <td className="px-4 py-2 font-mono text-xs text-slate-700 break-all">
+                    {row.entity}
+                    {row.entityId ? <span className="text-slate-500">/{row.entityId}</span> : null}
+                  </td>
+                  <td className="px-4 py-2">
+                    {row.before || row.after ? (
+                      <details>
+                        <summary className="cursor-pointer text-xs text-blue-600">
+                          {row.after ? "after" : "before"}
+                          {row.before && row.after ? " / before" : ""}
+                        </summary>
+                        <div className="mt-2 space-y-2">
+                          {row.after ? (
+                            <JsonBlock label="after" value={row.after} />
+                          ) : null}
+                          {row.before ? (
+                            <JsonBlock label="before" value={row.before} />
+                          ) : null}
+                        </div>
+                      </details>
+                    ) : (
+                      <span className="text-slate-400 text-xs">—</span>
+                    )}
+                  </td>
+                  <td className="px-4 py-2 text-xs text-slate-500 font-mono">
+                    {row.ipAddress ?? "—"}
+                  </td>
+                </tr>
+              ))}
+            </tbody>
+          </table>
+        )}
+      </div>
+
+      {/* ─── Pagination ──────────────────────────────────────────── */}
+      <div className="mt-4 flex items-center justify-between text-sm text-slate-600">
+        <div>{rows.length} row{rows.length === 1 ? "" : "s"} on this page</div>
+        {nextHref ? (
+          <Link
+            href={nextHref}
+            className="inline-flex items-center rounded-md border border-slate-300 bg-white px-3 py-1.5 text-sm hover:bg-slate-50"
+          >
+            Older →
+          </Link>
+        ) : (
+          <span className="text-slate-400">End of log</span>
+        )}
+      </div>
+    </div>
+  );
+}
+
+/**
+ * Pretty-prints a JSON audit payload. Falls back to the raw string if the
+ * row happens to contain non-JSON (older rows, or writes that logged a
+ * free-form message).
+ */
+function JsonBlock({ label, value }: { label: string; value: string }) {
+  let pretty = value;
+  try {
+    pretty = JSON.stringify(JSON.parse(value), null, 2);
+  } catch {
+    // leave as-is
+  }
+  return (
+    <div>
+      <div className="text-[10px] uppercase tracking-wide text-slate-500">{label}</div>
+      <pre className="mt-1 text-xs bg-slate-50 border border-slate-200 rounded-md p-2 overflow-x-auto">
+        {pretty}
+      </pre>
+    </div>
+  );
+}

app/admin/layout.tsx

@@ -18,6 +18,8 @@ export default async function AdminLayout({ children }: { children: React.ReactN
             <Link href="/admin/machines" className="hover:text-slate-900">Machines</Link>
             <Link href="/admin/operations" className="hover:text-slate-900">Operation templates</Link>
             <Link href="/admin/users" className="hover:text-slate-900">Users</Link>
+            <Link href="/admin/reports" className="hover:text-slate-900">Reports</Link>
+            <Link href="/admin/audit" className="hover:text-slate-900">Audit</Link>
           </nav>
           <div className="ml-auto flex items-center gap-3 text-sm">
             <span className="text-slate-500">{user.name}</span>

app/admin/page.tsx

@@ -1,20 +1,40 @@
 import Link from "next/link";
 import { prisma } from "@/lib/prisma";
+import {
+  getWipOperations,
+  getOverdueProjects,
+  getAuditLog,
+  getQcFailures,
+  formatRelative,
+} from "@/lib/reports";
 
 export const dynamic = "force-dynamic";
 
+/**
+ * Admin landing. Three jobs:
+ *   1. Top tiles — counts so the shop owner can spot a drop-off at a glance.
+ *   2. WIP + Overdue cards — "what's hot right now, what's slipping."
+ *   3. Recent activity — last handful of audit rows, linking to full log.
+ *
+ * Data comes from lib/reports.ts; the page itself is a dumb composition.
+ */
 export default async function AdminDashboardPage() {
+  const now = new Date();
   const [
     projectsTotal,
     projectsActive,
     assembliesTotal,
     partsTotal,
     operationsTotal,
-    operationsInProgress,
+    operationsActive,
     machinesActive,
     templatesActive,
     operatorsActive,
     adminsActive,
+    wip,
+    overdue,
+    qcFailures,
+    { rows: recentAudit },
     recentProjects,
   ] = await Promise.all([
     prisma.project.count(),
@@ -22,11 +42,15 @@ export default async function AdminDashboardPage() {
     prisma.assembly.count(),
     prisma.part.count(),
     prisma.operation.count(),
-    prisma.operation.count({ where: { status: "in_progress" } }),
+    prisma.operation.count({ where: { status: { in: ["in_progress", "partial"] } } }),
     prisma.machine.count({ where: { active: true } }),
     prisma.operationTemplate.count({ where: { active: true } }),
     prisma.user.count({ where: { role: "operator", active: true } }),
     prisma.user.count({ where: { role: "admin", active: true } }),
+    getWipOperations(20),
+    getOverdueProjects(now, 10),
+    getQcFailures(10),
+    getAuditLog({ limit: 8 }),
     prisma.project.findMany({
       orderBy: { updatedAt: "desc" },
       take: 5,
@@ -57,7 +81,7 @@ export default async function AdminDashboardPage() {
           href="/admin/projects"
           title="Operations"
           primary={operationsTotal}
-          secondary={`${operationsInProgress} in progress`}
+          secondary={`${operationsActive} in progress or partial`}
         />
         <Tile
           href="/admin/machines"
@@ -77,12 +101,246 @@ export default async function AdminDashboardPage() {
           primary={adminsActive + operatorsActive}
           secondary={`${adminsActive} admin${adminsActive === 1 ? "" : "s"} · ${operatorsActive} operator${operatorsActive === 1 ? "" : "s"}`}
         />
-        <div className="rounded-xl bg-white border border-slate-200 p-5">
+        <Tile
-          <h2 className="font-medium text-slate-700">Fasteners & POs</h2>
+          href="/admin/reports"
-          <p className="text-sm text-slate-500 mt-1">Purchasing lifecycle lands in step 6.</p>
+          title="Hours report"
-        </div>
+          primary={"→"}
+          secondary="Plan vs actual by machine and operator"
+        />
       </div>
 
+      {/* ─── Work in progress ─────────────────────────────────────── */}
+      <section className="mt-10">
+        <div className="flex items-center justify-between mb-3">
+          <div>
+            <h2 className="text-lg font-semibold">Work in progress</h2>
+            <p className="text-xs text-slate-500">
+              Active claims plus resumable (partial) steps. {wip.length} shown.
+            </p>
+          </div>
+        </div>
+        <div className="rounded-xl bg-white border border-slate-200 overflow-hidden">
+          {wip.length === 0 ? (
+            <p className="px-4 py-10 text-center text-slate-500 text-sm">
+              Nothing active. Operators scan travelers to begin a step.
+            </p>
+          ) : (
+            <table className="w-full text-sm">
+              <thead className="bg-slate-50 text-left text-slate-600 border-b border-slate-200">
+                <tr>
+                  <th className="px-4 py-2 font-medium">Project · Part</th>
+                  <th className="px-4 py-2 font-medium">Step</th>
+                  <th className="px-4 py-2 font-medium">Machine</th>
+                  <th className="px-4 py-2 font-medium">Operator</th>
+                  <th className="px-4 py-2 font-medium">Status</th>
+                  <th className="px-4 py-2 font-medium">Progress</th>
+                </tr>
+              </thead>
+              <tbody>
+                {wip.map((op) => {
+                  const totalUnits = op.part.qty * op.part.assembly.qty;
+                  return (
+                    <tr key={op.id} className="border-b border-slate-100 last:border-0">
+                      <td className="px-4 py-2">
+                        <Link
+                          href={`/admin/projects/${op.part.assembly.project.id}/assemblies/${op.part.assembly.id}/parts/${op.part.id}`}
+                          className="text-blue-600 hover:underline"
+                        >
+                          <span className="font-mono">{op.part.assembly.project.code}</span>
+                          {" · "}
+                          <span className="font-mono">{op.part.code}</span>
+                        </Link>
+                        <div className="text-xs text-slate-500">{op.part.name}</div>
+                      </td>
+                      <td className="px-4 py-2">
+                        <span className="text-slate-700">#{op.sequence}</span>{" "}
+                        <span className="text-slate-900">{op.name}</span>
+                      </td>
+                      <td className="px-4 py-2 text-slate-600">
+                        {op.machine?.name ?? <span className="text-slate-400">—</span>}
+                      </td>
+                      <td className="px-4 py-2 text-slate-700">
+                        {op.claimedBy?.name ?? <span className="text-slate-400">—</span>}
+                        {op.claimedAt ? (
+                          <div className="text-xs text-slate-500">
+                            since {formatRelative(op.claimedAt, now)}
+                          </div>
+                        ) : null}
+                      </td>
+                      <td className="px-4 py-2">
+                        <StatusPill status={op.status} />
+                      </td>
+                      <td className="px-4 py-2 text-slate-600">
+                        {op.unitsCompleted} / {totalUnits}
+                      </td>
+                    </tr>
+                  );
+                })}
+              </tbody>
+            </table>
+          )}
+        </div>
+      </section>
+
+      {/* ─── Overdue projects ─────────────────────────────────────── */}
+      <section className="mt-10">
+        <h2 className="text-lg font-semibold mb-3">Overdue projects</h2>
+        <div className="rounded-xl bg-white border border-slate-200 overflow-hidden">
+          {overdue.length === 0 ? (
+            <p className="px-4 py-10 text-center text-slate-500 text-sm">
+              Nothing overdue. Due dates live on the project edit screen.
+            </p>
+          ) : (
+            <table className="w-full text-sm">
+              <thead className="bg-slate-50 text-left text-slate-600 border-b border-slate-200">
+                <tr>
+                  <th className="px-4 py-2 font-medium">Code</th>
+                  <th className="px-4 py-2 font-medium">Name</th>
+                  <th className="px-4 py-2 font-medium">Due</th>
+                  <th className="px-4 py-2 font-medium">Late</th>
+                  <th className="px-4 py-2 font-medium">Progress</th>
+                </tr>
+              </thead>
+              <tbody>
+                {overdue.map((p) => (
+                  <tr key={p.id} className="border-b border-slate-100 last:border-0">
+                    <td className="px-4 py-2 font-mono">
+                      <Link href={`/admin/projects/${p.id}`} className="text-blue-600 hover:underline">
+                        {p.code}
+                      </Link>
+                    </td>
+                    <td className="px-4 py-2">{p.name}</td>
+                    <td className="px-4 py-2 text-slate-600">{p.dueDate.toLocaleDateString()}</td>
+                    <td className="px-4 py-2 text-red-600 font-medium">{p.daysLate}d</td>
+                    <td className="px-4 py-2">
+                      <div className="flex items-center gap-2">
+                        <div className="h-1.5 w-24 rounded-full bg-slate-100 overflow-hidden">
+                          <div
+                            className="h-full bg-emerald-500"
+                            style={{ width: `${p.progressPct}%` }}
+                          />
+                        </div>
+                        <span className="text-xs text-slate-600">
+                          {p.completedOps}/{p.totalOps} ops · {p.progressPct}%
+                        </span>
+                      </div>
+                    </td>
+                  </tr>
+                ))}
+              </tbody>
+            </table>
+          )}
+        </div>
+      </section>
+
+      {/* ─── QC failures ──────────────────────────────────────────── */}
+      {qcFailures.length > 0 ? (
+        <section className="mt-10">
+          <div className="flex items-center justify-between mb-3">
+            <div>
+              <h2 className="text-lg font-semibold text-red-800">QC failures</h2>
+              <p className="text-xs text-slate-500">
+                Steps blocked by a failing inspection. Open the part to review and hit{" "}
+                <span className="font-medium">Reset QC</span> to reopen for rework.
+              </p>
+            </div>
+          </div>
+          <div className="rounded-xl bg-white border border-red-200 overflow-hidden">
+            <table className="w-full text-sm">
+              <thead className="bg-red-50 text-left text-red-900 border-b border-red-200">
+                <tr>
+                  <th className="px-4 py-2 font-medium">Project · Part</th>
+                  <th className="px-4 py-2 font-medium">Step</th>
+                  <th className="px-4 py-2 font-medium">Kind</th>
+                  <th className="px-4 py-2 font-medium">Failed by</th>
+                  <th className="px-4 py-2 font-medium">Notes</th>
+                  <th className="px-4 py-2 font-medium">When</th>
+                </tr>
+              </thead>
+              <tbody>
+                {qcFailures.map((op) => {
+                  const last = op.qcRecords[0] ?? null;
+                  return (
+                    <tr key={op.id} className="border-b border-slate-100 last:border-0 align-top">
+                      <td className="px-4 py-2">
+                        <Link
+                          href={`/admin/projects/${op.part.assembly.project.id}/assemblies/${op.part.assembly.id}/parts/${op.part.id}`}
+                          className="text-blue-600 hover:underline"
+                        >
+                          <span className="font-mono">{op.part.assembly.project.code}</span>
+                          {" · "}
+                          <span className="font-mono">{op.part.code}</span>
+                        </Link>
+                        <div className="text-xs text-slate-500">{op.part.name}</div>
+                      </td>
+                      <td className="px-4 py-2">
+                        <span className="text-slate-700">#{op.sequence}</span>{" "}
+                        <span className="text-slate-900">{op.name}</span>
+                      </td>
+                      <td className="px-4 py-2 text-slate-600">
+                        {op.kind === "qc" ? "Inspection" : "Work"}
+                      </td>
+                      <td className="px-4 py-2 text-slate-700">
+                        {last?.operator.name ?? <span className="text-slate-400">—</span>}
+                      </td>
+                      <td className="px-4 py-2 text-slate-600 max-w-[24ch]">
+                        {last?.notes ? (
+                          <span className="line-clamp-2" title={last.notes}>
+                            {last.notes}
+                          </span>
+                        ) : (
+                          <span className="text-slate-400">—</span>
+                        )}
+                      </td>
+                      <td className="px-4 py-2 text-slate-500 text-xs whitespace-nowrap">
+                        {last ? formatRelative(last.createdAt, now) : formatRelative(op.updatedAt, now)}
+                      </td>
+                    </tr>
+                  );
+                })}
+              </tbody>
+            </table>
+          </div>
+        </section>
+      ) : null}
+
+      {/* ─── Recent activity (audit log peek) ───────────────────── */}
+      <section className="mt-10">
+        <div className="flex items-center justify-between mb-3">
+          <h2 className="text-lg font-semibold">Recent activity</h2>
+          <Link href="/admin/audit" className="text-sm text-blue-600 hover:underline">
+            Full audit log →
+          </Link>
+        </div>
+        <div className="rounded-xl bg-white border border-slate-200 overflow-hidden">
+          {recentAudit.length === 0 ? (
+            <p className="px-4 py-10 text-center text-slate-500 text-sm">No activity yet.</p>
+          ) : (
+            <ul className="divide-y divide-slate-100">
+              {recentAudit.map((row) => (
+                <li key={row.id} className="px-4 py-2 flex items-start gap-3 text-sm">
+                  <span className="text-xs text-slate-500 w-24 shrink-0 mt-0.5">
+                    {formatRelative(row.at, now)}
+                  </span>
+                  <span className="flex-1">
+                    <span className="font-medium text-slate-900">
+                      {row.actor?.name ?? "system"}
+                    </span>
+                    <span className="text-slate-500"> · {row.action}</span>
+                    <span className="text-slate-500"> · </span>
+                    <span className="font-mono text-xs text-slate-600">
+                      {row.entity}
+                      {row.entityId ? `/${row.entityId.slice(0, 8)}` : ""}
+                    </span>
+                  </span>
+                </li>
+              ))}
+            </ul>
+          )}
+        </div>
+      </section>
+
+      {/* ─── Recent projects ─────────────────────────────────────── */}
       <section className="mt-10">
         <div className="flex items-center justify-between mb-3">
           <h2 className="text-lg font-semibold">Recent projects</h2>
@@ -148,7 +406,7 @@ function Tile({
 }: {
   href: string;
   title: string;
-  primary: number;
+  primary: number | string;
   secondary: string;
 }) {
   return (
@@ -162,3 +420,21 @@ function Tile({
     </Link>
   );
 }
+
+function StatusPill({ status }: { status: string }) {
+  const tone =
+    status === "in_progress"
+      ? "bg-blue-100 text-blue-800"
+      : status === "partial"
+        ? "bg-orange-100 text-orange-800"
+        : status === "qc_failed"
+          ? "bg-red-100 text-red-800"
+          : "bg-slate-100 text-slate-700";
+  const label =
+    status === "in_progress" ? "in progress" : status === "qc_failed" ? "QC failed" : status;
+  return (
+    <span className={`inline-flex items-center rounded-full text-xs px-2 py-0.5 ${tone}`}>
+      {label}
+    </span>
+  );
+}

app/admin/projects/[id]/assemblies/[assemblyId]/parts/[partId]/PartDetailClient.tsx

@@ -54,6 +54,7 @@ export interface OperationRow {
   id: string;
   sequence: number;
   name: string;
+  kind: string;
   machineId: string | null;
   machineName: string | null;
   templateId: string | null;
@@ -89,6 +90,7 @@ const STATUS_TONE: Record<string, "slate" | "blue" | "green" | "amber" | "red">
   in_progress: "blue",
   partial: "amber",
   completed: "green",
+  qc_failed: "red",
 };
 
 const STATUS_LABEL: Record<string, string> = {
@@ -96,6 +98,7 @@ const STATUS_LABEL: Record<string, string> = {
   in_progress: "In progress",
   partial: "Partial",
   completed: "Completed",
+  qc_failed: "QC failed",
 };
 
 function formatBytes(n: number) {
@@ -295,6 +298,26 @@ function OperationsSection({
     }
   }
 
+  async function resetQc(op: OperationRow) {
+    if (
+      !confirm(
+        `Clear QC failure on step ${op.sequence}. ${op.name}? The step will reopen for rework; the failing QC record stays on file.`,
+      )
+    ) {
+      return;
+    }
+    setBusyId(op.id);
+    setError(null);
+    try {
+      await apiFetch(`/api/v1/operations/${op.id}/qc-reset`, { method: "POST" });
+      onChange();
+    } catch (err) {
+      setError(err instanceof ApiClientError ? err.message : "Reset failed");
+    } finally {
+      setBusyId(null);
+    }
+  }
+
   return (
     <section>
       <div className="flex items-center justify-between mb-3">
@@ -322,7 +345,10 @@ function OperationsSection({
               <tr key={op.id} className="border-b border-slate-100 last:border-0">
                 <td className="px-3 py-3 text-slate-600">{op.sequence}</td>
                 <td className="px-3 py-3">
-                  <div className="font-medium">{op.name}</div>
+                  <div className="font-medium flex items-center gap-2">
+                    <span>{op.name}</span>
+                    {op.kind === "qc" ? <Badge tone="blue">QC step</Badge> : null}
+                  </div>
                   {op.templateName ? (
                     <div className="text-xs text-slate-500">from {op.templateName}</div>
                   ) : null}
@@ -376,6 +402,16 @@ function OperationsSection({
                   <Button variant="ghost" size="sm" onClick={() => setEdit(op)} disabled={busyId !== null}>
                     Edit
                   </Button>
+                  {op.status === "qc_failed" ? (
+                    <Button
+                      variant="ghost"
+                      size="sm"
+                      onClick={() => resetQc(op)}
+                      disabled={busyId !== null}
+                    >
+                      Reset QC
+                    </Button>
+                  ) : null}
                   <Button
                     variant="ghost"
                     size="sm"
@@ -528,6 +564,9 @@ function OperationModal({
   const editing = !!operation;
   const [templateId, setTemplateId] = useState(operation?.templateId ?? "");
   const [name, setName] = useState(operation?.name ?? "");
+  const [kind, setKind] = useState<"work" | "qc">(
+    (operation?.kind as "work" | "qc") ?? "work",
+  );
   const [machineId, setMachineId] = useState(operation?.machineId ?? "");
   const [settings, setSettings] = useState(operation?.settings ?? "");
   const [materialNotes, setMaterialNotes] = useState(operation?.materialNotes ?? "");
@@ -563,6 +602,7 @@ function OperationModal({
       const body = {
         templateId: templateId || null,
         name,
+        kind,
         machineId: machineId || null,
         settings,
         materialNotes,
@@ -623,6 +663,15 @@ function OperationModal({
         <Field label="Name" required>
           <Input value={name} onChange={(e) => setName(e.target.value)} required />
         </Field>
+        <Field
+          label="Kind"
+          hint='"Work" is a normal production step. "QC" is a dedicated inspection step — close always demands a pass/fail record and unit counts are ignored.'
+        >
+          <Select value={kind} onChange={(e) => setKind(e.target.value as "work" | "qc")}>
+            <option value="work">Work — production step</option>
+            <option value="qc">QC — dedicated inspection</option>
+          </Select>
+        </Field>
         <Field label="Machine">
           <Select value={machineId} onChange={(e) => setMachineId(e.target.value)}>
             <option value="">— none —</option>
@@ -669,12 +718,16 @@ function OperationModal({
           <span>QC check required on close-out</span>
         </label>
         {editing && (
-          <Field label="Status">
+          <Field
+            label="Status"
+            hint="Use QC-failed only if you need to block a step out-of-band; the normal path is for the operator's Done/fail to set it."
+          >
             <Select value={status} onChange={(e) => setStatus(e.target.value)}>
               <option value="pending">Pending</option>
               <option value="in_progress">In progress</option>
               <option value="partial">Partial</option>
               <option value="completed">Completed</option>
+              <option value="qc_failed">QC failed</option>
             </Select>
           </Field>
         )}

app/admin/projects/[id]/assemblies/[assemblyId]/parts/[partId]/page.tsx

@@ -86,6 +86,7 @@ export default async function AdminPartDetailPage({
         id: op.id,
         sequence: op.sequence,
         name: op.name,
+        kind: op.kind,
         machineId: op.machineId,
         machineName: op.machine?.name ?? null,
         templateId: op.templateId,

app/admin/reports/page.tsx

@@ -0,0 +1,228 @@
+import Link from "next/link";
+import { getHoursReport, formatMinutes } from "@/lib/reports";
+
+export const dynamic = "force-dynamic";
+
+/**
+ * Plan-vs-actual hours report.
+ *
+ * Two tables: by machine, by operator. Durations come from closed TimeLog
+ * rows in the selected window (default: last 30 days). "Plan" is the sum
+ * of Operation.plannedMinutes for ops that had ANY TimeLog in the window
+ * — scoped the same way as actual so the two columns are apples-to-apples.
+ * Operator plans don't exist in the schema (an op has no planned operator),
+ * so the operator table only shows actuals.
+ */
+
+type RangeKey = "7d" | "30d" | "90d" | "all";
+
+function rangeStart(key: RangeKey): Date {
+  const now = new Date();
+  if (key === "all") return new Date(0);
+  const days = key === "7d" ? 7 : key === "30d" ? 30 : 90;
+  return new Date(now.getTime() - days * 86_400_000);
+}
+
+function isRange(v: unknown): v is RangeKey {
+  return v === "7d" || v === "30d" || v === "90d" || v === "all";
+}
+
+export default async function ReportsPage({
+  searchParams,
+}: {
+  searchParams: Promise<{ range?: string }>;
+}) {
+  const { range: rawRange } = await searchParams;
+  const range: RangeKey = isRange(rawRange) ? rawRange : "30d";
+  const since = rangeStart(range);
+  const report = await getHoursReport(since);
+
+  const planVarianceClass = (actual: number, planned: number | null) => {
+    if (planned == null) return "text-slate-500";
+    if (planned === 0) return "text-slate-500";
+    const ratio = actual / planned;
+    if (ratio > 1.15) return "text-red-600 font-medium";
+    if (ratio < 0.85) return "text-emerald-600 font-medium";
+    return "text-slate-700";
+  };
+
+  return (
+    <div className="mx-auto max-w-7xl px-4 py-8">
+      <div className="flex items-center justify-between mb-6">
+        <div>
+          <h1 className="text-2xl font-semibold tracking-tight">Hours report</h1>
+          <p className="text-slate-500 mt-1 text-sm">
+            Plan vs actual based on closed time logs. Longer sessions where an operator
+            paused and resumed count every segment separately.
+          </p>
+        </div>
+        <nav className="flex items-center gap-1 text-sm rounded-md border border-slate-200 bg-white p-1">
+          {(["7d", "30d", "90d", "all"] as const).map((k) => (
+            <Link
+              key={k}
+              href={`/admin/reports?range=${k}`}
+              className={`px-3 py-1 rounded ${
+                k === range
+                  ? "bg-slate-900 text-white"
+                  : "text-slate-600 hover:text-slate-900 hover:bg-slate-50"
+              }`}
+            >
+              {k === "all" ? "All time" : `Last ${k}`}
+            </Link>
+          ))}
+        </nav>
+      </div>
+
+      {/* ─── Summary strip ───────────────────────────────────────── */}
+      <div className="grid gap-4 sm:grid-cols-3 mb-8">
+        <SummaryCard
+          label="Total actual"
+          value={formatMinutes(report.totalActualMinutes)}
+          hint="Summed across every closed TimeLog"
+        />
+        <SummaryCard
+          label="Total planned"
+          value={report.totalPlannedMinutes > 0 ? formatMinutes(report.totalPlannedMinutes) : "—"}
+          hint="Sum of plannedMinutes for ops touched in range"
+        />
+        <SummaryCard
+          label="Variance"
+          value={
+            report.totalPlannedMinutes > 0
+              ? `${Math.round(
+                  ((report.totalActualMinutes - report.totalPlannedMinutes) /
+                    report.totalPlannedMinutes) *
+                    100,
+                )}%`
+              : "—"
+          }
+          hint="Positive means actual > plan"
+          tone={
+            report.totalPlannedMinutes === 0
+              ? "neutral"
+              : report.totalActualMinutes > report.totalPlannedMinutes * 1.15
+                ? "bad"
+                : report.totalActualMinutes < report.totalPlannedMinutes * 0.85
+                  ? "good"
+                  : "neutral"
+          }
+        />
+      </div>
+
+      {/* ─── By machine ──────────────────────────────────────────── */}
+      <section className="mb-8">
+        <h2 className="text-lg font-semibold mb-3">By machine</h2>
+        <div className="rounded-xl bg-white border border-slate-200 overflow-hidden">
+          {report.byMachine.length === 0 ? (
+            <p className="px-4 py-10 text-center text-slate-500 text-sm">
+              No machine-attached time in this window.
+            </p>
+          ) : (
+            <table className="w-full text-sm">
+              <thead className="bg-slate-50 text-left text-slate-600 border-b border-slate-200">
+                <tr>
+                  <th className="px-4 py-2 font-medium">Machine</th>
+                  <th className="px-4 py-2 font-medium">Ops</th>
+                  <th className="px-4 py-2 font-medium">Planned</th>
+                  <th className="px-4 py-2 font-medium">Actual</th>
+                  <th className="px-4 py-2 font-medium">Variance</th>
+                </tr>
+              </thead>
+              <tbody>
+                {report.byMachine.map((row) => (
+                  <tr key={row.id} className="border-b border-slate-100 last:border-0">
+                    <td className="px-4 py-2">{row.name}</td>
+                    <td className="px-4 py-2 text-slate-600">{row.operations}</td>
+                    <td className="px-4 py-2 text-slate-700">
+                      {row.plannedMinutes == null ? "—" : formatMinutes(row.plannedMinutes)}
+                    </td>
+                    <td
+                      className={`px-4 py-2 ${planVarianceClass(
+                        row.actualMinutes,
+                        row.plannedMinutes,
+                      )}`}
+                    >
+                      {formatMinutes(row.actualMinutes)}
+                    </td>
+                    <td className="px-4 py-2 text-slate-600">
+                      {row.plannedMinutes == null || row.plannedMinutes === 0
+                        ? "—"
+                        : `${Math.round(
+                            ((row.actualMinutes - row.plannedMinutes) / row.plannedMinutes) * 100,
+                          )}%`}
+                    </td>
+                  </tr>
+                ))}
+                {report.unassignedMachineMinutes > 0 && (
+                  <tr className="border-t border-slate-200 bg-slate-50 text-xs text-slate-500">
+                    <td className="px-4 py-2 italic">Ops without a machine assigned</td>
+                    <td className="px-4 py-2">—</td>
+                    <td className="px-4 py-2">—</td>
+                    <td className="px-4 py-2">{formatMinutes(report.unassignedMachineMinutes)}</td>
+                    <td className="px-4 py-2">—</td>
+                  </tr>
+                )}
+              </tbody>
+            </table>
+          )}
+        </div>
+      </section>
+
+      {/* ─── By operator ─────────────────────────────────────────── */}
+      <section>
+        <h2 className="text-lg font-semibold mb-3">By operator</h2>
+        <p className="text-xs text-slate-500 mb-3">
+          Plans are per-operation, not per-operator, so only actual time is shown here.
+        </p>
+        <div className="rounded-xl bg-white border border-slate-200 overflow-hidden">
+          {report.byOperator.length === 0 ? (
+            <p className="px-4 py-10 text-center text-slate-500 text-sm">
+              No operator time in this window.
+            </p>
+          ) : (
+            <table className="w-full text-sm">
+              <thead className="bg-slate-50 text-left text-slate-600 border-b border-slate-200">
+                <tr>
+                  <th className="px-4 py-2 font-medium">Operator</th>
+                  <th className="px-4 py-2 font-medium">Ops touched</th>
+                  <th className="px-4 py-2 font-medium">Actual</th>
+                </tr>
+              </thead>
+              <tbody>
+                {report.byOperator.map((row) => (
+                  <tr key={row.id} className="border-b border-slate-100 last:border-0">
+                    <td className="px-4 py-2">{row.name}</td>
+                    <td className="px-4 py-2 text-slate-600">{row.operations}</td>
+                    <td className="px-4 py-2 text-slate-700">{formatMinutes(row.actualMinutes)}</td>
+                  </tr>
+                ))}
+              </tbody>
+            </table>
+          )}
+        </div>
+      </section>
+    </div>
+  );
+}
+
+function SummaryCard({
+  label,
+  value,
+  hint,
+  tone = "neutral",
+}: {
+  label: string;
+  value: string;
+  hint: string;
+  tone?: "neutral" | "good" | "bad";
+}) {
+  const valueClass =
+    tone === "bad" ? "text-red-600" : tone === "good" ? "text-emerald-600" : "text-slate-900";
+  return (
+    <div className="rounded-xl bg-white border border-slate-200 p-5">
+      <p className="text-xs text-slate-500">{label}</p>
+      <p className={`text-2xl font-semibold tracking-tight mt-1 ${valueClass}`}>{value}</p>
+      <p className="text-xs text-slate-500 mt-1">{hint}</p>
+    </div>
+  );
+}

app/api/v1/operations/[id]/claim/route.ts

@@ -27,6 +27,13 @@ export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string
     if (existing.status === "completed") {
       throw new ApiError(409, "op_completed", "This step is already completed");
     }
+    if (existing.status === "qc_failed") {
+      throw new ApiError(
+        409,
+        "op_qc_failed",
+        "This step failed QC and is locked until an admin resets it",
+      );
+    }
     if (existing.claimedByUserId && existing.claimedByUserId !== actor.id) {
       throw new ApiError(409, "op_claimed", "Another operator is already working on this step");
     }

app/api/v1/operations/[id]/close/route.ts

@@ -28,6 +28,7 @@ export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string
       select: {
         id: true,
         status: true,
+        kind: true,
         claimedByUserId: true,
         qcRequired: true,
         unitsCompleted: true,
@@ -46,8 +47,18 @@ export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string
     if (existing.status !== "in_progress") {
       throw new ApiError(409, "op_not_active", "Step is not active");
     }
-    if (existing.qcRequired && !body.qc) {
+    // Dedicated QC ops (kind="qc") are all-about-QC — always demand the inline
-      throw new ApiError(400, "qc_required", "This step requires an inline QC check before completing");
+    // payload. Regular work ops only demand it when the template/op was flagged
+    // qcRequired. Either way, without a QC block we short-circuit.
+    const qcMandatory = existing.kind === "qc" || existing.qcRequired;
+    if (qcMandatory && !body.qc) {
+      throw new ApiError(
+        400,
+        "qc_required",
+        existing.kind === "qc"
+          ? "QC result is required to complete an inspection step"
+          : "This step requires an inline QC check before completing",
+      );
     }
 
     // --- Partial vs fully-done detection --------------------------------
@@ -63,11 +74,23 @@ export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string
     //
     // QC-required ops still demand a QC record even on partial close —
     // that's about material checks, not about finishing the batch.
+    // QC ops don't track units at all; treat them as "done" by default.
     const units = body.unitsProcessed ?? 0;
     const totalUnits = existing.part.assembly.qty * existing.part.qty;
     const remaining = Math.max(0, totalUnits - existing.unitsCompleted);
-    const wouldFinish = units === 0 || units >= remaining;
+    const isQcOp = existing.kind === "qc";
-    const nextStatus: "completed" | "partial" = wouldFinish ? "completed" : "partial";
+    const wouldFinish = isQcOp || units === 0 || units >= remaining;
+
+    // QC failure short-circuits the usual partial-vs-complete decision: the
+    // step moves to `qc_failed` which blocks further work until an admin
+    // clears it via /api/v1/operations/:id/qc-reset. We still log the QC
+    // record + close the timelog so the failure is on the paper trail.
+    const qcFailed = body.qc !== undefined && body.qc.passed === false;
+    const nextStatus: "completed" | "partial" | "qc_failed" = qcFailed
+      ? "qc_failed"
+      : wouldFinish
+        ? "completed"
+        : "partial";
 
     const now = new Date();
     await prisma.$transaction(async (tx) => {
@@ -99,8 +122,9 @@ export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string
       }
       // unitsCompleted is cumulative across pause/resume cycles; on close we
       // add this session's batch so the total reflects everything the step
-      // actually produced. Partial close releases the claim so the next
+      // actually produced. Partial + qc_failed close release the claim so the
-      // operator can resume; completed close sets completedAt for reporting.
+      // next operator (or admin, in the fail case) can act; completed close
+      // sets completedAt for reporting.
       await tx.operation.update({
         where: { id },
         data: {
@@ -114,9 +138,15 @@ export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string
     });
 
     const op = await prisma.operation.findUnique({ where: { id } });
+    const action =
+      nextStatus === "completed"
+        ? "close_op"
+        : nextStatus === "qc_failed"
+          ? "qc_fail_op"
+          : "partial_close_op";
     await audit({
       actorId: actor.id,
-      action: nextStatus === "completed" ? "close_op" : "partial_close_op",
+      action,
       entity: "Operation",
       entityId: id,
       after: {
@@ -128,7 +158,11 @@ export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string
       ipAddress: clientIp(req),
     });
 
-    return ok({ operation: op, partial: nextStatus === "partial" });
+    return ok({
+      operation: op,
+      partial: nextStatus === "partial",
+      qcFailed: nextStatus === "qc_failed",
+    });
   } catch (err) {
     return errorResponse(err);
   }

app/api/v1/operations/[id]/qc-reset/route.ts

@@ -0,0 +1,61 @@
+import { type NextRequest } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { ok, errorResponse, requireRole, ApiError } from "@/lib/api";
+import { audit } from "@/lib/audit";
+import { clientIp } from "@/lib/request";
+
+/**
+ * Admin-only: clear a QC failure so the step can be reworked. We roll the
+ * op back to either `pending` (nothing produced yet — the failed unit was
+ * the first attempt) or `partial` (some units had already been logged as
+ * good before the fail) based on the cumulative `unitsCompleted` counter.
+ *
+ * The failed QCRecord is intentionally LEFT IN PLACE so reporting can still
+ * count rework events — we just unblock the op.
+ */
+export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string }> }) {
+  try {
+    const actor = await requireRole("admin");
+    const { id } = await ctx.params;
+
+    const existing = await prisma.operation.findUnique({
+      where: { id },
+      select: { id: true, status: true, unitsCompleted: true },
+    });
+    if (!existing) throw new ApiError(404, "not_found", "Operation not found");
+    if (existing.status !== "qc_failed") {
+      throw new ApiError(
+        409,
+        "op_not_qc_failed",
+        "Only steps in qc_failed state can be reset",
+      );
+    }
+
+    const nextStatus = existing.unitsCompleted > 0 ? "partial" : "pending";
+    const updated = await prisma.operation.update({
+      where: { id },
+      data: {
+        status: nextStatus,
+        // Claim was already cleared on the failing close; belt-and-braces
+        // defensively zero it here in case something set it back somehow.
+        claimedByUserId: null,
+        claimedAt: null,
+        completedAt: null,
+      },
+    });
+
+    await audit({
+      actorId: actor.id,
+      action: "qc_reset_op",
+      entity: "Operation",
+      entityId: id,
+      before: { status: "qc_failed" },
+      after: { status: nextStatus, unitsCompleted: existing.unitsCompleted },
+      ipAddress: clientIp(req),
+    });
+
+    return ok({ operation: updated });
+  } catch (err) {
+    return errorResponse(err);
+  }
+}

app/api/v1/operations/[id]/route.ts

@@ -70,6 +70,13 @@ export async function PATCH(req: NextRequest, ctx: { params: Promise<{ id: strin
       data: {
         ...(body.templateId !== undefined ? { templateId: body.templateId } : {}),
         ...(body.name !== undefined ? { name: body.name } : {}),
+        // Switching to kind="qc" implicitly flips qcRequired on (an inspection
+        // step without mandatory QC is a contradiction). Switching back to
+        // kind="work" leaves qcRequired alone — the admin can toggle it
+        // explicitly if they want to drop the check.
+        ...(body.kind !== undefined
+          ? { kind: body.kind, ...(body.kind === "qc" ? { qcRequired: true } : {}) }
+          : {}),
         ...(body.machineId !== undefined ? { machineId: body.machineId } : {}),
         ...(body.settings !== undefined ? { settings: body.settings } : {}),
         ...(body.materialNotes !== undefined ? { materialNotes: body.materialNotes } : {}),

app/api/v1/parts/[id]/operations/route.ts

@@ -106,11 +106,14 @@ export async function POST(req: NextRequest, ctx: { params: Promise<{ id: string
         sequence,
         templateId: template?.id ?? null,
         name: body.name,
+        kind: body.kind ?? "work",
         machineId: effectiveMachineId,
         settings: effectiveSettings,
         materialNotes: body.materialNotes ?? null,
         instructions: effectiveInstructions,
-        qcRequired: effectiveQcRequired,
+        // Dedicated inspection ops are always QC-on-close — force the flag on
+        // at create time so downstream code doesn't have to special-case kind.
+        qcRequired: (body.kind ?? "work") === "qc" ? true : effectiveQcRequired,
         plannedMinutes: body.plannedMinutes ?? null,
         plannedUnits: body.plannedUnits ?? null,
         qrToken,

app/op/scan/[token]/ScanClient.tsx

@@ -10,6 +10,7 @@ export type ScanOp = {
   id: string;
   sequence: number;
   name: string;
+  kind: string;
   status: string;
   qcRequired: boolean;
   instructions: string | null;
@@ -70,6 +71,13 @@ export default function ScanClient({ initialOp, viewer }: { initialOp: ScanOp; v
   const active = op.status === "in_progress";
   const partial = op.status === "partial";
   const completed = op.status === "completed";
+  const qcFailed = op.status === "qc_failed";
+  // Dedicated inspection step: we show only the QC panel + Done button and
+  // hide unit counts / partial previews. Close demands a pass/fail record.
+  const isQcStep = op.kind === "qc";
+  // Any path that forces the inline QC block — dedicated QC ops, or work ops
+  // the admin flagged qcRequired.
+  const qcMandatory = isQcStep || op.qcRequired;
 
   // Total units the shop needs to run through this op to satisfy the project:
   //   assembly.qty (how many assemblies we're building) × part.qty (parts per
@@ -133,8 +141,12 @@ export default function ScanClient({ initialOp, viewer }: { initialOp: ScanOp; v
   }
 
   function onClose() {
-    if (op.qcRequired && qcPassed === null) {
+    if (qcMandatory && qcPassed === null) {
-      setError("This step requires QC — mark pass or fail before completing");
+      setError(
+        isQcStep
+          ? "Inspection step — mark pass or fail to complete"
+          : "This step requires QC — mark pass or fail before completing",
+      );
       return;
     }
     startTransition(async () => {
@@ -189,18 +201,26 @@ export default function ScanClient({ initialOp, viewer }: { initialOp: ScanOp; v
                   ? "bg-amber-100 text-amber-800"
                   : partial
                     ? "bg-orange-100 text-orange-800"
-                    : "bg-slate-100 text-slate-700"
+                    : qcFailed
+                      ? "bg-red-100 text-red-800"
+                      : "bg-slate-100 text-slate-700"
             }`}
           >
             {op.status === "in_progress"
               ? "in progress"
               : op.status === "partial"
                 ? "partial"
-                : op.status}
+                : op.status === "qc_failed"
+                  ? "QC failed"
+                  : op.status}
           </span>
-          {op.qcRequired ? (
+          {isQcStep ? (
+            <span className="inline-flex items-center rounded-full bg-blue-100 text-blue-800 text-xs px-2 py-1">
+              Inspection step
+            </span>
+          ) : op.qcRequired ? (
             <span className="inline-flex items-center rounded-full bg-purple-100 text-purple-800 text-xs px-2 py-1">
-              QC
+              QC required
             </span>
           ) : null}
         </div>
@@ -299,7 +319,17 @@ export default function ScanClient({ initialOp, viewer }: { initialOp: ScanOp; v
         </div>
       ) : null}
 
-      {isOperator && !completed ? (
+      {qcFailed ? (
+        <div className="rounded-2xl bg-red-50 border border-red-200 p-5 text-center">
+          <div className="text-red-900 font-semibold">Blocked — QC failed</div>
+          <div className="text-sm text-red-800 mt-1">
+            The last run on this step failed inspection. An admin has to clear the failure
+            before the step can be reworked.
+          </div>
+        </div>
+      ) : null}
+
+      {isOperator && !completed && !qcFailed ? (
         <div className="rounded-2xl bg-white border border-slate-200 p-5 space-y-4">
           {!claimedByMe && op.claimedBy && op.claimedByUserId !== viewer.id ? (
             <div className="rounded-md bg-amber-50 border border-amber-200 text-amber-900 text-sm px-3 py-2">
@@ -316,37 +346,46 @@ export default function ScanClient({ initialOp, viewer }: { initialOp: ScanOp; v
               {isPending
                 ? partial
                   ? "Resuming…"
-                  : "Claiming…"
+                  : isQcStep
+                    ? "Starting inspection…"
+                    : "Claiming…"
                 : partial
                   ? "Resume this step"
-                  : "Start this step"}
+                  : isQcStep
+                    ? "Start inspection"
+                    : "Start this step"}
             </button>
           ) : (
             <>
+              {/* Dedicated QC ops don't track units — the purpose is the
+                  pass/fail record, not a count — so we hide the units input
+                  entirely and keep only the free-form note. */}
               <div className="grid grid-cols-1 gap-3">
-                <label className="block">
+                {!isQcStep ? (
-                  <span className="text-sm font-medium text-slate-900">
+                  <label className="block">
-                    Units processed
+                    <span className="text-sm font-medium text-slate-900">
-                    {op.unitsCompleted > 0 ? (
+                      Units processed
-                      <span className="ml-2 text-xs text-slate-500 font-normal">
+                      {op.unitsCompleted > 0 ? (
-                        {op.unitsCompleted} of {totalUnits} already done
+                        <span className="ml-2 text-xs text-slate-500 font-normal">
-                      </span>
+                          {op.unitsCompleted} of {totalUnits} already done
-                    ) : null}
+                        </span>
-                  </span>
+                      ) : null}
-                  <input
+                    </span>
-                    type="number"
+                    <input
-                    inputMode="numeric"
+                      type="number"
-                    min={0}
+                      inputMode="numeric"
-                    value={units}
+                      min={0}
-                    onChange={(e) => setUnits(e.target.value)}
+                      value={units}
-                    placeholder={
+                      onChange={(e) => setUnits(e.target.value)}
-                      op.unitsCompleted > 0
+                      placeholder={
-                        ? `${Math.max(0, totalUnits - op.unitsCompleted)} remaining`
+                        op.unitsCompleted > 0
-                        : op.plannedUnits?.toString() ?? totalUnits.toString()
+                          ? `${Math.max(0, totalUnits - op.unitsCompleted)} remaining`
-                    }
+                          : op.plannedUnits?.toString() ?? totalUnits.toString()
-                    className="mt-1 w-full rounded-md border border-slate-300 px-3 py-2 text-base"
+                      }
-                  />
+                      className="mt-1 w-full rounded-md border border-slate-300 px-3 py-2 text-base"
-                </label>
+                    />
+                  </label>
+                ) : null}
                 <label className="block">
                   <span className="text-sm font-medium text-slate-900">Note (optional)</span>
                   <textarea
@@ -358,9 +397,11 @@ export default function ScanClient({ initialOp, viewer }: { initialOp: ScanOp; v
                 </label>
               </div>
 
-              {op.qcRequired ? (
+              {qcMandatory ? (
                 <div className="rounded-md bg-purple-50 border border-purple-200 p-3 space-y-2">
-                  <div className="text-sm font-medium text-purple-900">QC check (required)</div>
+                  <div className="text-sm font-medium text-purple-900">
+                    {isQcStep ? "Inspection result (required)" : "QC check (required)"}
+                  </div>
                   <div className="flex gap-2">
                     <button
                       type="button"
@@ -385,6 +426,13 @@ export default function ScanClient({ initialOp, viewer }: { initialOp: ScanOp; v
                       Fail
                     </button>
                   </div>
+                  {qcPassed === false ? (
+                    <div className="rounded-md bg-red-50 border border-red-200 text-red-800 text-xs px-3 py-2">
+                      Submitting <span className="font-semibold">Fail</span> will lock this step
+                      in <span className="font-semibold">QC failed</span> — an admin has to clear
+                      it before anyone can rework it.
+                    </div>
+                  ) : null}
                   {qcPassed !== null ? (
                     <textarea
                       value={qcNotes}
@@ -402,39 +450,55 @@ export default function ScanClient({ initialOp, viewer }: { initialOp: ScanOp; v
                 close route's partial-detection logic: units blank or >=
                 remaining means "fully done", anything less is a partial
                 handoff that releases the claim so the next operator can pick
-                it up.
+                it up. QC ops don't apply — they're all-or-nothing.
               */}
-              {(() => {
+              {!isQcStep
-                const typed = units ? Number(units) : 0;
+                ? (() => {
-                const remaining = Math.max(0, totalUnits - op.unitsCompleted);
+                    const typed = units ? Number(units) : 0;
-                const willPartial = typed > 0 && typed < remaining;
+                    const remaining = Math.max(0, totalUnits - op.unitsCompleted);
-                return willPartial ? (
+                    const willPartial = typed > 0 && typed < remaining;
-                  <div className="rounded-md bg-orange-50 border border-orange-200 text-orange-900 text-xs px-3 py-2">
+                    return willPartial ? (
-                    Pressing <span className="font-semibold">Done</span> with {typed} of {remaining}{" "}
+                      <div className="rounded-md bg-orange-50 border border-orange-200 text-orange-900 text-xs px-3 py-2">
-                    remaining will mark this step <span className="font-semibold">Partial</span> and
+                        Pressing <span className="font-semibold">Done</span> with {typed} of{" "}
-                    release the claim so another operator can resume. Enter{" "}
+                        {remaining} remaining will mark this step{" "}
-                    <span className="font-mono">{remaining}</span> (or leave blank) if you actually
+                        <span className="font-semibold">Partial</span> and release the claim so
-                    finished the batch.
+                        another operator can resume. Enter{" "}
-                  </div>
+                        <span className="font-mono">{remaining}</span> (or leave blank) if you
-                ) : null;
+                        actually finished the batch.
-              })()}
+                      </div>
+                    ) : null;
+                  })()
+                : null}
 
-              <div className="grid grid-cols-2 gap-3">
+              {/* Pause doesn't make sense on a dedicated inspection step —
-                <button
+                  either the checker passes, fails, or walks away without
-                  onClick={onRelease}
+                  stamping anything. Show Done only for QC ops. */}
-                  disabled={isPending}
+              {isQcStep ? (
-                  className="h-14 rounded-xl bg-white border border-slate-300 text-slate-900 text-lg font-medium disabled:opacity-60"
-                >
-                  {isPending ? "…" : "Pause"}
-                </button>
                 <button
                   onClick={onClose}
                   disabled={isPending}
-                  className="h-14 rounded-xl bg-emerald-600 text-white text-lg font-medium disabled:bg-emerald-400"
+                  className="w-full h-14 rounded-xl bg-emerald-600 text-white text-lg font-medium disabled:bg-emerald-400"
                 >
-                  {isPending ? "…" : "Done"}
+                  {isPending ? "…" : qcPassed === false ? "Submit failure" : "Submit inspection"}
                 </button>
-              </div>
+              ) : (
+                <div className="grid grid-cols-2 gap-3">
+                  <button
+                    onClick={onRelease}
+                    disabled={isPending}
+                    className="h-14 rounded-xl bg-white border border-slate-300 text-slate-900 text-lg font-medium disabled:opacity-60"
+                  >
+                    {isPending ? "…" : "Pause"}
+                  </button>
+                  <button
+                    onClick={onClose}
+                    disabled={isPending}
+                    className="h-14 rounded-xl bg-emerald-600 text-white text-lg font-medium disabled:bg-emerald-400"
+                  >
+                    {isPending ? "…" : "Done"}
+                  </button>
+                </div>
+              )}
             </>
           )}
         </div>

docs/BUILD-PLAN.md

@@ -10,16 +10,43 @@ The roadmap agreed at project kickoff. Each step is committed separately so the
 | 4 | Operator scan flow: claim → start → units/notes → QC prompt → close | **done** |
 | 5 | PDF generation: per-operation card + per-part cover sheet | **done** |
 | 6 | Fasteners + PO (PDF + lifecycle: draft → sent → partial → received) | **done** |
-| 7 | Admin dashboard (WIP, overdue, plan-vs-actual) + audit log viewer | planned |
+| 7 | Admin dashboard (WIP, overdue, plan-vs-actual hours by machine/operator) + audit log viewer | **done** |
 | 8 | In-browser STEP viewer + server-side thumbnails | **done** |
-| 9 | QC records (inline checkboxes + dedicated QC operation type) | planned |
+| 9 | QC records (inline checkboxes + dedicated QC op type + fail-handling workflow) | **done** |
 | 10 | OpenAPI docs at `/api/docs`, nightly SQLite backup script | planned |
 
+## Post-kickoff additions
+
+Items that came out of floor-testing, not in the original roadmap.
+
+### Landed
+
+| Step | What | Status |
+| ---- | ---- | ------ |
+| A1 | File attachments on Assembly (STEP / drawing / cut) — shared across all parts in the assembly | **done** |
+| A2 | Quick-link files on operator scan card (drawing + cut tap-targets; STEP rendered inline instead of downloaded) | **done** |
+| A3 | Total quantity to produce (`assembly.qty × part.qty`) shown on scan card, traveler cover, op cards | **done** |
+| A4 | Part + assembly drawing PDFs inlined into the traveler output (cover → assembly drawing → part drawing → op cards) | **done** |
+| A5 | Partial-completion state (`partial` status + cumulative `unitsCompleted` counter); `claim` accepts pending OR partial; `release` → partial when units>0 | **done** |
+| A6 | 3D STEP viewer embedded on operator scan card + admin assembly page (shared `StepViewerPanel`, load-on-tap) | **done** |
+| A7 | "Done" button auto-detects partial: if typed units < remaining, step ends `partial` and releases claim instead of locking `completed` | **done** |
+| A8 | QC fail workflow: `kind="qc"` dedicated inspection steps + `qc_failed` status blocks reclaim until admin hits qc-reset (landed together with Step 9) | **done** |
+
+### Planned
+
+| Step | What | Notes |
+| ---- | ---- | ----- |
+| B1 | Operator `/op` dashboard lists **resumable** ops (`status = "partial"` with no current claim) | Needed because A5+A7 mean partial ops become unclaimed — they currently only re-surface when someone physically re-scans the card |
+| B2 | Progress column on traveler cover + op cards (`X of Y done`) driven by `unitsCompleted` | Makes paper reflect reality when a traveler is re-printed mid-run |
+| ~~B3~~ | ~~QC fail workflow on close~~ | Landed as A8 alongside Step 9 — `qc_failed` locks the step; admin `qc-reset` rolls it back to `pending`/`partial` based on `unitsCompleted` |
+
+Hours-by-machine / plan-vs-actual reporting is already scoped in Step 7. Fresh-testing findings are tracked ad-hoc.
+
 ## Locked design decisions
 
 - **Hierarchy:** Project → Assembly → Part → Operation.
 - **QR granularity:** one QR per Operation; each step prints its own card.
-- **Claim model:** an Operation locks to one operator on Start; other scans of an in-progress operation show a read-only view noting who holds it.
+- **Claim model:** an Operation locks to one operator on Start; other scans of an in-progress operation show a read-only view noting who holds it. `partial` ops are unclaimed and resumable by any operator.
 - **Operators can hold multiple operations at once** (across different parts).
 - **Purchase orders:** PDF generation + lifecycle states (`draft → sent → partial → received → cancelled`).
 - **No offline mode.** The app assumes the shop LAN is up.

lib/reports.ts

@@ -0,0 +1,403 @@
+// Admin-dashboard data-access helpers. Built as plain async functions so admin
+// server components can await them directly (no HTTP round-trip) and we can
+// still expose them under /api/v1 later if a client UI needs live refresh.
+//
+// All of these are read-only. Write paths stay in the existing route handlers.
+
+import { prisma } from "./prisma";
+
+// ---------------------------------------------------------------------------
+// Work-in-progress
+// ---------------------------------------------------------------------------
+
+/**
+ * Operations currently being worked on the shop floor: status is either
+ * `in_progress` (an operator holds the claim) or `partial` (unclaimed but has
+ * unitsCompleted logged — resumable). Ordered newest-claim first so the most
+ * recent activity surfaces at the top of the dashboard.
+ */
+export async function getWipOperations(limit = 50) {
+  const rows = await prisma.operation.findMany({
+    where: { status: { in: ["in_progress", "partial"] } },
+    orderBy: [{ status: "asc" }, { claimedAt: "desc" }, { updatedAt: "desc" }],
+    take: limit,
+    select: {
+      id: true,
+      sequence: true,
+      name: true,
+      status: true,
+      claimedAt: true,
+      unitsCompleted: true,
+      plannedMinutes: true,
+      plannedUnits: true,
+      machine: { select: { name: true, kind: true } },
+      claimedBy: { select: { id: true, name: true } },
+      part: {
+        select: {
+          id: true,
+          code: true,
+          name: true,
+          qty: true,
+          assembly: {
+            select: {
+              id: true,
+              code: true,
+              name: true,
+              qty: true,
+              project: { select: { id: true, code: true, name: true } },
+            },
+          },
+        },
+      },
+    },
+  });
+  return rows;
+}
+
+// ---------------------------------------------------------------------------
+// QC failures (blocked steps)
+// ---------------------------------------------------------------------------
+
+/**
+ * Operations currently in `qc_failed` — an operator stamped a failing QC
+ * record on close and the step is blocked until an admin hits qc-reset.
+ * We surface the most recent failing QCRecord alongside so the dashboard
+ * can show the failing note / who did the inspection without needing a
+ * second round-trip.
+ */
+export async function getQcFailures(limit = 25) {
+  const rows = await prisma.operation.findMany({
+    where: { status: "qc_failed" },
+    orderBy: { updatedAt: "desc" },
+    take: limit,
+    select: {
+      id: true,
+      sequence: true,
+      name: true,
+      kind: true,
+      updatedAt: true,
+      part: {
+        select: {
+          id: true,
+          code: true,
+          name: true,
+          assembly: {
+            select: {
+              id: true,
+              code: true,
+              project: { select: { id: true, code: true, name: true } },
+            },
+          },
+        },
+      },
+      qcRecords: {
+        where: { passed: false },
+        orderBy: { createdAt: "desc" },
+        take: 1,
+        select: {
+          id: true,
+          createdAt: true,
+          notes: true,
+          operator: { select: { id: true, name: true } },
+        },
+      },
+    },
+  });
+  return rows;
+}
+
+// ---------------------------------------------------------------------------
+// Overdue projects
+// ---------------------------------------------------------------------------
+
+/**
+ * Projects whose `dueDate` has passed and which are not yet `completed` /
+ * `cancelled`. We also compute a completion percentage (completed ops /
+ * total ops) so the dashboard can show "40% through, 3 days late" at a
+ * glance. Project is the only entity in the schema with a due-date field;
+ * there's no per-operation deadline.
+ */
+export async function getOverdueProjects(now: Date = new Date(), limit = 50) {
+  const projects = await prisma.project.findMany({
+    where: {
+      dueDate: { lt: now },
+      status: { notIn: ["completed", "cancelled"] },
+    },
+    orderBy: { dueDate: "asc" },
+    take: limit,
+    select: {
+      id: true,
+      code: true,
+      name: true,
+      status: true,
+      dueDate: true,
+      assemblies: {
+        select: {
+          parts: {
+            select: {
+              _count: { select: { operations: true } },
+              operations: { select: { status: true } },
+            },
+          },
+        },
+      },
+    },
+  });
+
+  return projects.map((p) => {
+    let total = 0;
+    let completed = 0;
+    for (const a of p.assemblies) {
+      for (const part of a.parts) {
+        for (const op of part.operations) {
+          total += 1;
+          if (op.status === "completed") completed += 1;
+        }
+      }
+    }
+    return {
+      id: p.id,
+      code: p.code,
+      name: p.name,
+      status: p.status,
+      dueDate: p.dueDate!, // guaranteed non-null by the where clause
+      totalOps: total,
+      completedOps: completed,
+      progressPct: total === 0 ? 0 : Math.round((completed / total) * 100),
+      daysLate: Math.max(0, Math.floor((now.getTime() - p.dueDate!.getTime()) / 86_400_000)),
+    };
+  });
+}
+
+// ---------------------------------------------------------------------------
+// Hours: plan vs actual
+// ---------------------------------------------------------------------------
+//
+// We fetch every closed TimeLog in the window (endedAt IS NOT NULL, inside
+// since..until) and sum durations ourselves rather than using SQL GROUP BY —
+// Prisma's groupBy doesn't support computed duration columns, and a shop
+// floor's TimeLog volume (tens/day) makes in-memory aggregation trivial.
+//
+// "Plan" is the sum of Operation.plannedMinutes scoped the same way: ops
+// that have ANY TimeLog overlapping the window. That keeps plan and actual
+// comparable — we don't count ops the team never touched.
+
+export interface HoursRow {
+  id: string; // machine or operator id
+  name: string;
+  kind: "machine" | "operator";
+  actualMinutes: number;
+  plannedMinutes: number | null; // null when no ops in the window had plans
+  operations: number; // distinct ops touched
+}
+
+export interface HoursReport {
+  sinceIso: string;
+  untilIso: string;
+  byMachine: HoursRow[];
+  byOperator: HoursRow[];
+  unassignedMachineMinutes: number; // ops with machineId null
+  totalActualMinutes: number;
+  totalPlannedMinutes: number;
+}
+
+export async function getHoursReport(since: Date, until: Date = new Date()): Promise<HoursReport> {
+  const logs = await prisma.timeLog.findMany({
+    where: {
+      endedAt: { not: null, gte: since, lte: until },
+    },
+    select: {
+      startedAt: true,
+      endedAt: true,
+      operatorId: true,
+      operator: { select: { name: true } },
+      operation: {
+        select: {
+          id: true,
+          plannedMinutes: true,
+          machineId: true,
+          machine: { select: { name: true } },
+        },
+      },
+    },
+  });
+
+  const byMachine = new Map<string, HoursRow>();
+  const byOperator = new Map<string, HoursRow>();
+  // Ops we've already counted a plan for (plannedMinutes is per-op, not per-log)
+  const planCountedOps = new Set<string>();
+  // Distinct ops seen per bucket, so `operations` isn't double-counted across logs
+  const opsPerMachine = new Map<string, Set<string>>();
+  const opsPerOperator = new Map<string, Set<string>>();
+
+  let unassignedMachineMinutes = 0;
+  let totalActual = 0;
+  let totalPlanned = 0;
+
+  for (const log of logs) {
+    const minutes = Math.max(
+      0,
+      Math.round((log.endedAt!.getTime() - log.startedAt.getTime()) / 60_000),
+    );
+    if (minutes === 0) continue;
+    totalActual += minutes;
+
+    // --- by machine ---
+    const mId = log.operation.machineId;
+    if (mId) {
+      const row = byMachine.get(mId) ?? {
+        id: mId,
+        name: log.operation.machine?.name ?? "(unknown)",
+        kind: "machine" as const,
+        actualMinutes: 0,
+        plannedMinutes: 0,
+        operations: 0,
+      };
+      row.actualMinutes += minutes;
+      byMachine.set(mId, row);
+      const ops = opsPerMachine.get(mId) ?? new Set<string>();
+      ops.add(log.operation.id);
+      opsPerMachine.set(mId, ops);
+    } else {
+      unassignedMachineMinutes += minutes;
+    }
+
+    // --- by operator ---
+    const opRow = byOperator.get(log.operatorId) ?? {
+      id: log.operatorId,
+      name: log.operator.name,
+      kind: "operator" as const,
+      actualMinutes: 0,
+      plannedMinutes: 0,
+      operations: 0,
+    };
+    opRow.actualMinutes += minutes;
+    byOperator.set(log.operatorId, opRow);
+    const ops = opsPerOperator.get(log.operatorId) ?? new Set<string>();
+    ops.add(log.operation.id);
+    opsPerOperator.set(log.operatorId, ops);
+
+    // --- planned total (per-op, once) ---
+    if (log.operation.plannedMinutes != null && !planCountedOps.has(log.operation.id)) {
+      planCountedOps.add(log.operation.id);
+      totalPlanned += log.operation.plannedMinutes;
+      if (mId) {
+        const row = byMachine.get(mId)!;
+        row.plannedMinutes = (row.plannedMinutes ?? 0) + log.operation.plannedMinutes;
+      }
+      // Operator plans don't really make sense (one op, many operators) —
+      // leave byOperator.plannedMinutes at 0 and only show actual in that table.
+    }
+  }
+
+  // Resolve distinct op counts
+  for (const [id, ops] of opsPerMachine) byMachine.get(id)!.operations = ops.size;
+  for (const [id, ops] of opsPerOperator) byOperator.get(id)!.operations = ops.size;
+
+  // Machines without plans → display null so UI shows "—"
+  for (const row of byMachine.values()) {
+    if (row.plannedMinutes === 0) row.plannedMinutes = null;
+  }
+  for (const row of byOperator.values()) row.plannedMinutes = null;
+
+  return {
+    sinceIso: since.toISOString(),
+    untilIso: until.toISOString(),
+    byMachine: [...byMachine.values()].sort((a, b) => b.actualMinutes - a.actualMinutes),
+    byOperator: [...byOperator.values()].sort((a, b) => b.actualMinutes - a.actualMinutes),
+    unassignedMachineMinutes,
+    totalActualMinutes: totalActual,
+    totalPlannedMinutes: totalPlanned,
+  };
+}
+
+// ---------------------------------------------------------------------------
+// Audit log
+// ---------------------------------------------------------------------------
+
+export interface AuditQuery {
+  limit?: number;
+  cursor?: string | null; // AuditLog.id — we order by at desc, so cursor = last id on the page
+  action?: string | null;
+  entity?: string | null;
+  actorId?: string | null;
+  since?: Date | null;
+  until?: Date | null;
+}
+
+export async function getAuditLog(q: AuditQuery = {}) {
+  const limit = Math.min(200, Math.max(1, q.limit ?? 50));
+  const rows = await prisma.auditLog.findMany({
+    where: {
+      ...(q.action ? { action: q.action } : {}),
+      ...(q.entity ? { entity: q.entity } : {}),
+      ...(q.actorId ? { actorId: q.actorId } : {}),
+      ...(q.since || q.until
+        ? { at: { ...(q.since ? { gte: q.since } : {}), ...(q.until ? { lte: q.until } : {}) } }
+        : {}),
+    },
+    orderBy: { at: "desc" },
+    take: limit + 1, // over-fetch by one so we can tell if there's a next page
+    ...(q.cursor ? { cursor: { id: q.cursor }, skip: 1 } : {}),
+    select: {
+      id: true,
+      actorId: true,
+      action: true,
+      entity: true,
+      entityId: true,
+      before: true,
+      after: true,
+      ipAddress: true,
+      at: true,
+      actor: { select: { id: true, name: true, role: true } },
+    },
+  });
+  const hasMore = rows.length > limit;
+  const page = hasMore ? rows.slice(0, limit) : rows;
+  return { rows: page, nextCursor: hasMore ? page[page.length - 1]?.id ?? null : null };
+}
+
+/**
+ * Distinct facet values so the admin filter dropdowns know what to offer
+ * (instead of making the user guess action/entity names).
+ */
+export async function getAuditFacets() {
+  const [actions, entities, actors] = await Promise.all([
+    prisma.auditLog.findMany({ select: { action: true }, distinct: ["action"], orderBy: { action: "asc" } }),
+    prisma.auditLog.findMany({ select: { entity: true }, distinct: ["entity"], orderBy: { entity: "asc" } }),
+    prisma.user.findMany({
+      where: { auditLogs: { some: {} } },
+      select: { id: true, name: true, role: true },
+      orderBy: { name: "asc" },
+    }),
+  ]);
+  return {
+    actions: actions.map((a) => a.action),
+    entities: entities.map((e) => e.entity),
+    actors,
+  };
+}
+
+// ---------------------------------------------------------------------------
+// Formatters (shared across admin pages)
+// ---------------------------------------------------------------------------
+
+export function formatMinutes(m: number): string {
+  if (m < 60) return `${m}m`;
+  const hours = Math.floor(m / 60);
+  const mins = m % 60;
+  return mins === 0 ? `${hours}h` : `${hours}h ${mins}m`;
+}
+
+export function formatRelative(d: Date, now: Date = new Date()): string {
+  const sec = Math.round((now.getTime() - d.getTime()) / 1000);
+  if (sec < 45) return "just now";
+  if (sec < 90) return "a minute ago";
+  const min = Math.round(sec / 60);
+  if (min < 60) return `${min}m ago`;
+  const hr = Math.round(min / 60);
+  if (hr < 24) return `${hr}h ago`;
+  const day = Math.round(hr / 24);
+  if (day < 30) return `${day}d ago`;
+  return d.toLocaleDateString();
+}

lib/schemas.ts

@@ -209,11 +209,28 @@ export const UpdatePartSchema = z
 // Behaves like "pending" for claim purposes (any operator can resume it) but
 // visually distinct so admins can see work-in-flight that isn't actively
 // being run right now.
-export const OperationStatuses = ["pending", "in_progress", "partial", "completed"] as const;
+// "qc_failed" = operator submitted a failing QC record on close. The step is
+// blocked until an admin clears the failure via the qc-reset route (which
+// rolls the step back to pending or partial depending on how much work was
+// already logged against it).
+export const OperationStatuses = [
+  "pending",
+  "in_progress",
+  "partial",
+  "completed",
+  "qc_failed",
+] as const;
+
+// "work" (default) = normal production step; may optionally require QC on close.
+// "qc" = dedicated inspection step — the whole point of the op is the QC
+// record, so close always requires the inline qc payload and we don't care
+// about unit counts or machine assignment.
+export const OperationKinds = ["work", "qc"] as const;
 
 export const CreateOperationSchema = z.object({
   templateId: z.string().min(1).nullable().optional(),
   name: NonEmpty,
+  kind: z.enum(OperationKinds).default("work").optional(),
   machineId: z.string().min(1).nullable().optional(),
   settings: JsonString,
   materialNotes: OptionalText,
@@ -228,6 +245,7 @@ export const UpdateOperationSchema = z
   .object({
     templateId: z.string().min(1).nullable().optional(),
     name: NonEmpty.optional(),
+    kind: z.enum(OperationKinds).optional(),
     machineId: z.string().min(1).nullable().optional(),
     settings: JsonString,
     materialNotes: OptionalText,

prisma/migrations/20260422183000_operation_kind_and_qc_failed/migration.sql

@@ -0,0 +1,4 @@
+-- Adds Operation.kind ("work" | "qc") for dedicated inspection steps.
+-- The `qc_failed` status value is application-level only (status is TEXT),
+-- so no schema change is needed for that — migration is just the column add.
+ALTER TABLE "Operation" ADD COLUMN "kind" TEXT NOT NULL DEFAULT 'work';

prisma/schema.prisma

@@ -167,11 +167,18 @@ model Operation {
   templateId      String?
   name            String
   machineId       String?
+  /// "work" (default) = regular production step, "qc" = dedicated inspection
+  /// step whose entire purpose is pass/fail. QC ops always require a QC record
+  /// on close and don't care about machines/units.
+  kind            String    @default("work") // work | qc
   settings        String? // JSON
   materialNotes   String?
   instructions    String?
   qcRequired      Boolean   @default(false)
-  status          String    @default("pending") // pending | in_progress | partial | completed
+  /// pending | in_progress | partial | completed | qc_failed
+  /// qc_failed: operator submitted QC fail on close — step is blocked until
+  /// an admin resets it via /api/v1/operations/:id/qc-reset.
+  status          String    @default("pending")
   qrToken         String    @unique
   claimedByUserId String?
   claimedAt       DateTime?