bakery-ia/services/procurement/app/services/replenishment_planning_service.py

"""
Replenishment Planning Service

Main orchestrator for advanced procurement planning that integrates:
- Lead time planning
- Inventory projection
- Safety stock calculation
- Shelf life management
"""

from datetime import date, timedelta
from decimal import Decimal
from typing import List, Dict, Optional, Tuple
from dataclasses import dataclass, asdict
import logging
import uuid

from .lead_time_planner import LeadTimePlanner, LeadTimeRequirement, LeadTimePlan
from .inventory_projector import (
    InventoryProjector,
    DailyDemand,
    ScheduledReceipt,
    IngredientProjection
)
from .safety_stock_calculator import SafetyStockCalculator, SafetyStockResult
from .shelf_life_manager import ShelfLifeManager, ShelfLifeAdjustment

logger = logging.getLogger(__name__)


@dataclass
class IngredientRequirement:
    """Complete requirement for one ingredient"""
    ingredient_id: str
    ingredient_name: str
    required_quantity: Decimal
    required_by_date: date
    supplier_id: Optional[str] = None
    lead_time_days: int = 3
    shelf_life_days: Optional[int] = None
    is_perishable: bool = False
    category: str = 'dry'
    unit_of_measure: str = 'kg'
    current_stock: Decimal = Decimal('0')
    daily_consumption_rate: float = 0.0
    demand_std_dev: float = 0.0


@dataclass
class ReplenishmentPlanItem:
    """Single item in replenishment plan"""
    id: str
    ingredient_id: str
    ingredient_name: str

    # Quantities
    base_quantity: Decimal
    safety_stock_quantity: Decimal
    shelf_life_adjusted_quantity: Decimal
    final_order_quantity: Decimal

    # Dates
    order_date: date
    delivery_date: date
    required_by_date: date

    # Metadata
    lead_time_days: int
    is_urgent: bool
    urgency_reason: Optional[str]
    waste_risk: str
    stockout_risk: str
    supplier_id: Optional[str]

    # Calculation details
    safety_stock_calculation: Dict
    shelf_life_adjustment: Dict
    inventory_projection: Optional[Dict]


@dataclass
class ReplenishmentPlan:
    """Complete replenishment plan"""
    plan_id: str
    tenant_id: str
    planning_date: date
    projection_horizon_days: int

    items: List[ReplenishmentPlanItem]

    # Summary statistics
    total_items: int
    urgent_items: int
    high_risk_items: int
    total_estimated_cost: Decimal

    # Metadata
    created_at: date


class ReplenishmentPlanningService:
    """
    Orchestrates advanced replenishment planning.

    Workflow:
    1. Project inventory levels (InventoryProjector)
    2. Identify coverage gaps and required quantities
    3. Calculate safety stock (SafetyStockCalculator)
    4. Adjust for shelf life (ShelfLifeManager)
    5. Calculate order dates (LeadTimePlanner)
    6. Generate complete replenishment plan
    """

    def __init__(
        self,
        projection_horizon_days: int = 7,
        default_service_level: float = 0.95,
        default_buffer_days: int = 1
    ):
        """
        Initialize replenishment planning service.

        Args:
            projection_horizon_days: Days to project ahead
            default_service_level: Default target service level
            default_buffer_days: Default buffer days for orders
        """
        self.projection_horizon_days = projection_horizon_days

        # Initialize sub-services
        self.inventory_projector = InventoryProjector(projection_horizon_days)
        self.safety_stock_calculator = SafetyStockCalculator(default_service_level)
        self.shelf_life_manager = ShelfLifeManager()
        self.lead_time_planner = LeadTimePlanner(default_buffer_days)

    async def generate_replenishment_plan(
        self,
        tenant_id: str,
        requirements: List[IngredientRequirement],
        forecast_id: Optional[str] = None,
        production_schedule_id: Optional[str] = None
    ) -> ReplenishmentPlan:
        """
        Generate complete replenishment plan.

        Args:
            tenant_id: Tenant ID
            requirements: List of ingredient requirements
            forecast_id: Optional reference to forecast
            production_schedule_id: Optional reference to production schedule

        Returns:
            Complete replenishment plan
        """
        plan_id = str(uuid.uuid4())
        planning_date = date.today()

        logger.info(
            f"Generating replenishment plan {plan_id} for {len(requirements)} ingredients"
        )

        plan_items = []

        for req in requirements:
            try:
                item = await self._plan_ingredient_replenishment(req)
                plan_items.append(item)
            except Exception as e:
                logger.error(
                    f"Failed to plan replenishment for {req.ingredient_name}: {e}"
                )
                # Continue with other ingredients

        # Calculate summary statistics
        total_items = len(plan_items)
        urgent_items = sum(1 for item in plan_items if item.is_urgent)
        high_risk_items = sum(
            1 for item in plan_items
            if item.stockout_risk in ['high', 'critical']
        )

        # Estimate total cost (placeholder - need price data)
        total_estimated_cost = sum(
            item.final_order_quantity
            for item in plan_items
        )

        plan = ReplenishmentPlan(
            plan_id=plan_id,
            tenant_id=tenant_id,
            planning_date=planning_date,
            projection_horizon_days=self.projection_horizon_days,
            items=plan_items,
            total_items=total_items,
            urgent_items=urgent_items,
            high_risk_items=high_risk_items,
            total_estimated_cost=total_estimated_cost,
            created_at=planning_date
        )

        logger.info(
            f"Replenishment plan generated: {total_items} items, "
            f"{urgent_items} urgent, {high_risk_items} high risk"
        )

        return plan

    async def _plan_ingredient_replenishment(
        self,
        req: IngredientRequirement
    ) -> ReplenishmentPlanItem:
        """
        Plan replenishment for a single ingredient.

        Args:
            req: Ingredient requirement

        Returns:
            Replenishment plan item
        """
        # Step 1: Project inventory to identify needs
        projection = await self._project_ingredient_inventory(req)

        # Step 2: Calculate base quantity needed
        base_quantity = self._calculate_base_quantity(req, projection)

        # Step 3: Calculate safety stock
        safety_stock_result = self._calculate_safety_stock(req)
        safety_stock_quantity = safety_stock_result.safety_stock_quantity

        # Step 4: Adjust for shelf life
        total_quantity = base_quantity + safety_stock_quantity
        shelf_life_adjustment = self._adjust_for_shelf_life(
            req,
            total_quantity
        )

        # Step 5: Calculate order dates
        lead_time_plan = self._calculate_order_dates(
            req,
            shelf_life_adjustment.adjusted_quantity
        )

        # Create plan item
        item = ReplenishmentPlanItem(
            id=str(uuid.uuid4()),
            ingredient_id=req.ingredient_id,
            ingredient_name=req.ingredient_name,
            base_quantity=base_quantity,
            safety_stock_quantity=safety_stock_quantity,
            shelf_life_adjusted_quantity=shelf_life_adjustment.adjusted_quantity,
            final_order_quantity=shelf_life_adjustment.adjusted_quantity,
            order_date=lead_time_plan.order_date,
            delivery_date=lead_time_plan.delivery_date,
            required_by_date=req.required_by_date,
            lead_time_days=req.lead_time_days,
            is_urgent=lead_time_plan.is_urgent,
            urgency_reason=lead_time_plan.urgency_reason,
            waste_risk=shelf_life_adjustment.waste_risk,
            stockout_risk=projection.stockout_risk if projection else 'unknown',
            supplier_id=req.supplier_id,
            safety_stock_calculation=self.safety_stock_calculator.export_to_dict(safety_stock_result),
            shelf_life_adjustment=self.shelf_life_manager.export_to_dict(shelf_life_adjustment),
            inventory_projection=self.inventory_projector.export_projection_to_dict(projection) if projection else None
        )

        return item

    async def _project_ingredient_inventory(
        self,
        req: IngredientRequirement
    ) -> Optional[IngredientProjection]:
        """
        Project inventory for ingredient.

        Args:
            req: Ingredient requirement

        Returns:
            Inventory projection
        """
        try:
            # Build daily demand forecast
            daily_demand = []
            if req.daily_consumption_rate > 0:
                for i in range(self.projection_horizon_days):
                    demand_date = date.today() + timedelta(days=i)
                    daily_demand.append(
                        DailyDemand(
                            ingredient_id=req.ingredient_id,
                            date=demand_date,
                            quantity=Decimal(str(req.daily_consumption_rate))
                        )
                    )

            # No scheduled receipts for now (could add future POs here)
            scheduled_receipts = []

            projection = self.inventory_projector.project_inventory(
                ingredient_id=req.ingredient_id,
                ingredient_name=req.ingredient_name,
                current_stock=req.current_stock,
                unit_of_measure=req.unit_of_measure,
                daily_demand=daily_demand,
                scheduled_receipts=scheduled_receipts
            )

            return projection

        except Exception as e:
            logger.error(f"Failed to project inventory for {req.ingredient_name}: {e}")
            return None

    def _calculate_base_quantity(
        self,
        req: IngredientRequirement,
        projection: Optional[IngredientProjection]
    ) -> Decimal:
        """
        Calculate base quantity needed.

        Args:
            req: Ingredient requirement
            projection: Inventory projection

        Returns:
            Base quantity
        """
        if projection:
            # Use projection to calculate need
            required = self.inventory_projector.calculate_required_order_quantity(
                projection,
                target_coverage_days=self.projection_horizon_days
            )
            return max(required, req.required_quantity)
        else:
            # Fallback to required quantity
            return req.required_quantity

    def _calculate_safety_stock(
        self,
        req: IngredientRequirement
    ) -> SafetyStockResult:
        """
        Calculate safety stock.

        Args:
            req: Ingredient requirement

        Returns:
            Safety stock result
        """
        if req.demand_std_dev > 0:
            # Use statistical method
            return self.safety_stock_calculator.calculate_safety_stock(
                demand_std_dev=req.demand_std_dev,
                lead_time_days=req.lead_time_days
            )
        elif req.daily_consumption_rate > 0:
            # Use percentage method
            return self.safety_stock_calculator.calculate_using_fixed_percentage(
                average_demand=req.daily_consumption_rate,
                lead_time_days=req.lead_time_days,
                percentage=0.20
            )
        else:
            # No safety stock
            return SafetyStockResult(
                safety_stock_quantity=Decimal('0'),
                service_level=0.0,
                z_score=0.0,
                demand_std_dev=0.0,
                lead_time_days=req.lead_time_days,
                calculation_method='none',
                confidence='low',
                reasoning='ERROR:INSUFFICIENT_DATA'  # Error code for i18n translation
            )

    def _adjust_for_shelf_life(
        self,
        req: IngredientRequirement,
        quantity: Decimal
    ) -> ShelfLifeAdjustment:
        """
        Adjust quantity for shelf life constraints.

        Args:
            req: Ingredient requirement
            quantity: Proposed quantity

        Returns:
            Shelf life adjustment
        """
        if not req.is_perishable or not req.shelf_life_days:
            # No shelf life constraint
            return ShelfLifeAdjustment(
                original_quantity=quantity,
                adjusted_quantity=quantity,
                adjustment_reason='Non-perishable or no shelf life data',
                waste_risk='low',
                recommended_order_date=date.today(),
                use_by_date=date.today() + timedelta(days=365),
                is_constrained=False
            )

        return self.shelf_life_manager.adjust_order_quantity_for_shelf_life(
            ingredient_id=req.ingredient_id,
            ingredient_name=req.ingredient_name,
            requested_quantity=quantity,
            daily_consumption_rate=req.daily_consumption_rate,
            shelf_life_days=req.shelf_life_days,
            category=req.category,
            is_perishable=req.is_perishable,
            delivery_date=req.required_by_date - timedelta(days=req.lead_time_days)
        )

    def _calculate_order_dates(
        self,
        req: IngredientRequirement,
        quantity: Decimal
    ) -> LeadTimePlan:
        """
        Calculate order and delivery dates.

        Args:
            req: Ingredient requirement
            quantity: Order quantity

        Returns:
            Lead time plan
        """
        lead_time_req = LeadTimeRequirement(
            ingredient_id=req.ingredient_id,
            ingredient_name=req.ingredient_name,
            required_quantity=quantity,
            required_by_date=req.required_by_date,
            supplier_id=req.supplier_id,
            lead_time_days=req.lead_time_days
        )

        plans = self.lead_time_planner.plan_requirements([lead_time_req])

        return plans[0] if plans else LeadTimePlan(
            ingredient_id=req.ingredient_id,
            ingredient_name=req.ingredient_name,
            order_quantity=quantity,
            order_date=date.today(),
            delivery_date=date.today() + timedelta(days=req.lead_time_days),
            required_by_date=req.required_by_date,
            lead_time_days=req.lead_time_days,
            buffer_days=1,
            is_urgent=False,
            supplier_id=req.supplier_id
        )

    def export_plan_to_dict(self, plan: ReplenishmentPlan) -> Dict:
        """
        Export plan to dictionary for API response.

        Args:
            plan: Replenishment plan

        Returns:
            Dictionary representation
        """
        return {
            'plan_id': plan.plan_id,
            'tenant_id': plan.tenant_id,
            'planning_date': plan.planning_date.isoformat(),
            'projection_horizon_days': plan.projection_horizon_days,
            'total_items': plan.total_items,
            'urgent_items': plan.urgent_items,
            'high_risk_items': plan.high_risk_items,
            'total_estimated_cost': float(plan.total_estimated_cost),
            'created_at': plan.created_at.isoformat(),
            'items': [
                {
                    'id': item.id,
                    'ingredient_id': item.ingredient_id,
                    'ingredient_name': item.ingredient_name,
                    'base_quantity': float(item.base_quantity),
                    'safety_stock_quantity': float(item.safety_stock_quantity),
                    'shelf_life_adjusted_quantity': float(item.shelf_life_adjusted_quantity),
                    'final_order_quantity': float(item.final_order_quantity),
                    'order_date': item.order_date.isoformat(),
                    'delivery_date': item.delivery_date.isoformat(),
                    'required_by_date': item.required_by_date.isoformat(),
                    'lead_time_days': item.lead_time_days,
                    'is_urgent': item.is_urgent,
                    'urgency_reason': item.urgency_reason,
                    'waste_risk': item.waste_risk,
                    'stockout_risk': item.stockout_risk,
                    'supplier_id': item.supplier_id,
                    'safety_stock_calculation': item.safety_stock_calculation,
                    'shelf_life_adjustment': item.shelf_life_adjustment,
                    'inventory_projection': item.inventory_projection
                }
                for item in plan.items
            ]
        }