Add roll, Job Card and quotation-estimate fields; lay Makap fields out in tabs

- Batch gets roll details (stage, width, length, micron, net/gross kg,
  supplier lot, machine, Work Order) so each roll is a traceable batch (B3).
- Job Card gets operator output and waste capture on its first tab, with a
  derived waste % and a required reason whenever waste is entered.
- Quotation Item can cost a line from an estimating BOM: material grossed up
  for expected waste, BOM operating cost, set-up and cylinder charge, with
  the resulting margin shown against the quoted rate (M4).
- About 120 fields used to stack after amended_from with no sections. They
  now sit in a "Makap" tab per form (a section on child rows) with labelled
  sub-sections, and positions are updated on migrate (m1).
- Tooling Readiness is read-only: it is derived from the cylinder register.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>

makap_backend/hooks.py

@@ -22,6 +22,9 @@ doc_events = {
     "Work Order": {
         "validate": "makap_backend.makap_backend.controls.validate_work_order",
     },
+    "Job Card": {
+        "validate": "makap_backend.makap_backend.controls.validate_job_card",
+    },
     "Quality Inspection": {
         "validate": "makap_backend.makap_backend.controls.validate_quality_inspection",
     },

makap_backend/makap_backend/controls.py

@@ -1,4 +1,5 @@
 import frappe
+from frappe.utils import flt
 
 from makap_backend.makap_backend import work_order_readiness
 
@@ -73,6 +74,60 @@ def validate_quotation(doc, method=None):
             line.makap_specification_revision = spec.revision
             line.makap_technical_summary = spec.customer_facing_technical_summary
 
+        _estimate_line_cost(line)
+
+
+def _estimate_line_cost(line):
+    """Cost a quotation line from its estimating BOM: material (grossed up for
+    expected waste) + conversion (BOM operations) + set-up + cylinder charge.
+
+    The rate stays the salesperson's decision; this only shows the cost and
+    margin behind it, in company currency.
+    """
+    if not line.get("makap_estimate_bom"):
+        for field in ("makap_material_cost", "makap_conversion_cost", "makap_estimated_cost", "makap_estimated_margin_pct"):
+            line.set(field, 0)
+        return
+
+    bom = frappe.db.get_value(
+        "BOM",
+        line.makap_estimate_bom,
+        ["item", "quantity", "raw_material_cost", "operating_cost", "docstatus"],
+        as_dict=True,
+    )
+    if not bom or bom.docstatus == 2:
+        frappe.throw(f"Estimating BOM {line.makap_estimate_bom} does not exist or is cancelled.")
+    if bom.item != line.item_code:
+        frappe.throw(f"Estimating BOM {line.makap_estimate_bom} is for {bom.item}, not {line.item_code}.")
+
+    qty = flt(line.stock_qty or line.qty)
+    per_unit = 1 / flt(bom.quantity or 1)
+    waste_factor = 1 + flt(line.makap_waste_pct) / 100
+
+    line.makap_material_cost = flt(bom.raw_material_cost) * per_unit * qty * waste_factor
+    line.makap_conversion_cost = flt(bom.operating_cost) * per_unit * qty
+    line.makap_estimated_cost = (
+        line.makap_material_cost
+        + line.makap_conversion_cost
+        + flt(line.makap_setup_cost)
+        + flt(line.makap_cylinder_charge)
+    )
+    revenue = flt(line.base_net_amount or line.base_amount)
+    line.makap_estimated_margin_pct = (revenue - line.makap_estimated_cost) / revenue * 100 if revenue else 0
+
+
+def validate_job_card(doc, method=None):
+    setup = flt(doc.get("makap_setup_waste_kg"))
+    running = flt(doc.get("makap_running_waste_kg"))
+    output = flt(doc.get("makap_output_weight_kg"))
+    if setup < 0 or running < 0 or output < 0:
+        frappe.throw("Output and waste weights cannot be negative.")
+
+    waste = setup + running
+    doc.makap_waste_pct = waste / (output + waste) * 100 if (output + waste) else 0
+    if waste and not doc.get("makap_waste_reason"):
+        frappe.throw("Record the main waste reason when waste is entered.")
+
 
 def validate_sales_order(doc, method=None):
     if doc.docstatus == 1 and not doc.makap_customer_acceptance_basis:

makap_backend/makap_backend/setup_extensions.py

@@ -1,4 +1,5 @@
 import frappe
+from frappe.custom.doctype.custom_field.custom_field import create_custom_fields
 
 
 FIELDS = [
@@ -13,6 +14,7 @@ FIELDS = [
     ("Sales Order", "makap_acceptance_reference", "Acceptance Reference", "Data", None, 0),
     # Module 4 — manufacturing readiness and process classification
     ("Operation", "makap_process_type", "Makap Process Type", "Select", "Printing — Gravure\nPrinting — Flexographic\nLamination\nSlitting\nRewinding\nConversion / Bag Making\nFinishing\nOther", 0),
+    ("Work Order", "makap_release_section", "Release Readiness", "Section Break", None, 0),
     ("Work Order", "makap_packaging_specification", "Packaging Specification", "Link", "Packaging Specification", 1),
     ("Work Order", "makap_specification_revision", "Specification Revision", "Data", None, 1),
     ("Work Order", "makap_sales_order_item_reference", "Sales Order Item Reference", "Data", None, 0),
@@ -25,9 +27,10 @@ FIELDS = [
     ("Work Order", "makap_bom_compatibility_confirmed_by", "BOM Compatibility Confirmed By", "Link", "User", 1),
     ("Work Order", "makap_bom_compatibility_confirmed_on", "BOM Compatibility Confirmed On", "Datetime", None, 1),
     ("Work Order", "makap_process_compatibility_status", "Process Compatibility Status", "Select", "Not Checked\nCompatible\nIncompatible\nNot Applicable", 0),
-    ("Work Order", "makap_tooling_readiness_status", "Tooling Readiness Status", "Select", "Not Checked\nReady\nBlocked\nNot Required", 0),
+    ("Work Order", "makap_tooling_readiness_status", "Tooling Readiness Status", "Select", "Not Checked\nReady\nBlocked\nNot Required", 1),
     # Module 5 — bounded material accountability controls
     ("Item", "makap_material_control_class", "Material Control Class", "Select", "Standard\nControlled\nHigh Traceability", 0),
+    ("Work Order", "makap_material_section", "Material Accountability", "Section Break", None, 0),
     ("Work Order", "makap_material_availability_status", "Material Availability Status", "Select", "Not Checked\nBlocked\nPartially Available\nAvailable", 0),
     ("Work Order", "makap_material_availability_checked_by", "Material Availability Checked By", "Link", "User", 1),
     ("Work Order", "makap_material_availability_checked_on", "Material Availability Checked On", "Datetime", None, 1),
@@ -42,6 +45,7 @@ FIELDS = [
     ("Quality Inspection", "makap_work_order", "Work Order", "Link", "Work Order", 0),
     ("Quality Inspection", "makap_quality_gate_stage", "Quality Gate Stage", "Select", "First-Off\nIn-Process\nFinal\nIncoming\nOutgoing\nNot Applicable", 0),
     ("Quality Inspection", "makap_inspection_trigger", "Inspection Trigger", "Select", "Routine\nFirst-Off\nPeriodic\nPost-Adjustment\nPost-Rework\nComplaint\nRetrospective Hold", 0),
+    ("Quality Inspection", "makap_eligibility_section", "Eligibility and Disposition", "Section Break", None, 0),
     ("Quality Inspection", "makap_quality_eligibility", "Quality Eligibility", "Select", "Not Determined\nEligible\nIneligible\nHold", 0),
     ("Quality Inspection", "makap_inspection_population_quantity", "Inspection Population Quantity", "Float", None, 0),
     ("Quality Inspection", "makap_population_uom", "Population UOM", "Link", "UOM", 0),
@@ -53,6 +57,7 @@ FIELDS = [
     ("Quality Inspection", "makap_disposition_on", "Disposition On", "Datetime", None, 1),
     ("Quality Inspection", "makap_disposition_reason", "Disposition Reason", "Small Text", None, 0),
     ("Quality Inspection", "makap_defect_failure_category", "Defect / Failure Category", "Data", None, 0),
+    ("Quality Inspection", "makap_exception_section", "Exceptions, Reinspection and Concessions", "Section Break", None, 0),
     ("Quality Inspection", "makap_quality_exception_type", "Quality Exception Type", "Select", "None\nConcession\nReinspection\nRetrospective Hold\nTraceability Exception", 0),
     ("Quality Inspection", "makap_reinspection_of", "Reinspection Of", "Link", "Quality Inspection", 0),
     ("Quality Inspection", "makap_reinspection_type", "Reinspection Type", "Select", "Full\nPartial\nTargeted", 0),
@@ -84,6 +89,7 @@ FIELDS = [
     ("Delivery Note", "makap_dispatch_accountability_notes", "Dispatch Accountability Notes", "Small Text", None, 0),
     # Placeholder only — real deposit/credit logic lands in Module 8B. Defaults to Not Required
     # so the Dispatch Gate can already evaluate it without blocking every delivery today.
+    ("Delivery Note", "makap_release_section", "Financial Release and Short-Close", "Section Break", None, 0),
     ("Delivery Note", "makap_financial_release_status", "Financial Release Status", "Select", "Not Required\nNot Assessed\nBlocked\nCleared\nException Approved", 0),
     ("Delivery Note", "makap_short_close", "Short-Close", "Check", None, 0),
     ("Delivery Note", "makap_short_close_reason", "Short-Close Reason", "Small Text", None, 0),
@@ -130,32 +136,97 @@ FIELDS = [
     ("Purchase Invoice Item", "makap_quantity_variance", "Quantity Variance", "Float", None, 1),
     ("Purchase Invoice Item", "makap_rate_variance", "Rate Variance", "Float", None, 1),
     # Module 8F — manufacturing execution cost interpretation
+    ("Work Order", "makap_cost_section", "Cost Interpretation", "Section Break", None, 0),
     ("Work Order", "makap_cost_status", "Cost Status", "Select", "Not Assessed\nProvisional\nReady to Close\nClosed\nRestatement Required", 0),
     ("Work Order", "makap_cost_confidence", "Cost Confidence", "Select", "Not Assessed\nHigh\nQualified\nLow / Provisional", 0),
     ("Work Order", "makap_cost_attribution_basis", "Cost Attribution Basis", "Select", "Not Assessed\nExact\nDirectly Derived\nPooled / Valuation-Based\nQualified", 0),
+    # Roll tracking — every film/roll batch carries its physical dimensions (PRD 4, B3)
+    ("Batch", "makap_roll_stage", "Roll Stage", "Select", "\nResin / Raw Material\nBase Film\nPrinted Roll\nLaminated Roll\nSlit Reel\nFinished Goods", 0),
+    ("Batch", "makap_width_mm", "Width (mm)", "Float", None, 0),
+    ("Batch", "makap_length_m", "Length (m)", "Float", None, 0),
+    ("Batch", "makap_micron", "Thickness (micron)", "Float", None, 0),
+    ("Batch", "makap_roll_col", None, "Column Break", None, 0),
+    ("Batch", "makap_net_weight_kg", "Net Weight (kg)", "Float", None, 0),
+    ("Batch", "makap_gross_weight_kg", "Gross Weight (kg)", "Float", None, 0),
+    ("Batch", "makap_supplier_lot", "Supplier Lot / Roll No", "Data", None, 0),
+    ("Batch", "makap_workstation", "Produced On", "Link", "Workstation", 0),
+    ("Batch", "makap_work_order", "Work Order", "Link", "Work Order", 0),
+    # Operator capture on each stage's Job Card (PRD 4 stage 3, problem 4)
+    ("Job Card", "makap_output_rolls", "Output Rolls", "Int", None, 0),
+    ("Job Card", "makap_output_length_m", "Output Length (m)", "Float", None, 0),
+    ("Job Card", "makap_output_weight_kg", "Output Weight (kg)", "Float", None, 0),
+    ("Job Card", "makap_output_col", None, "Column Break", None, 0),
+    ("Job Card", "makap_setup_waste_kg", "Set-up Waste (kg)", "Float", None, 0),
+    ("Job Card", "makap_running_waste_kg", "Running Waste (kg)", "Float", None, 0),
+    ("Job Card", "makap_waste_pct", "Waste %", "Percent", None, 1),
+    ("Job Card", "makap_waste_reason", "Main Waste Reason", "Select", "\nSet-up / Make-ready\nRegistration\nColour Match\nWeb Break\nWrinkles / Creasing\nBond Failure\nSeal Failure\nEdge Trim\nMaterial Defect\nMachine Fault\nOther", 0),
+    ("Job Card", "makap_waste_notes", "Waste Notes", "Small Text", None, 0),
+    # Quotation cost estimate from an estimating BOM (PRD 4 stage 1, M4)
+    ("Quotation Item", "makap_estimate_bom", "Estimating BOM", "Link", "BOM", 0),
+    ("Quotation Item", "makap_waste_pct", "Expected Waste %", "Percent", None, 0),
+    ("Quotation Item", "makap_setup_cost", "Set-up Cost", "Currency", None, 0),
+    ("Quotation Item", "makap_cylinder_charge", "Cylinder / Plate Charge", "Currency", None, 0),
+    ("Quotation Item", "makap_estimate_col", None, "Column Break", None, 0),
+    ("Quotation Item", "makap_material_cost", "Estimated Material Cost", "Currency", None, 1),
+    ("Quotation Item", "makap_conversion_cost", "Estimated Conversion Cost", "Currency", None, 1),
+    ("Quotation Item", "makap_estimated_cost", "Estimated Total Cost", "Currency", None, 1),
+    ("Quotation Item", "makap_estimated_margin_pct", "Estimated Margin %", "Percent", None, 1),
 ]
 
 
-def ensure_custom_fields():
-    created = []
+# Where each DocType's Makap fields live. Parent forms get one "Makap" tab;
+# child rows get a section. Operator and roll fields sit in the main view
+# because they are filled in on the shop floor, not reviewed later.
+CONTAINERS = {
+    "Job Card": ("Section Break", "Output and Waste", "actual_end_date"),
+    "Batch": ("Section Break", "Roll Details", None),
+}
+
+
+def _end_anchor(meta):
+    """Last standard field, keeping a trailing Connections tab last."""
+    standard = [df for df in meta.fields if not df.get("is_custom_field")]
+    if len(standard) > 1 and standard[-1].fieldtype == "Tab Break":
+        return standard[-2].fieldname
+    return standard[-1].fieldname
+
+
+def build_custom_fields():
+    grouped = {}
     for dt, fieldname, label, fieldtype, options, read_only in FIELDS:
+        grouped.setdefault(dt, []).append(
+            {"fieldname": fieldname, "label": label, "fieldtype": fieldtype, "options": options, "read_only": read_only}
+        )
+
+    result = {}
+    for dt, fields in grouped.items():
         if not frappe.db.exists("DocType", dt):
             continue
-        if frappe.db.exists("Custom Field", {"dt": dt, "fieldname": fieldname}):
-            continue
-        doc = frappe.get_doc(
+        meta = frappe.get_meta(dt)
+        if dt in CONTAINERS:
+            break_type, label, anchor = CONTAINERS[dt]
+        elif meta.istable:
+            break_type, label, anchor = "Section Break", "Makap", None
+        else:
+            break_type, label, anchor = "Tab Break", "Makap", None
+
+        chain = [
             {
-                "doctype": "Custom Field",
-                "dt": dt,
-                "fieldname": fieldname,
+                "fieldname": "makap_tab" if break_type == "Tab Break" else "makap_section",
                 "label": label,
-                "fieldtype": fieldtype,
-                "options": options,
-                "read_only": read_only,
-                "insert_after": "amended_from" if dt in {"Sales Order", "Work Order", "Quality Inspection", "Delivery Note", "Sales Invoice", "Purchase Invoice"} else None,
+                "fieldtype": break_type,
+                "insert_after": anchor or _end_anchor(meta),
             }
-        )
-        doc.insert(ignore_permissions=True)
-        created.append(f"{dt}.{fieldname}")
-    frappe.db.commit()
-    return created
+        ]
+        for field in fields:
+            field["insert_after"] = chain[-1]["fieldname"]
+            chain.append(field)
+        result[dt] = chain
+    return result
+
+
+def ensure_custom_fields():
+    """Create or update every Makap custom field, including its position on the form."""
+    fields = build_custom_fields()
+    create_custom_fields(fields, update=True)
+    return sorted(f"{dt}.{f['fieldname']}" for dt, rows in fields.items() for f in rows)