feat: JKKP 6/7 PDF generation via pdf-lib, download from incident detail

Also excludes node_modules.nosync from vitest test discovery to fix pre-existing bleed.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01FFDuBhMKvoWjrWT3ZnGmmr

app/(protected)/hse/incidents/[id]/page.tsx

@@ -18,6 +18,7 @@ export default async function HseIncidentDetailPage({ params }: Props) {
     .select(`
       id, reference_no, incident_type, description, severity, status,
       injury_involved, asset_involved, medical_status, lost_days,
+      is_fatality, is_serious_bodily_injury, is_dangerous_occurrence, is_occupational_disease,
       reported_at, closed_at,
       sites (id, name),
       zones (id, name),
@@ -69,6 +70,30 @@ export default async function HseIncidentDetailPage({ params }: Props) {
           </Link>
         </div>
       )}
+
+      {Boolean(
+        (incident as { is_fatality?: boolean }).is_fatality ||
+        (incident as { is_serious_bodily_injury?: boolean }).is_serious_bodily_injury ||
+        (incident as { is_dangerous_occurrence?: boolean }).is_dangerous_occurrence ||
+        ((incident as { lost_days?: number | null }).lost_days ?? 0) >= 4
+      ) && (
+        <div className="mt-4 flex gap-3">
+          <a
+            href={`/api/incidents/${id}/jkkp-pdf?form=jkkp6`}
+            target="_blank"
+            className="inline-block bg-gray-800 text-white rounded-lg px-4 py-2 text-sm font-semibold hover:bg-gray-900"
+          >
+            Download JKKP 6 (PDF)
+          </a>
+          <a
+            href={`/api/incidents/${id}/jkkp-pdf?form=jkkp7`}
+            target="_blank"
+            className="inline-block bg-gray-600 text-white rounded-lg px-4 py-2 text-sm font-semibold hover:bg-gray-700"
+          >
+            Download JKKP 7 (PDF)
+          </a>
+        </div>
+      )}
     </main>
   )
 }

app/api/incidents/[id]/jkkp-pdf/route.ts

@@ -0,0 +1,75 @@
+export const dynamic = 'force-dynamic'
+
+import { NextRequest, NextResponse } from 'next/server'
+import { createClient } from '@/lib/supabase/server'
+import { buildJkkp6Pdf, buildJkkp7Pdf, type JkkpIncident } from '@/lib/pdf/jkkp'
+import { computeDoshObligation } from '@/lib/incidents/dosh'
+
+export async function GET(
+  request: NextRequest,
+  { params }: { params: Promise<{ id: string }> }
+) {
+  const { id } = await params
+  const form = request.nextUrl.searchParams.get('form')
+  if (form !== 'jkkp6' && form !== 'jkkp7')
+    return NextResponse.json({ error: 'form must be jkkp6 or jkkp7' }, { status: 422 })
+
+  const supabase = await createClient()
+  const { data: { user }, error: authError } = await supabase.auth.getUser()
+  if (authError || !user) return NextResponse.json({ error: 'Unauthorized' }, { status: 401 })
+
+  const { data: profile } = await supabase
+    .from('users').select('role').eq('id', user.id).single()
+  if (!profile || !['hse', 'admin'].includes(profile.role))
+    return NextResponse.json({ error: 'Forbidden' }, { status: 403 })
+
+  const { data: incident } = await supabase
+    .from('incidents')
+    .select(`
+      reference_no, incident_type, description, reported_at, severity, lost_days,
+      is_fatality, is_serious_bodily_injury, is_dangerous_occurrence, is_occupational_disease,
+      sites (name),
+      reporter:users!reported_by (name)
+    `)
+    .eq('id', id)
+    .single()
+
+  if (!incident) return NextResponse.json({ error: 'Not found' }, { status: 404 })
+
+  const dosh = computeDoshObligation({
+    is_fatality: (incident as { is_fatality: boolean }).is_fatality,
+    is_serious_bodily_injury: (incident as { is_serious_bodily_injury: boolean }).is_serious_bodily_injury,
+    is_dangerous_occurrence: (incident as { is_dangerous_occurrence: boolean }).is_dangerous_occurrence,
+    is_occupational_disease: (incident as { is_occupational_disease: boolean }).is_occupational_disease,
+    lost_days: (incident as { lost_days: number | null }).lost_days,
+  })
+
+  const required = form === 'jkkp6' ? dosh.requires_jkkp6 : dosh.requires_jkkp7
+  if (!required) return NextResponse.json({ error: 'This form is not required for this incident' }, { status: 400 })
+
+  const jkkpIncident: JkkpIncident = {
+    reference_no: (incident as { reference_no: string | null }).reference_no,
+    incident_type: (incident as { incident_type: string }).incident_type,
+    description: (incident as { description: string }).description,
+    reported_at: (incident as { reported_at: string }).reported_at,
+    severity: (incident as { severity: number | null }).severity,
+    is_fatality: (incident as { is_fatality: boolean }).is_fatality,
+    is_serious_bodily_injury: (incident as { is_serious_bodily_injury: boolean }).is_serious_bodily_injury,
+    is_dangerous_occurrence: (incident as { is_dangerous_occurrence: boolean }).is_dangerous_occurrence,
+    lost_days: (incident as { lost_days: number | null }).lost_days,
+    site_name: (incident.sites as unknown as { name: string } | null)?.name ?? 'Unknown',
+    reporter_name: (incident.reporter as unknown as { name: string } | null)?.name ?? 'Unknown',
+  }
+
+  const pdfBytes = form === 'jkkp6'
+    ? await buildJkkp6Pdf(jkkpIncident)
+    : await buildJkkp7Pdf(jkkpIncident)
+
+  const ref = jkkpIncident.reference_no ?? id
+  return new NextResponse(Buffer.from(pdfBytes), {
+    headers: {
+      'Content-Type': 'application/pdf',
+      'Content-Disposition': `attachment; filename="${form}-${ref}.pdf"`,
+    },
+  })
+}

lib/pdf/jkkp.ts

@@ -0,0 +1,104 @@
+import { PDFDocument, StandardFonts, rgb } from 'pdf-lib'
+
+export type JkkpIncident = {
+  reference_no: string | null
+  incident_type: string
+  description: string
+  reported_at: string
+  severity: number | null
+  is_fatality: boolean
+  is_serious_bodily_injury: boolean
+  is_dangerous_occurrence: boolean
+  lost_days: number | null
+  site_name: string
+  reporter_name: string
+}
+
+type EmbeddedFont = Awaited<ReturnType<PDFDocument['embedFont']>>
+type Page = ReturnType<PDFDocument['addPage']>
+
+async function createBaseDoc(title: string): Promise<{
+  doc: PDFDocument
+  page: Page
+  font: EmbeddedFont
+  boldFont: EmbeddedFont
+  y: { value: number }
+}> {
+  const doc = await PDFDocument.create()
+  const page = doc.addPage([595, 842]) // A4
+  const font = await doc.embedFont(StandardFonts.Helvetica)
+  const boldFont = await doc.embedFont(StandardFonts.HelveticaBold)
+  const y = { value: 800 }
+
+  page.drawText(title, { x: 50, y: y.value, size: 14, font: boldFont, color: rgb(0, 0, 0) })
+  y.value -= 8
+  page.drawLine({ start: { x: 50, y: y.value }, end: { x: 545, y: y.value }, thickness: 1, color: rgb(0, 0, 0) })
+  y.value -= 20
+
+  return { doc, page, font, boldFont, y }
+}
+
+function drawField(
+  page: Page,
+  label: string,
+  value: string,
+  font: EmbeddedFont,
+  boldFont: EmbeddedFont,
+  y: { value: number }
+) {
+  page.drawText(label + ':', { x: 50, y: y.value, size: 9, font: boldFont, color: rgb(0.3, 0.3, 0.3) })
+  const lines = value.length > 80 ? [value.slice(0, 80), value.slice(80, 160)] : [value]
+  for (const line of lines) {
+    y.value -= 14
+    page.drawText(line || '—', { x: 50, y: y.value, size: 10, font, color: rgb(0, 0, 0) })
+  }
+  y.value -= 8
+}
+
+export async function buildJkkp6Pdf(incident: JkkpIncident): Promise<Uint8Array> {
+  const { doc, page, font, boldFont, y } = await createBaseDoc('BORANG JKKP 6 — Notis Kemalangan / Kejadian Berbahaya')
+
+  const reportedDate = new Date(incident.reported_at).toLocaleDateString('en-MY', { timeZone: 'Asia/Kuala_Lumpur' })
+
+  drawField(page, 'Rujukan / Reference', incident.reference_no ?? '—', font, boldFont, y)
+  drawField(page, 'Tapak / Site', incident.site_name, font, boldFont, y)
+  drawField(page, 'Tarikh Laporan / Date Reported', reportedDate, font, boldFont, y)
+  drawField(page, 'Jenis Insiden / Incident Type', incident.incident_type.replace(/_/g, ' '), font, boldFont, y)
+  drawField(page, 'Dilaporkan Oleh / Reported By', incident.reporter_name, font, boldFont, y)
+  drawField(page, 'Penerangan / Description', incident.description, font, boldFont, y)
+  drawField(page, 'Kematian / Fatality', incident.is_fatality ? 'Yes' : 'No', font, boldFont, y)
+  drawField(page, 'Kecederaan Serius / Serious Bodily Injury', incident.is_serious_bodily_injury ? 'Yes' : 'No', font, boldFont, y)
+  drawField(page, 'Kejadian Berbahaya / Dangerous Occurrence', incident.is_dangerous_occurrence ? 'Yes' : 'No', font, boldFont, y)
+  drawField(page, 'Hari Hilang Kerja / Lost Days', incident.lost_days !== null ? String(incident.lost_days) : '—', font, boldFont, y)
+
+  y.value -= 20
+  page.drawText('Nota: Borang ini adalah draf yang dijana secara automatik. Sila semak sebelum dikemukakan ke DOSH.',
+    { x: 50, y: y.value, size: 8, font, color: rgb(0.5, 0.5, 0.5) })
+
+  return doc.save()
+}
+
+export async function buildJkkp7Pdf(incident: JkkpIncident): Promise<Uint8Array> {
+  const { doc, page, font, boldFont, y } = await createBaseDoc('BORANG JKKP 7 — Laporan Siasatan Kemalangan')
+
+  const reportedDate = new Date(incident.reported_at).toLocaleDateString('en-MY', { timeZone: 'Asia/Kuala_Lumpur' })
+
+  drawField(page, 'Rujukan / Reference', incident.reference_no ?? '—', font, boldFont, y)
+  drawField(page, 'Tapak / Site', incident.site_name, font, boldFont, y)
+  drawField(page, 'Tarikh Kemalangan / Incident Date', reportedDate, font, boldFont, y)
+  drawField(page, 'Jenis Insiden / Incident Type', incident.incident_type.replace(/_/g, ' '), font, boldFont, y)
+  drawField(page, 'Penerangan Kemalangan / Incident Description', incident.description, font, boldFont, y)
+  drawField(page, 'Keterukan / Severity', incident.severity !== null ? String(incident.severity) + ' / 5' : '—', font, boldFont, y)
+  drawField(page, 'Hari Hilang Kerja / Lost Days', incident.lost_days !== null ? String(incident.lost_days) : '—', font, boldFont, y)
+
+  y.value -= 20
+  page.drawText('Rumusan Punca Asas / Root Cause Summary:', { x: 50, y: y.value, size: 9, font: boldFont, color: rgb(0.3, 0.3, 0.3) })
+  y.value -= 14
+  page.drawText('[To be completed by HSE investigator]', { x: 50, y: y.value, size: 10, font, color: rgb(0.6, 0.6, 0.6) })
+
+  y.value -= 30
+  page.drawText('Nota: Borang ini adalah draf yang dijana secara automatik. Sila semak sebelum dikemukakan ke DOSH.',
+    { x: 50, y: y.value, size: 8, font, color: rgb(0.5, 0.5, 0.5) })
+
+  return doc.save()
+}

package-lock.json

@@ -11,6 +11,7 @@
         "@supabase/ssr": "^0.12.0",
         "@supabase/supabase-js": "^2.110.2",
         "next": "^15.5.20",
+        "pdf-lib": "^1.17.1",
         "react": "^19.2.7",
         "react-dom": "^19.2.7",
         "resend": "^6.17.2"
@@ -2008,6 +2009,24 @@
         "url": "https://github.com/sponsors/Boshen"
       }
     },
+    "node_modules/@pdf-lib/standard-fonts": {
+      "version": "1.0.0",
+      "resolved": "https://registry.npmjs.org/@pdf-lib/standard-fonts/-/standard-fonts-1.0.0.tgz",
+      "integrity": "sha512-hU30BK9IUN/su0Mn9VdlVKsWBS6GyhVfqjwl1FjZN4TxP6cCw0jP2w7V3Hf5uX7M0AZJ16vey9yE0ny7Sa59ZA==",
+      "license": "MIT",
+      "dependencies": {
+        "pako": "^1.0.6"
+      }
+    },
+    "node_modules/@pdf-lib/upng": {
+      "version": "1.0.1",
+      "resolved": "https://registry.npmjs.org/@pdf-lib/upng/-/upng-1.0.1.tgz",
+      "integrity": "sha512-dQK2FUMQtowVP00mtIksrlZhdFXQZPC+taih1q4CvPZ5vqdxR/LKBaFg0oAfzd1GlHZXXSPdQfzQnt+ViGvEIQ==",
+      "license": "MIT",
+      "dependencies": {
+        "pako": "^1.0.10"
+      }
+    },
     "node_modules/@rolldown/binding-android-arm64": {
       "version": "1.1.5",
       "resolved": "https://registry.npmjs.org/@rolldown/binding-android-arm64/-/binding-android-arm64-1.1.5.tgz",
@@ -7305,6 +7324,12 @@
         "node": ">=6"
       }
     },
+    "node_modules/pako": {
+      "version": "1.0.11",
+      "resolved": "https://registry.npmjs.org/pako/-/pako-1.0.11.tgz",
+      "integrity": "sha512-4hLB8Py4zZce5s4yd9XzopqwVv/yGNhV1Bl8NTmCq1763HeK2+EwVTv+leGeL13Dnh2wfbqowVPXCIO0z4taYw==",
+      "license": "(MIT AND Zlib)"
+    },
     "node_modules/parent-module": {
       "version": "1.0.1",
       "resolved": "https://registry.npmjs.org/parent-module/-/parent-module-1.0.1.tgz",
@@ -7365,6 +7390,24 @@
       "dev": true,
       "license": "MIT"
     },
+    "node_modules/pdf-lib": {
+      "version": "1.17.1",
+      "resolved": "https://registry.npmjs.org/pdf-lib/-/pdf-lib-1.17.1.tgz",
+      "integrity": "sha512-V/mpyJAoTsN4cnP31vc0wfNA1+p20evqqnap0KLoRUN0Yk/p3wN52DOEsL4oBFcLdb76hlpKPtzJIgo67j/XLw==",
+      "license": "MIT",
+      "dependencies": {
+        "@pdf-lib/standard-fonts": "^1.0.0",
+        "@pdf-lib/upng": "^1.0.1",
+        "pako": "^1.0.11",
+        "tslib": "^1.11.1"
+      }
+    },
+    "node_modules/pdf-lib/node_modules/tslib": {
+      "version": "1.14.1",
+      "resolved": "https://registry.npmjs.org/tslib/-/tslib-1.14.1.tgz",
+      "integrity": "sha512-Xni35NKzjgMrwevysHTCArtLDpPvye8zV/0E4EyYn43P7/7qvQwPh9BGkHewbMulVntbigmcT7rdX3BNo9wRJg==",
+      "license": "0BSD"
+    },
     "node_modules/picocolors": {
       "version": "1.1.1",
       "resolved": "https://registry.npmjs.org/picocolors/-/picocolors-1.1.1.tgz",

package.json

@@ -15,6 +15,7 @@
     "@supabase/ssr": "^0.12.0",
     "@supabase/supabase-js": "^2.110.2",
     "next": "^15.5.20",
+    "pdf-lib": "^1.17.1",
     "react": "^19.2.7",
     "react-dom": "^19.2.7",
     "resend": "^6.17.2"

tests/lib/pdf/jkkp.test.ts

@@ -0,0 +1,44 @@
+import { describe, it, expect } from 'vitest'
+import { buildJkkp6Pdf, buildJkkp7Pdf } from '@/lib/pdf/jkkp'
+
+const mockIncident = {
+  reference_no: 'TEST-202607-0001',
+  incident_type: 'injury',
+  description: 'Worker fell from platform',
+  reported_at: new Date('2026-07-01T08:00:00Z').toISOString(),
+  severity: 4,
+  is_fatality: false,
+  is_serious_bodily_injury: true,
+  is_dangerous_occurrence: false,
+  lost_days: 5,
+  site_name: 'Setia Corporation Warehouse 1',
+  reporter_name: 'John Doe',
+}
+
+describe('buildJkkp6Pdf', () => {
+  it('returns a non-empty Uint8Array', async () => {
+    const pdf = await buildJkkp6Pdf(mockIncident)
+    expect(pdf).toBeInstanceOf(Uint8Array)
+    expect(pdf.length).toBeGreaterThan(100)
+  })
+
+  it('PDF bytes start with %PDF', async () => {
+    const pdf = await buildJkkp6Pdf(mockIncident)
+    const header = new TextDecoder().decode(pdf.slice(0, 4))
+    expect(header).toBe('%PDF')
+  })
+})
+
+describe('buildJkkp7Pdf', () => {
+  it('returns a non-empty Uint8Array', async () => {
+    const pdf = await buildJkkp7Pdf(mockIncident)
+    expect(pdf).toBeInstanceOf(Uint8Array)
+    expect(pdf.length).toBeGreaterThan(100)
+  })
+
+  it('PDF bytes start with %PDF', async () => {
+    const pdf = await buildJkkp7Pdf(mockIncident)
+    const header = new TextDecoder().decode(pdf.slice(0, 4))
+    expect(header).toBe('%PDF')
+  })
+})

vitest.config.ts

@@ -9,6 +9,7 @@ export default defineConfig({
     environment: 'jsdom',
     globals: true,
     setupFiles: [],
+    exclude: ['node_modules/**', 'node_modules.nosync/**', '.next/**'],
   },
   resolve: {
     alias: {