ims/app/api/incidents/[id]/ai/rca-draft/route.ts

export const dynamic = 'force-dynamic'

import { NextRequest, NextResponse } from 'next/server'
import { createClient } from '@/lib/supabase/server'
import { createAnthropicClient } from '@/lib/claude/client'
import { getApiKey } from '@/lib/settings'

export async function POST(
  _request: NextRequest,
  { params }: { params: Promise<{ id: string }> }
) {
  const { id } = await params
  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 since = new Date(Date.now() - 60_000).toISOString()
  const { count: recentCount } = await supabase
    .from('audit_log')
    .select('id', { count: 'exact', head: true })
    .eq('changed_by', user.id)
    .eq('action', 'ai_rca_draft')
    .gte('changed_at', since)
  if ((recentCount ?? 0) > 0)
    return NextResponse.json({ error: 'Rate limited — please wait 60 seconds' }, { status: 429 })

  const anthropicKey = await getApiKey(supabase, 'ANTHROPIC_API_KEY')
  const anthropic = createAnthropicClient(anthropicKey)

  const { data: incident } = await supabase
    .from('incidents')
    .select(`
      id, incident_type, description, severity, injury_involved, medical_status,
      is_fatality, is_serious_bodily_injury, triage_notes,
      sites (name), zones (name)
    `)
    .eq('id', id)
    .single()
  if (!incident) return NextResponse.json({ error: 'Not found' }, { status: 404 })

  const inc = incident as {
    incident_type: string
    description: string
    severity: number | null
    injury_involved: boolean
    medical_status: string | null
    is_fatality: boolean
    is_serious_bodily_injury: boolean
    triage_notes: string | null
  }
  const siteName = (incident.sites as unknown as { name: string } | null)?.name ?? 'Unknown'
  const zoneName = (incident.zones as unknown as { name: string } | null)?.name ?? 'Unknown'

  let message: Awaited<ReturnType<typeof anthropic.messages.create>>
  try {
    message = await anthropic.messages.create({
      model: 'claude-opus-4-8',
      thinking: { type: 'adaptive' },
      max_tokens: 2048,
      tools: [{
        name: 'draft_rca',
        description: 'Draft a 5-Why root cause analysis and CAPA suggestions for an HSE incident',
        input_schema: {
          type: 'object' as const,
          properties: {
            five_why_steps: {
              type: 'array',
              items: {
                type: 'object',
                properties: {
                  why: { type: 'string', description: 'The why question' },
                  answer: { type: 'string', description: 'The finding or answer' },
                },
                required: ['why', 'answer'],
              },
              description: '3 to 5 why steps',
            },
            root_cause_summary: {
              type: 'string',
              description: 'One-sentence root cause statement',
            },
            capa_suggestions: {
              type: 'array',
              items: { type: 'string' },
              description: 'Up to 3 corrective/preventive action suggestions',
            },
          },
          required: ['five_why_steps', 'root_cause_summary', 'capa_suggestions'],
        },
      }],
      tool_choice: { type: 'tool', name: 'draft_rca' },
      messages: [{
        role: 'user',
        content: `You are an experienced HSE investigator for a Malaysian 3PL warehouse. Draft a 5-Why root cause analysis for this incident.

Site: ${siteName}
Zone: ${zoneName}
Incident type: ${inc.incident_type}
Description: ${inc.description}
Severity: ${inc.severity ?? 'not yet assigned'}/5
Injury involved: ${inc.injury_involved ? `yes — ${inc.medical_status}` : 'no'}
Fatality: ${inc.is_fatality ? 'yes' : 'no'}
Serious bodily injury: ${inc.is_serious_bodily_injury ? 'yes' : 'no'}
Triage notes: ${inc.triage_notes ?? 'none'}

Provide 3–5 Why steps drilling from immediate cause to root cause. Give a one-sentence root cause statement. Suggest 3 corrective/preventive actions appropriate for a Malaysian warehouse context.`,
      }],
    })
  } catch {
    return NextResponse.json({ error: 'AI service unavailable' }, { status: 503 })
  }

  const toolBlock = message.content.find(b => b.type === 'tool_use')
  if (!toolBlock || toolBlock.type !== 'tool_use')
    return NextResponse.json({ error: 'AI draft failed' }, { status: 500 })

  const draft = toolBlock.input as {
    five_why_steps?: unknown
    root_cause_summary?: unknown
    capa_suggestions?: unknown
  }

  if (
    !Array.isArray(draft.five_why_steps) ||
    typeof draft.root_cause_summary !== 'string' ||
    !Array.isArray(draft.capa_suggestions)
  ) {
    return NextResponse.json({ error: 'AI returned unexpected structure' }, { status: 500 })
  }

  await supabase.rpc('write_audit_log', {
    p_table_name: 'incidents',
    p_record_id: id,
    p_action: 'ai_rca_draft',
    p_new_value: {
      root_cause_summary: draft.root_cause_summary,
      model: 'claude-opus-4-8',
    } as never,
  })

  return NextResponse.json(draft)
}