# ScanLook - Inventory Management System

**Barcode-based inventory counting system designed for food production facilities**

Replace 5 days of manual year-end physical inventory with a weekend project. Track variances, location errors, phantom lots, and ghost inventory in real-time.

---

## 🚀 Quick Start

### 1. Install Dependencies

```bash
pip install flask werkzeug --break-system-packages
```

### 2. Initialize Database

```bash
cd /home/claude/scanlook
python database/init_db.py
```

This creates the database with default users:
- **Owner**: `owner` / `owner123`
- **Admin**: `admin` / `admin123`  
- **Staff**: `staff1` / `staff123`
- **Staff**: `staff2` / `staff123`

### 3. Run Application

```bash
python app.py
```

Access at: **http://localhost:5000**

---

## 📱 Accessing from Scanner Devices

For Zebra Android scanners or tablets on the same network:

1. Find your server's IP address:
   ```bash
   hostname -I
   ```

2. On scanner device, open browser and navigate to:
   ```
   http://YOUR_SERVER_IP:5000
   ```

3. Scanner trigger acts as Enter key (keyboard wedge mode)

---

## 👥 User Roles

### Owner (Level 1)
- Super admin privileges
- Manage all admins
- View all sessions across branches

### Admin (Level 2)
- Create count sessions
- Upload MASTER baseline (morning snapshot)
- Upload CURRENT baseline (refresh anytime)
- View real-time dashboard
- Export variance reports
- Manage staff users

### Staff/Counter (Level 3)
- Select active count session
- Scan locations and lots
- Enter weights
- Edit/delete their own scans
- View their progress

---

## 🔄 Core Workflow

### Phase 1: Session Setup (Admin)

1. **Log in as admin**
2. **Create new count session**:
   - Session name: "January 17, 2026 - Daily Cycle Count"
   - Type: Cycle Count OR Full Physical Inventory
3. **Upload MASTER baseline** CSV from NetSuite:
   - Format: `Item, Description, Lot Number, Location, Bin Number, On Hand`
   - Creates baseline version 1
4. Session status: **Active**
5. Counters can now begin

### Phase 2: Counting (Staff)

1. **Log in as staff**
2. **Select active session**
3. **Scan location barcode** (e.g., R903B)
   - System marks location "in progress"
   - Shows: "Counting R903B"
4. **Scan lot barcode**
5. System checks lot against MASTER baseline:
   - ✅ **MATCH**: Expected here, location correct
   - ⚠️ **WRONG LOCATION**: Lot exists but system says different location
   - ❌ **GHOST LOT**: Not in system at all
6. **Enter weight**
7. Save → returns to scan input (autofocus)
8. Repeat for all lots in location
9. Click **"Finish Location"**

### Phase 3: Admin Monitoring

**Real-Time Dashboard Shows:**
- Total locations & completion percentage
- Active counters with current location
- Variance summary (matches, wrong locations, missing, ghost lots)

**Optional CURRENT Baseline Refresh:**
- Admin uploads new CSV from NetSuite
- System recalculates CURRENT status for all scans
- Shows what changed in system after count
- Proves count was correct, lot moved later

---

## 📊 CSV Import Format

**Required columns:**
```csv
Item,Description,Lot Number,Location,Bin Number,On Hand
100001,Beef MDM,20260108-132620-PO25146,Wisconsin G & H,R903B,2030
100001,Beef MDM,20260108-132700-PO25146,Wisconsin G & H,R903B,2030
100001,Beef MDM,20260106-150649-PO24949,Wisconsin G & H,R905C,2065
```

**Column Descriptions:**
- **Item**: SKU or item number
- **Description**: Product description
- **Lot Number**: Unique lot identifier
- **Location**: Warehouse location name
- **Bin Number**: Specific bin/rack location code
- **On Hand**: Current quantity in pounds

---

## 🎯 Key Features

### Dual Baseline System

**MASTER Baseline**:
- Uploaded once at session start (e.g., 6:00 AM)
- Never changes during session
- What counters validate against
- Represents "what should have been there when we started"

**CURRENT Baseline**:
- Admin can refresh unlimited times
- Only affects admin dashboard/reporting  
- Counters never see it
- Shows "where is it in the system NOW"
- Identifies movement after count

### Variance Detection

- **Perfect Match**: Right location, weight within tolerance
- **Weight Variance**: Right location, weight differs (calculates %)
- **Wrong Location**: Lot exists but scanned in different location
- **Ghost Lot**: Scanned but not in baseline at all
- **Missing/Phantom**: In baseline but not found during count

### Blind Counting

- Counters don't see expected quantities
- Prevents bias
- Ensures honest count

### Real-Time Dashboard

- Active counters with current location
- Progress by location
- Variance counts updating live
- Dual view (MASTER vs CURRENT) after refresh

### Audit Trail

- Every scan timestamped with user
- Soft deletes tracked
- Edits tracked with modified timestamp
- Baseline version tracking

---

## 🗂️ Database Schema

### Tables:
- **Users**: Authentication and role management
- **CountSessions**: Count session metadata
- **BaselineInventory_Master**: Morning baseline (never changes)
- **BaselineInventory_Current**: Refreshable baseline (soft delete)
- **LocationCounts**: Location-by-location progress
- **ScanEntries**: Every lot scan with dual status tracking
- **MissingLots**: Expected lots not found

### Indexes:
Optimized for fast lookups on lot numbers, locations, and statuses.

---

## 🔧 Technology Stack

- **Backend**: Python 3.13 + Flask
- **Database**: SQLite
- **Frontend**: HTML5 + CSS3 + Vanilla JavaScript
- **Templates**: Jinja2

---

## 📂 Project Structure

```
scanlook/
├── app.py                 # Main Flask application
├── database/
│   ├── init_db.py         # Database initialization
│   └── scanlook.db        # SQLite database (created)
├── static/
│   ├── css/
│   │   └── style.css      # Main stylesheet
│   └── js/
│       └── main.js        # Client-side JavaScript
└── templates/
    ├── base.html          # Base template
    ├── login.html         # Login page
    ├── admin_dashboard.html
    ├── staff_dashboard.html
    ├── create_session.html
    ├── session_detail.html
    ├── count_session.html
    └── count_location.html
```

---

## 🎨 Design Philosophy

**Mobile-First, Warehouse-Optimized:**
- High contrast dark theme for warehouse lighting
- Large touch targets (44px minimum)
- Autofocus on scan inputs
- Scanner trigger = Enter key
- Visual feedback with color-coded statuses
- Minimal typing required

**Color Coding:**
- ✅ Green: Perfect match
- ⚠️ Yellow: Wrong location
- ❌ Red: Missing or ghost lot
- 🔵 Blue: Weight variance

---

## 🚧 Current Status: Phase 1 Complete (MVP)

### ✅ Implemented:
- User authentication (3 roles)
- Session creation
- MASTER baseline upload
- Location scanning
- Lot scanning with MASTER status
- Weight entry
- Basic dashboard
- Real-time progress tracking
- Mobile-optimized UI

### 🔜 Next Phases:
- **Phase 2**: CURRENT baseline refresh & dual status recalculation
- **Phase 3**: Missing lot detection, enhanced dashboard
- **Phase 4**: Excel export with multiple tabs
- **Phase 5**: Data retention automation, user management
- **Phase 6**: Docker deployment

---

## 📝 Development Notes

### Default Accounts (Testing)
All passwords should be changed in production!

### Security Considerations
- Passwords are hashed with Werkzeug
- Session management via Flask sessions
- SQL injection prevention (parameterized queries)
- Soft deletes preserve audit trail

### Data Retention
- Plan: Keep data for 30 days
- Nightly cleanup job (to be implemented)
- Archive old sessions

---

## 🎯 Success Metrics

**Current State (Year-End Physical):**
- Duration: 5 days
- Data entry: Manual, error-prone
- Variance resolution: Weeks later

**Target State (with ScanLook):**
- Duration: 1 weekend (2 days max)
- Data entry: Zero (all scanned)
- Variance resolution: Real-time flagging
- Accuracy: 99%+ (no handwriting errors)
- Time savings: 60%+

---

## 💡 Future Enhancements

- Multi-branch support
- Direct NetSuite API integration
- Photo capture for variance proof
- Barcode generation for location labels
- Native mobile apps
- Offline mode with sync

---

## 📧 Support

This is a custom internal tool. Contact your system administrator for support.

**Built with ❤️ for efficient inventory management**

*Inspired by BomLook from the FoxPro days* 🚀
