resolve conflicts

api_server.py

@@ -30,6 +30,7 @@ logger = logging.getLogger(__name__)
 
 app = None
 config = None
+scheduler_thread = None
 
 
 def cleanup_old_reports(output_dir: Path, reports_dir: Path, max_reports: int = 10):
@@ -219,8 +220,38 @@ def create_app(config_path: Optional[str] = None):
                                     'sharepoint_error': True
                                 }), 500
                 except Exception as e:
-                    logger.error(f"Failed to download from SharePoint: {e}", exc_info=True)
-                    # Check if we have existing files as fallback
+                    error_msg = str(e)
+                    logger.error(f"Failed to download from SharePoint: {error_msg}", exc_info=True)
+                    
+                    # Check if this is a locked file error
+                    is_locked_file_error = 'locked' in error_msg.lower() or 'cannot access the file' in error_msg.lower() or 'being used by another process' in error_msg.lower()
+                    
+                    if is_locked_file_error:
+                        # Extract filename from error if possible
+                        locked_file_match = None
+                        import re
+                        # Try to find filename in error message
+                        match = re.search(r"['\"]([^'\"]*\.xlsx?)['\"]", error_msg)
+                        if match:
+                            locked_file_match = match.group(1)
+                        
+                        locked_file_info = f" ({locked_file_match})" if locked_file_match else ""
+                        return jsonify({
+                            'error': f'Cannot download from SharePoint: File is locked{locked_file_info}',
+                            'details': f'A file in the reports directory is being used by another program (likely Excel). Please close Excel and any other programs that might have this file open, then try again. Error: {error_msg}',
+                            'instructions': [
+                                '1. Close Microsoft Excel completely',
+                                '2. Close any file explorer windows showing the reports folder',
+                                '3. Wait a few seconds',
+                                '4. Try generating the report again',
+                                '',
+                                'Alternatively, use manual file upload instead of SharePoint download.'
+                            ],
+                            'sharepoint_error': True,
+                            'locked_file_error': True
+                        }), 500
+                    
+                    # Check if we have existing files as fallback (only for non-locked errors)
                     reports_dir_path = Path(report_config.get('reports_dir', 'reports'))
                     if not reports_dir_path.is_absolute():
                         script_dir = Path(__file__).parent.absolute()
@@ -233,13 +264,13 @@ def create_app(config_path: Optional[str] = None):
                             downloaded_files = []  # Continue with existing files
                         else:
                             return jsonify({
-                                'error': f'SharePoint download failed: {str(e)}',
+                                'error': f'SharePoint download failed: {error_msg}',
                                 'details': 'No existing files found. Please use manual file upload or fix SharePoint permissions.',
                                 'sharepoint_error': True
                             }), 500
                     else:
                         return jsonify({
-                            'error': f'SharePoint download failed: {str(e)}',
+                            'error': f'SharePoint download failed: {error_msg}',
                             'details': 'Reports directory does not exist. Please use manual file upload or fix SharePoint permissions.',
                             'sharepoint_error': True
                         }), 500
@@ -286,59 +317,53 @@ def create_app(config_path: Optional[str] = None):
                                 logger.error(f"Failed to clear unexpected file {file.name}: {e}")
             elif not download_from_sp:
                 # Manual upload was used (download_from_sharepoint=False)
-                # Upload endpoint should have cleared old files, but double-check
-                # Only use files uploaded in the last 10 minutes to avoid combining with old files
+                # Upload endpoint should have cleared old files before saving new ones
+                # Use ALL files in the directory (they should all be from the recent upload)
                 if reports_dir_path.exists():
                     excel_files = list(reports_dir_path.glob('*.xlsx')) + list(reports_dir_path.glob('*.xls'))
                     current_time = datetime.now().timestamp()
                     recent_files = []
+                    
+                    logger.info(f"Manual upload generation: Found {len(excel_files)} file(s) in reports directory")
+                    
+                    # Only use files modified in the last 2 minutes (very recent = just uploaded)
+                    # This ensures we don't accidentally use SharePoint-downloaded files
                     for excel_file in excel_files:
                         mtime = excel_file.stat().st_mtime
-                        # Only use files modified in the last 10 minutes (should be the uploaded ones)
-                        # Increased from 5 to 10 minutes to account for upload + generation delay
-                        if current_time - mtime < 600:  # 10 minutes
+                        age_seconds = current_time - mtime
+                        # Only use files uploaded in the last 2 minutes (120 seconds)
+                        # This is tight enough to catch only the most recent upload
+                        if age_seconds < 120:  # 2 minutes
                             recent_files.append(excel_file)
                             mtime_str = datetime.fromtimestamp(mtime).strftime('%Y-%m-%d %H:%M:%S')
-                            logger.info(f"  - {excel_file.name} (modified: {mtime_str}) - will be used for manual upload generation")
+                            logger.info(f"  - {excel_file.name} (modified: {mtime_str}, age: {age_seconds:.1f}s) - will be used for manual upload generation")
                         else:
-                            logger.warning(f"  - {excel_file.name} (modified: {datetime.fromtimestamp(mtime).strftime('%Y-%m-%d %H:%M:%S')}) - skipping (too old, might be from previous run)")
+                            logger.warning(f"  - {excel_file.name} (modified: {datetime.fromtimestamp(mtime).strftime('%Y-%m-%d %H:%M:%S')}, age: {age_seconds:.1f}s) - skipping (too old, might be from SharePoint download)")
                     
+                    # Clear any files that are too old (likely from SharePoint)
                     if len(recent_files) < len(excel_files):
-                        logger.warning(f"Found {len(excel_files)} total file(s), but only {len(recent_files)} are recent. Clearing old files to avoid combining...")
-                        # Clear old files to ensure we only use the manually uploaded ones
+                        logger.warning(f"Found {len(excel_files)} total file(s), but only {len(recent_files)} are recent (< 2 min old). Clearing old files...")
                         for excel_file in excel_files:
                             if excel_file not in recent_files:
                                 try:
                                     excel_file.unlink()
-                                    logger.info(f"Cleared old file: {excel_file.name}")
+                                    logger.info(f"Cleared old file (likely from SharePoint): {excel_file.name}")
                                 except Exception as e:
                                     logger.warning(f"Failed to clear old file {excel_file.name}: {e}")
                     
                     if len(recent_files) == 0:
-                        logger.error("Manual upload was used but no recent files found in reports directory!")
+                        logger.error("Manual upload was used but no recent files (< 2 min old) found in reports directory!")
                         logger.error("This might mean:")
                         logger.error("1. Files were not uploaded successfully")
-                        logger.error("2. Files were uploaded but cleared before generation")
+                        logger.error("2. Upload happened more than 2 minutes ago")
                         logger.error("3. File modification times are incorrect")
+                        logger.error("4. SharePoint download happened after upload")
                         return jsonify({
-                            'error': 'No files found for manual upload generation',
-                            'details': 'Files were uploaded but not found in reports directory. Please try uploading again.',
+                            'error': 'No recent files found for manual upload generation',
+                            'details': 'Files were uploaded but not found or are too old. Please try uploading again and generating immediately.',
                             'manual_upload_error': True
                         }), 400
                     
-                    # Verify we only have the recently uploaded files
-                    all_files = list(reports_dir_path.glob('*.xlsx')) + list(reports_dir_path.glob('*.xls'))
-                    if len(all_files) != len(recent_files):
-                        logger.warning(f"WARNING: Found {len(all_files)} file(s) but only {len(recent_files)} are recent!")
-                        logger.warning("Clearing old files to ensure only uploaded files are used...")
-                        for file in all_files:
-                            if file not in recent_files:
-                                try:
-                                    file.unlink()
-                                    logger.info(f"Cleared unexpected old file: {file.name}")
-                                except Exception as e:
-                                    logger.error(f"Failed to clear unexpected file {file.name}: {e}")
-                    
                     logger.info(f"Will generate report from {len(recent_files)} recently uploaded file(s)")
                 else:
                     logger.error("Manual upload was used but reports directory does not exist!")
@@ -358,6 +383,34 @@ def create_app(config_path: Optional[str] = None):
                     'sharepoint_error': True
                 }), 400
             
+            # FINAL VERIFICATION: Before generation, ensure only expected files exist
+            final_files = list(reports_dir_path.glob('*.xlsx')) + list(reports_dir_path.glob('*.xls'))
+            if len(final_files) > 1:
+                logger.error(f"CRITICAL: Found {len(final_files)} Excel file(s) before generation!")
+                logger.error("This will cause data mixing. Files found:")
+                for f in final_files:
+                    mtime = f.stat().st_mtime
+                    mtime_str = datetime.fromtimestamp(mtime).strftime('%Y-%m-%d %H:%M:%S')
+                    logger.error(f"  - {f.name} (modified: {mtime_str})")
+                logger.error("Attempting to keep only the most recent file...")
+                
+                # Keep only the newest file
+                final_files_sorted = sorted(final_files, key=lambda f: f.stat().st_mtime, reverse=True)
+                newest_file = final_files_sorted[0]
+                for old_file in final_files_sorted[1:]:
+                    try:
+                        old_file.unlink()
+                        logger.info(f"Removed older file before generation: {old_file.name}")
+                    except Exception as e:
+                        logger.error(f"Failed to remove {old_file.name}: {e}")
+                        return jsonify({
+                            'error': f'Multiple Excel files found and cannot remove old ones',
+                            'details': f'Found {len(final_files)} files. Please ensure only one file exists. Files may be locked.',
+                            'files_found': [f.name for f in final_files]
+                        }), 400
+                
+                logger.warning(f"Proceeding with only the newest file: {newest_file.name}")
+            
             report_data = generate_report(
                 reports_dir=str(reports_dir_path),
                 output_file=output_file,
@@ -400,12 +453,16 @@ def create_app(config_path: Optional[str] = None):
     @app.route('/api/upload', methods=['POST'])
     def upload_files():
         """Upload Excel files manually. Clears old files before uploading new ones."""
+        logger.info("=== MANUAL UPLOAD REQUEST RECEIVED ===")
         try:
             if 'files' not in request.files:
+                logger.error("Upload request missing 'files' field")
                 return jsonify({'error': 'No files provided'}), 400
             
             files = request.files.getlist('files')
+            logger.info(f"Received {len(files)} file(s) in upload request")
             if not files or all(f.filename == '' for f in files):
+                logger.error("No valid files in upload request")
                 return jsonify({'error': 'No files selected'}), 400
             
             report_config = app.config['REPORT_CONFIG']
@@ -426,33 +483,70 @@ def create_app(config_path: Optional[str] = None):
             
             for old_file in old_excel_files:
                 try:
-                    # On Windows, files might be locked - try multiple times
-                    max_retries = 3
+                    # On Windows, files might be locked - try multiple times with increasing delays
+                    max_retries = 5
                     retry_count = 0
-                    while retry_count < max_retries:
+                    cleared_this_file = False
+                    
+                    while retry_count < max_retries and not cleared_this_file:
                         try:
                             old_file.unlink()
                             cleared_count += 1
+                            cleared_this_file = True
                             logger.info(f"Cleared old file before upload: {old_file.name}")
                             break
-                        except PermissionError:
+                        except PermissionError as pe:
                             retry_count += 1
                             if retry_count < max_retries:
+                                # Increasing delay: 0.5s, 1s, 2s, 3s
                                 import time
-                                time.sleep(0.5)  # Wait 500ms before retry
+                                delay = min(0.5 * (2 ** retry_count), 3.0)
+                                logger.warning(f"File {old_file.name} is locked (attempt {retry_count}/{max_retries}), waiting {delay}s...")
+                                time.sleep(delay)
                             else:
-                                raise
+                                # Last attempt failed - try renaming instead of deleting
+                                logger.warning(f"Cannot delete {old_file.name}, trying to rename instead...")
+                                try:
+                                    import time
+                                    timestamp = int(time.time())
+                                    backup_name = f"{old_file.stem}_backup_{timestamp}{old_file.suffix}"
+                                    backup_path = old_file.parent / backup_name
+                                    old_file.rename(backup_path)
+                                    cleared_count += 1
+                                    cleared_this_file = True
+                                    logger.info(f"Renamed locked file to backup: {old_file.name} -> {backup_name}")
+                                except Exception as rename_error:
+                                    logger.error(f"Could not rename file either: {rename_error}")
+                                    raise pe  # Raise original PermissionError
                         except Exception as e:
+                            if retry_count >= max_retries - 1:
+                                raise
+                            retry_count += 1
+                            import time
+                            time.sleep(1)
+                    
+                    if not cleared_this_file:
+                        failed_to_clear.append(old_file.name)
+                        logger.error(f"Failed to clear old file {old_file.name} after {max_retries} attempts")
+                except Exception as e:
+                    if old_file.name not in failed_to_clear:
                         failed_to_clear.append(old_file.name)
                     logger.error(f"Failed to clear old file {old_file.name}: {e}")
             
             # If any files failed to clear, fail the upload to prevent mixing old and new data
             if failed_to_clear:
                 logger.error(f"CRITICAL: Failed to clear {len(failed_to_clear)} file(s) before upload: {failed_to_clear}")
+                locked_files_list = ', '.join(failed_to_clear)
                 return jsonify({
-                    'error': f'Failed to clear {len(failed_to_clear)} old file(s) before upload. Please ensure files are not locked or in use.',
+                    'error': f'Cannot upload: {len(failed_to_clear)} file(s) are locked',
                     'failed_files': failed_to_clear,
-                    'details': 'Old files must be cleared before upload to ensure report generation uses only the new file(s). Files may be locked by Excel or another process.'
+                    'details': f'File(s) {locked_files_list} are being used by another program (likely Excel). Please close Excel and any other programs that might have these files open, then try again.',
+                    'instructions': [
+                        '1. Close Microsoft Excel completely',
+                        '2. Close any file explorer windows showing these files',
+                        '3. Wait a few seconds',
+                        '4. Try uploading again'
+                    ]
                 }), 500
             
             if cleared_count > 0:
@@ -460,6 +554,30 @@ def create_app(config_path: Optional[str] = None):
             else:
                 logger.info("No old Excel files found to clear (reports directory was empty)")
             
+            # VERIFY: Double-check that all Excel files are actually gone
+            remaining_files = list(reports_dir.glob('*.xlsx')) + list(reports_dir.glob('*.xls'))
+            if remaining_files:
+                logger.error(f"CRITICAL: After clearing, {len(remaining_files)} file(s) still exist: {[f.name for f in remaining_files]}")
+                logger.error("These files are likely locked. Attempting force removal...")
+                force_failed = []
+                for remaining_file in remaining_files:
+                    try:
+                        remaining_file.unlink()
+                        logger.info(f"Force-removed locked file: {remaining_file.name}")
+                    except Exception as e:
+                        force_failed.append(remaining_file.name)
+                        logger.error(f"CRITICAL: Cannot remove locked file {remaining_file.name}: {e}")
+                
+                if force_failed:
+                    logger.error(f"CRITICAL: {len(force_failed)} file(s) still locked after force removal: {force_failed}")
+                    return jsonify({
+                        'error': f'Cannot upload: {len(force_failed)} file(s) are locked and cannot be deleted',
+                        'failed_files': force_failed,
+                        'details': 'Please close Excel or any other program using these files, then try again.'
+                    }), 500
+            
+            logger.info("✓ Verified: All old Excel files cleared successfully before upload")
+            
             uploaded_count = 0
             uploaded_files = []
             
@@ -475,10 +593,20 @@ def create_app(config_path: Optional[str] = None):
                 
                 # Save file to reports directory
                 file_path = reports_dir / filename
+                logger.info(f"Saving uploaded file: {filename} -> {file_path}")
                 file.save(str(file_path))
+                
+                # Verify file was saved and get its modification time
+                if file_path.exists():
+                    mtime = file_path.stat().st_mtime
+                    mtime_str = datetime.fromtimestamp(mtime).strftime('%Y-%m-%d %H:%M:%S')
+                    file_size = file_path.stat().st_size
+                    logger.info(f"Successfully saved file: {filename} (size: {file_size} bytes, modified: {mtime_str})")
                     uploaded_count += 1
                     uploaded_files.append(filename)
-                logger.info(f"Uploaded file: {filename} -> {file_path}")
+                else:
+                    logger.error(f"CRITICAL: File was not saved! {file_path} does not exist after save()")
+                    raise Exception(f"Failed to save file {filename}")
             
             if uploaded_count == 0:
                 return jsonify({'error': 'No valid Excel files uploaded'}), 400
@@ -664,10 +792,44 @@ def create_app(config_path: Optional[str] = None):
     return app
 
 
+def start_scheduler(config_path: Optional[str] = None):
+    """Start the scheduler in a background thread."""
+    global scheduler_thread
+    
+    scheduler_config = config.get('scheduler', {})
+    if not scheduler_config.get('enabled'):
+        logger.info("Scheduler is disabled in configuration")
+        return
+    
+    try:
+        from scheduler import ReportScheduler
+        import threading
+        
+        def run_scheduler():
+            try:
+                scheduler = ReportScheduler(config_path=config_path)
+                scheduler.start()
+            except Exception as e:
+                logger.error(f"Scheduler error: {e}", exc_info=True)
+        
+        scheduler_thread = threading.Thread(target=run_scheduler, daemon=True)
+        scheduler_thread.start()
+        logger.info("Scheduler started in background thread")
+    except ImportError:
+        logger.warning("Scheduler module not available. Install apscheduler to enable scheduling.")
+    except Exception as e:
+        logger.error(f"Failed to start scheduler: {e}", exc_info=True)
+
+
 def run_server(config_path: Optional[str] = None, host: Optional[str] = None, port: Optional[int] = None):
     """Run the API server."""
+    global app, config
+    
     app = create_app(config_path)
     
+    # Start scheduler if enabled
+    start_scheduler(config_path)
+    
     api_config = config.get('api', {})
     server_host = host or api_config.get('host', '0.0.0.0')
     server_port = port or api_config.get('port', 8080)

config.py

@@ -34,10 +34,10 @@ DEFAULT_CONFIG = {
     },
     'scheduler': {
         'enabled': False,
-        'schedule_type': 'interval',  # 'interval', 'cron', or 'once'
+        'schedule_type': 'cron',  # 'interval', 'cron', or 'once'
         'interval_hours': 24,  # For interval type
-        'cron_expression': '0 8 * * *',  # For cron type (8 AM daily)
-        'timezone': 'America/New_York'
+        'cron_expression': '0 10 * * *',  # For cron type (10 AM EST/EDT daily)
+        'timezone': 'America/New_York'  # EST/EDT timezone
     },
     'api': {
         'enabled': False,
@@ -186,10 +186,14 @@ def _load_from_env(config: Dict) -> Dict:
     # Scheduler settings
     if os.getenv('SCHEDULER_ENABLED'):
         config['scheduler']['enabled'] = os.getenv('SCHEDULER_ENABLED').lower() == 'true'
+    if os.getenv('SCHEDULER_SCHEDULE_TYPE'):
+        config['scheduler']['schedule_type'] = os.getenv('SCHEDULER_SCHEDULE_TYPE')
     if os.getenv('SCHEDULER_INTERVAL_HOURS'):
         config['scheduler']['interval_hours'] = int(os.getenv('SCHEDULER_INTERVAL_HOURS'))
     if os.getenv('SCHEDULER_CRON'):
         config['scheduler']['cron_expression'] = os.getenv('SCHEDULER_CRON')
+    if os.getenv('SCHEDULER_TIMEZONE'):
+        config['scheduler']['timezone'] = os.getenv('SCHEDULER_TIMEZONE')
     
     # API settings
     if os.getenv('API_ENABLED'):

output/preprocessed_data.txt

@@ -1,7 +1,7 @@
 PREPROCESSED EXCEL DATA
 ================================================================================
-Current Date (Baltimore/Eastern): 2025-11-07 12:05:51 EST
-Total Items: 167
+Current Date (Baltimore/Eastern): 2025-11-09 06:19:52 EST
+Total Items: 171
 
 VENDOR: Amazon
 --------------------------------------------------------------------------------
@@ -11,7 +11,7 @@ Total Items: 1
   Monitor: 0
 
 OLDEST UNADDRESSED (Top 3):
-  AWCS Multiple Destinations | Age: 23 days | 10/15/25 | Incomplete
+  AWCS Multiple Destinations | Age: 25 days | 10/15/25 | Incomplete
 
 VERY HIGH PRIORITY (1 items):
   AWCS Multiple Destinations | Incomplete | 10/15/25
@@ -23,32 +23,30 @@ ALL ITEMS:
 
 VENDOR: Autstand
 --------------------------------------------------------------------------------
-Total Items: 79
-  Closed: 64
-  Open: 9
-  Monitor: 6
-
-RECENT UPDATES (Yesterday's Date):
-  ADDED: Fix tippers faulting mid-dump sequence | 2025-11-06 00:00:00 | Incomplete
-  ADDED: PS8-5 Jammed but not showing on SCADA | 2025-11-06 00:00:00 | Incomplete
+Total Items: 83
+  Closed: 66
+  Open: 10
+  Monitor: 7
 
 OLDEST UNADDRESSED (Top 3):
-  Encoder failure (4x)  + 2 x | Age: 28 days | 2025-10-10 00:00:00 | Incomplete
-  Jam Reset buttons on Bulk divert platforms to be relocated | Age: 23 days | 10/15/25 | Incomplete
-  PS11-11CH6NC Intralox Sorter (S02) | Age: 21 days | 10/17/2025 | Incomplete
+  Encoder failure (4x)  + 2 x | Age: 30 days | 2025-10-10 00:00:00 | Incomplete
+  PS11-11CH6NC Intralox Sorter (S02) | Age: 23 days | 10/17/2025 | Incomplete
+  Bypass improvements | Age: 6 days | 2025-11-03 00:00:00 | Incomplete
 
-VERY HIGH PRIORITY (6 items):
+VERY HIGH PRIORITY (8 items):
   Semi-Auto Exception Arm Logic | Complete | 10/14/25
   PS Conveyor chute clearing Issues | Complete | 10/14/25
   Replicate logic timers from semi VS-D to the rest of the semis | Monitor | 10/14/25
   Tipper timer | Complete | 10/14/25
   SCADA Accurate Status Reads | Complete | 10/14/25
   NC boxes are diverting to xbelt causing jams particullary at bypass curves | Complete | 10/17
+  Jiffys to noncon | Incomplete | 2025-11-07 00:00:00
+  Over-width noncons diverting to crossbelt | Incomplete | 2025-11-07 00:00:00
 
-HIGH PRIORITY (58 items):
+HIGH PRIORITY (60 items):
   Problem Solve dead rollers | Complete | 10/14/25
   Jam Reset Button needed at end of NC Jackpots | Complete | 10/15/25
-  Jam Reset buttons on Bulk divert platforms to be relocated | Incomplete | 10/15/25
+  Jam Reset buttons on Bulk divert platforms to be relocated | Complete | 10/15/25
   Flow Splitter Verification | Complete | 10/15/25
   Jam Reset NC End of Sorter | Complete | 10/15/25
   "Destination Not Attempted" Reason Code | Complete | 10/15/25
@@ -106,6 +104,8 @@ The PLC is not reporting S04 message divert fails properly (no reads to jackpot,
   Bypass improvements | Incomplete | 2025-11-03 00:00:00
   Sorter statistics on SCADA | Monitor | 2025-11-03 00:00:00
   Update SCADA to show inch and store status of conveyors with such functionality | Incomplete | 2025-11-07 00:00:00
+  NCP1-6-TPE1 did not alarm correctly on SCADA when jammed | Complete | 2025-11-07 00:00:00
+  PS8-6 flow splitter eating packages | Monitor | 2025-11-07 00:00:00
 
 ALL ITEMS:
   Semi-Auto Exception Arm Logic | Vendor: Autstand | Priority: (1) Very High (very_high) | Status: Complete (CLOSED) | Date: 10/14/25 | Description: Exception chute arm disengaged prior to all carton...
@@ -115,7 +115,7 @@ ALL ITEMS:
   SCADA Accurate Status Reads | Vendor: Autstand | Priority: (1) Very High (very_high) | Status: Complete (CLOSED) | Date: 10/14/25 | Description: Update SCADA status accuracy with info sent from B...
   Problem Solve dead rollers | Vendor: Autstand | Priority: (2) High (high) | Status: Complete (CLOSED) | Date: 10/14/25 | Description: First few rollers not able to be engaged due to mi...
   Jam Reset Button needed at end of NC Jackpots | Vendor: Autstand | Priority: (2) High (high) | Status: Complete (CLOSED) | Date: 10/15/25 | Description: There is no reset at the end of the NC sorters   n...
-  Jam Reset buttons on Bulk divert platforms to be relocated | Vendor: Autstand | Priority: (2) High (high) | Status: Incomplete (OPEN) | Date: 10/15/25 | Description: JR button is behind the saefty fencing move to out...
+  Jam Reset buttons on Bulk divert platforms to be relocated | Vendor: Autstand | Priority: (2) High (high) | Status: Complete (CLOSED) | Date: 10/15/25 | Description: JR button is behind the saefty fencing move to out...
   Flow Splitter Verification | Vendor: Autstand | Priority: (2) High (high) | Status: Complete (CLOSED) | Date: 10/15/25 | Description: Conveyable cartons are entering the non-con at a h...
   Semi-Auto Chute fullness PE Height | Vendor: Autstand | Priority: (3) Medium (medium) | Status: Complete (CLOSED) | Date: 10/14/25 | Description: Adjust 50% and 100% Full PE locations to better op...
   Jam Cam visibility in SCADA | Vendor: Autstand | Priority: (3) Medium (medium) | Status: Complete (CLOSED) | Date: 10/15/25 | Description: Autstand needs to set up passwords/remove pw  for ...
@@ -189,6 +189,10 @@ The PLC is not reporting S04 message divert fails properly (no reads to jackpot,
   Bypass improvements | Vendor: Autstand | Priority: (2) High (high) | Status: Incomplete (OPEN) | Date: 2025-11-03 00:00:00 | Description: Bypass showing lane unavailable when not running, ...
   Sorter statistics on SCADA | Vendor: Autstand | Priority: (2) High (high) | Status: Monitor (OPEN) | Date: 2025-11-03 00:00:00 | Description: Add crossbelt sorter statistics to ignition SCADA ...
   Update SCADA to show inch and store status of conveyors with such functionality | Vendor: Autstand | Priority: (2) High (high) | Status: Incomplete (OPEN) | Date: 2025-11-07 00:00:00 | Description: Update SCADA to show inch and store conveyors as Y...
+  NCP1-6-TPE1 did not alarm correctly on SCADA when jammed | Vendor: Autstand | Priority: (2) High (high) | Status: Complete (CLOSED) | Date: 2025-11-07 00:00:00 | Description: Jiffy got to noncon and stuck in a T-plate causing...
+  Jiffys to noncon | Vendor: Autstand | Priority: (1) Very High (very_high) | Status: Incomplete (OPEN) | Date: 2025-11-07 00:00:00 | Description: Jiffys are getting to noncon causing jams and pote...
+  Over-width noncons diverting to crossbelt | Vendor: Autstand | Priority: (1) Very High (very_high) | Status: Incomplete (OPEN) | Date: 2025-11-07 00:00:00 | Description: Packages that are over-width that should pass thro...
+  PS8-6 flow splitter eating packages | Vendor: Autstand | Priority: (2) High (high) | Status: Monitor (OPEN) | Date: 2025-11-07 00:00:00 | Description: PS8-6 flow splitter is sucking in packages at the ...
 
 ================================================================================
 
@@ -231,9 +235,9 @@ Total Items: 32
   Monitor: 5
 
 OLDEST UNADDRESSED (Top 3):
-  BYPASS ATOC Auto induct reoccuring flase Jam | Age: 22 days | 10/16/2025 | Incomplete
-  Allocations are correct - wrong packages coming down | Age: 22 days | 10/16/2025 | Incomplete
-  Auto induct - D back fireing packages that can go - also demissionier is off | Age: 22 days | 10/16/2025 | Incomplete
+  BYPASS ATOC Auto induct reoccuring flase Jam | Age: 24 days | 10/16/2025 | Incomplete
+  Allocations are correct - wrong packages coming down | Age: 24 days | 10/16/2025 | Incomplete
+  Auto induct - D back fireing packages that can go - also demissionier is off | Age: 24 days | 10/16/2025 | Incomplete
 
 VERY HIGH PRIORITY (6 items):
   Bypasses Not On Due to Auto-Induct Status | Monitor | 10/14/25
@@ -301,10 +305,10 @@ Total Items: 4
   Monitor: 0
 
 OLDEST UNADDRESSED (Top 3):
-  Photoeyes at Caljan not wired properly | Age: 23 days | 10/15/25 | Incomplete
+  Photoeyes at Caljan not wired properly | Age: 25 days | 10/15/25 | Incomplete
   Maxx Reach at DD 332 not working
-https://t.corp.amazon.com/V1969041198 | Age: 23 days | 10/15/2025 | Incomplete
-  Max Reach 100% PE logic is backwards All 300 and 100 DD | Age: 22 days | 10/16/2025 | Incomplete
+https://t.corp.amazon.com/V1969041198 | Age: 25 days | 10/15/2025 | Incomplete
+  Max Reach 100% PE logic is backwards All 300 and 100 DD | Age: 24 days | 10/16/2025 | Incomplete
 
 HIGH PRIORITY (3 items):
   Photoeyes at Caljan not wired properly | Incomplete | 10/15/25
@@ -329,8 +333,8 @@ Total Items: 25
   Monitor: 1
 
 OLDEST UNADDRESSED (Top 3):
-  NCS1-1 aligner belt failed | Age: 6 days | 2025-11-01 00:00:00 | Incomplete
-  3) The black UHMW strip under the belt which transitions the belt from slider bed to tail roller is too sharp and is shaving the bottom side of the belt.  Jesse and his team are going to look into pulling this uhmw strip out, properly chamfering it and then re-installing. | Age: 3 days | 2025-11-04 00:00:00 | Incomplete
+  NCS1-1 aligner belt failed | Age: 8 days | 2025-11-01 00:00:00 | Incomplete
+  3) The black UHMW strip under the belt which transitions the belt from slider bed to tail roller is too sharp and is shaving the bottom side of the belt.  Jesse and his team are going to look into pulling this uhmw strip out, properly chamfering it and then re-installing. | Age: 5 days | 2025-11-04 00:00:00 | Incomplete
   Add air pressure valves  (autstand request to DCS) | Age: None days |  | Incomplete
 
 VERY HIGH PRIORITY (4 items):
@@ -434,9 +438,9 @@ Total Items: 5
   Monitor: 1
 
 OLDEST UNADDRESSED (Top 3):
-  Long-Term Error Tracking Solution | Age: 30 days | 10/8/25 | Incomplete
-  High Multi-Label Read Rate | Age: 24 days | 10/14/25 | Incomplete
-  Pull stats for error codes from Datalogic | Age: 24 days | 10/14/25 | Incomplete
+  Long-Term Error Tracking Solution | Age: 32 days | 10/8/25 | Incomplete
+  High Multi-Label Read Rate | Age: 26 days | 10/14/25 | Incomplete
+  Pull stats for error codes from Datalogic | Age: 26 days | 10/14/25 | Incomplete
 
 VERY HIGH PRIORITY (1 items):
   Add DHL label to Scan tunnel valid message | Incomplete | 2025-10-27 00:00:00
@@ -504,9 +508,9 @@ Total Items: 7
   Monitor: 0
 
 OLDEST UNADDRESSED (Top 3):
-  supply cabinet in NON Con | Age: 22 days | 10/16/2025 | Incomplete
-  drop zone banner in Non Con | Age: 22 days | 10/16/2025 | Incomplete
-  printer station at both ends in Non Con | Age: 22 days | 10/16/2025 | Incomplete
+  supply cabinet in NON Con | Age: 24 days | 10/16/2025 | Incomplete
+  drop zone banner in Non Con | Age: 24 days | 10/16/2025 | Incomplete
+  printer station at both ends in Non Con | Age: 24 days | 10/16/2025 | Incomplete
 
 HIGH PRIORITY (2 items):
   Non - Con Jam rest button - | Complete | 10/15/2025
@@ -531,7 +535,7 @@ Total Items: 1
   Monitor: 0
 
 OLDEST UNADDRESSED (Top 3):
-  Jam Clearing Equipment on Mezzanine | Age: 24 days | 10/14/25 | Incomplete
+  Jam Clearing Equipment on Mezzanine | Age: 26 days | 10/14/25 | Incomplete
 
 HIGH PRIORITY (1 items):
   Jam Clearing Equipment on Mezzanine | Incomplete | 10/14/25

scheduler.py

@@ -12,6 +12,7 @@ from pathlib import Path
 
 try:
     from apscheduler.schedulers.blocking import BlockingScheduler
+    from apscheduler.schedulers.background import BackgroundScheduler
     from apscheduler.triggers.interval import IntervalTrigger
     from apscheduler.triggers.cron import CronTrigger
     from apscheduler.triggers.date import DateTrigger
@@ -26,6 +27,52 @@ from sharepoint_downloader import download_from_sharepoint
 
 logger = logging.getLogger(__name__)
 
+# Cleanup function (duplicated from api_server to avoid circular import)
+def cleanup_old_reports(output_dir: Path, reports_dir: Path, max_reports: int = 10):
+    """
+    Cleanup old reports and Excel files, keeping only the last max_reports.
+    
+    Args:
+        output_dir: Directory containing report HTML/JSON files
+        reports_dir: Directory containing Excel files
+        max_reports: Maximum number of reports to keep
+    """
+    try:
+        # Get all report HTML files sorted by modification time (newest first)
+        html_files = sorted(output_dir.glob('report-*.html'), key=lambda p: p.stat().st_mtime, reverse=True)
+        
+        if len(html_files) <= max_reports:
+            return  # No cleanup needed
+        
+        # Get reports to delete (oldest ones)
+        reports_to_delete = html_files[max_reports:]
+        
+        deleted_count = 0
+        for html_file in reports_to_delete:
+            report_id = html_file.stem
+            
+            # Delete HTML file
+            try:
+                html_file.unlink()
+                logger.info(f"Deleted old report HTML: {html_file.name}")
+                deleted_count += 1
+            except Exception as e:
+                logger.warning(f"Failed to delete {html_file.name}: {e}")
+            
+            # Delete corresponding JSON file
+            json_file = output_dir / f"{report_id}.json"
+            if json_file.exists():
+                try:
+                    json_file.unlink()
+                    logger.info(f"Deleted old report JSON: {json_file.name}")
+                except Exception as e:
+                    logger.warning(f"Failed to delete {json_file.name}: {e}")
+        
+        if deleted_count > 0:
+            logger.info(f"Cleanup completed: deleted {deleted_count} old report(s)")
+    except Exception as e:
+        logger.error(f"Error during cleanup: {e}", exc_info=True)
+
 
 class ReportScheduler:
     """Manages scheduled report generation."""
@@ -44,7 +91,14 @@ class ReportScheduler:
             )
         
         self.config = load_config(config_path)
-        self.scheduler = BlockingScheduler(timezone=self.config['scheduler']['timezone'])
+        scheduler_timezone = self.config['scheduler'].get('timezone', 'America/New_York')
+        # Use BackgroundScheduler for thread compatibility (when run from API server)
+        # Use BlockingScheduler when run standalone
+        self.use_background = True  # Set to False if running standalone
+        if self.use_background:
+            self.scheduler = BackgroundScheduler(timezone=scheduler_timezone)
+        else:
+            self.scheduler = BlockingScheduler(timezone=scheduler_timezone)
         self.scheduler_config = self.config['scheduler']
         self.sharepoint_config = self.config.get('sharepoint', {})
         self.report_config = self.config.get('report', {})
@@ -78,10 +132,15 @@ class ReportScheduler:
                     logger.error(f"Failed to download from SharePoint: {e}")
                     # Continue with report generation even if download fails
             
-            # Generate report
+            # Generate report with timestamp
             logger.info("Generating report...")
             reports_dir = self.report_config.get('reports_dir', 'reports')
-            output_file = Path(self.report_config.get('output_dir', 'output')) / 'report.json'
+            output_dir = Path(self.report_config.get('output_dir', 'output'))
+            
+            # Create timestamped filename (same format as API server)
+            timestamp = datetime.now().strftime('%Y-%m-%d-%H-%M-%S')
+            report_id = f"report-{timestamp}"
+            output_file = output_dir / f"{report_id}.json"
             
             report_data = generate_report(
                 reports_dir=reports_dir,
@@ -91,6 +150,12 @@ class ReportScheduler:
             
             if report_data:
                 logger.info("✓ Scheduled report generation completed successfully")
+                
+                # Cleanup old reports (keep last 10)
+                try:
+                    cleanup_old_reports(output_dir, Path(reports_dir), max_reports=10)
+                except Exception as e:
+                    logger.warning(f"Failed to cleanup old reports: {e}")
             else:
                 logger.error("✗ Scheduled report generation failed")
                 
@@ -150,11 +215,18 @@ class ReportScheduler:
             replace_existing=True
         )
         
+        if self.use_background:
+            # BackgroundScheduler - just start it, don't block
+            self.scheduler.start()
+            logger.info("Scheduler started in background mode")
+        else:
+            # BlockingScheduler - block until interrupted
             logger.info("Scheduler started. Press Ctrl+C to stop.")
             try:
                 self.scheduler.start()
             except KeyboardInterrupt:
                 logger.info("Scheduler stopped by user")
+                self.scheduler.shutdown()
 
 
 if __name__ == "__main__":
@@ -168,5 +240,7 @@ if __name__ == "__main__":
     config_path = sys.argv[1] if len(sys.argv) > 1 else None
     
     scheduler = ReportScheduler(config_path=config_path)
+    scheduler.use_background = False  # Use BlockingScheduler for standalone mode
+    scheduler.scheduler = BlockingScheduler(timezone=scheduler.config['scheduler'].get('timezone', 'America/New_York'))
     scheduler.start()
 

sharepoint_downloader.py

@@ -284,42 +284,92 @@ class SharePointDownloader:
         
         # ALWAYS clear ALL existing Excel files before downloading (to ensure only new files are used)
         # This is critical to prevent combining multiple files
+        # Wait a moment first to allow any previous file operations to complete
+        import time
+        time.sleep(1.0)  # Give file handles time to close
+        
         existing_files = list(local_dir_path.glob('*.xlsx')) + list(local_dir_path.glob('*.xls'))
         cleared_count = 0
         failed_to_clear = []
         
         for old_file in existing_files:
             try:
-                # On Windows, files might be locked - try multiple times
-                max_retries = 3
+                # On Windows, files might be locked - try multiple times with increasing delays
+                max_retries = 5
                 retry_count = 0
-                while retry_count < max_retries:
+                cleared_this_file = False
+                
+                while retry_count < max_retries and not cleared_this_file:
                     try:
                         old_file.unlink()
                         cleared_count += 1
+                        cleared_this_file = True
                         logger.info(f"Cleared existing file before download: {old_file.name}")
                         break
-                    except PermissionError:
+                    except PermissionError as pe:
                         retry_count += 1
                         if retry_count < max_retries:
+                            # Increasing delay: 0.5s, 1s, 2s, 3s
                             import time
-                            time.sleep(0.5)  # Wait 500ms before retry
+                            delay = min(0.5 * (2 ** retry_count), 3.0)
+                            logger.warning(f"File {old_file.name} is locked (attempt {retry_count}/{max_retries}), waiting {delay}s...")
+                            time.sleep(delay)
                         else:
-                            raise
+                            # Last attempt failed - try renaming instead of deleting
+                            logger.warning(f"Cannot delete {old_file.name}, trying to rename instead...")
+                            try:
+                                import time
+                                timestamp = int(time.time())
+                                backup_name = f"{old_file.stem}_backup_{timestamp}{old_file.suffix}"
+                                backup_path = old_file.parent / backup_name
+                                old_file.rename(backup_path)
+                                cleared_count += 1
+                                cleared_this_file = True
+                                logger.info(f"Renamed locked file to backup: {old_file.name} -> {backup_name}")
+                            except Exception as rename_error:
+                                logger.error(f"Could not rename file either: {rename_error}")
+                                raise pe  # Raise original PermissionError
                     except Exception as e:
+                        if retry_count >= max_retries - 1:
+                            raise
+                        retry_count += 1
+                        import time
+                        time.sleep(1)
+                
+                if not cleared_this_file:
+                    failed_to_clear.append(old_file.name)
+                    logger.error(f"Failed to clear existing file {old_file.name} after {max_retries} attempts")
+            except Exception as e:
+                if old_file.name not in failed_to_clear:
                     failed_to_clear.append(old_file.name)
                 logger.error(f"Failed to clear existing file {old_file.name}: {e}")
         
         if failed_to_clear:
             logger.error(f"CRITICAL: Failed to clear {len(failed_to_clear)} file(s) before download: {failed_to_clear}")
             logger.error("This will cause data mixing! Files may be locked by another process.")
-            # Don't fail here - let the download proceed, but log the warning
+            logger.error("ABORTING download to prevent combining multiple files.")
+            raise Exception(f"Cannot download from SharePoint: {len(failed_to_clear)} file(s) could not be cleared. Please close any programs that might have these files open: {failed_to_clear}")
         
         if cleared_count > 0:
             logger.info(f"Cleared {cleared_count} existing Excel file(s) before downloading from SharePoint")
         else:
             logger.info("No existing Excel files found to clear (reports directory was empty)")
         
+        # VERIFY: Double-check that all Excel files are actually gone
+        remaining_files = list(local_dir_path.glob('*.xlsx')) + list(local_dir_path.glob('*.xls'))
+        if remaining_files:
+            logger.error(f"CRITICAL: After clearing, {len(remaining_files)} file(s) still exist: {[f.name for f in remaining_files]}")
+            logger.error("These files are likely locked. Attempting force removal...")
+            for remaining_file in remaining_files:
+                try:
+                    remaining_file.unlink()
+                    logger.info(f"Force-removed locked file: {remaining_file.name}")
+                except Exception as e:
+                    logger.error(f"CRITICAL: Cannot remove locked file {remaining_file.name}: {e}")
+                    raise Exception(f"Cannot proceed: File {remaining_file.name} is locked and cannot be deleted. Please close Excel or any other program using this file.")
+        
+        logger.info("✓ Verified: All old Excel files cleared successfully")
+        
         # List files in folder
         files = self.list_files_in_folder(folder_path, file_pattern)