inno-installers/ShopfloorConnect/IMPROVEMENTS.md

ShopfloorConnect Installer Improvements

Date: 2025-10-10 Version: 1.1

Changes Made

1. Fixed Output Directory Path (Line 16)

Before:

OutputDir=C:\Users\570005354\Downloads\Output

After:

OutputDir=.\Output

Reason: The hardcoded user path would fail when building on different machines. Using a relative path .\Output creates the output directory next to the .iss script file.

---

2. Added Comprehensive Error Handling

Before:

• No error checking on Exec() calls
• No validation of result codes
• Installation continued even if steps failed
• No feedback if something went wrong

After:

• ✅ Checks both Exec() return value AND ResultCode
• ✅ Shows detailed error messages with error codes
• ✅ Exits installation on failure (prevents cascading errors)
• ✅ Provides remediation steps in error messages
• ✅ Validates that configuration file was created

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3. Fixed Batch File Pause Issue (Line 61)

Problem: The install.bat file has a pause command at the end (line 93), which would hang the installer waiting for user input.

Solution: Added echo. | to pipe a newline to the batch file, automatically responding to the pause:

// Before
Exec('cmd.exe', '/c cd /d "C:\ShopFloorConnect\MachineToolClient_Service" && call install.bat', '', SW_SHOW, ewWaitUntilTerminated, ResultCode);

// After
Exec('cmd.exe', '/c cd /d "C:\ShopFloorConnect\MachineToolClient_Service" && echo. | call install.bat', '', SW_SHOW, ewWaitUntilTerminated, ResultCode);

---

4. Added Comprehensive Installation Validation (Lines 73-130)

New Features: After running installation steps, the installer now performs multiple validation checks:

4a. Verify FIT-MI_Server Folder Created (Lines 73-85)

if not DirExists('C:\ShopFloorConnect\FIT-MI_Server') then
begin
  MsgBox('Installation Error: FIT-MI_Server folder not created!' + ...);
  Exit;
end;

This checks that the Ant build script successfully created the service folder structure.

4b. Verify Windows Service Registration (Lines 87-106)

// Query the Windows service
if not Exec('cmd.exe', '/c sc query SFCMTCService', '', SW_HIDE, ewWaitUntilTerminated, ResultCode) then
begin
  MsgBox('Warning: Unable to query Windows service!' + ...);
  Exit;
end;

if ResultCode <> 0 then
begin
  MsgBox('Service Registration Failed!' + ...);
  Exit;
end;

This verifies that the Windows service "SFCMTCService" was actually registered and is queryable.

4c. Verify Configuration File Created (Lines 121-130)

if not FileExists('C:\ShopFloorConnect\FIT-MI_Server\webapps\wut\WEB-INF\conf\mi_server.ini') then
begin
  MsgBox('Configuration Error: mi_server.ini not found!' + ...);
  Exit;
end;

This ensures the critical configuration file was created and populated.

Why These Checks Matter: These validations catch installation failures early and provide specific error messages with remediation steps, preventing the "Installation Complete!" message from showing when installation actually failed.

---

5. Enhanced Error Messages and Success Confirmation

All error messages now include:

• Clear description of what failed
• Error codes when available
• Specific file paths involved
• Remediation steps (what to do manually)

Example Error:

Service Registration Failed!

The Windows service "SFCMTCService" was not created.
Error Code: 1060

The installation may have completed, but the service was not registered.

You may need to manually register the service by running:
C:\ShopFloorConnect\FIT-MI_Server\Tomcat 5.0\bin\SFC_MTC_Tomcat_service.bat install

Enhanced Success Message (Lines 132-145): The completion message now includes service details and instructions:

Installation Complete!

The ShopfloorConnect MTC Service has been installed and configured.

Windows Service: SFCMTCService (Registered)
Startup Type: Delayed Automatic
Site Configuration: West Jefferson CA-LR
Teamcenter Server: 10.233.113.141
Shop Floor PC FQDN: Auto-detected

Config file: C:\ShopFloorConnect\FIT-MI_Server\webapps\wut\WEB-INF\conf\mi_server.ini

To start the service:
  1. Open Services (services.msc)
  2. Find "SFCMTCService"
  3. Right-click → Start

Or run: sc start SFCMTCService

---

Installation Flow (Updated)

┌─────────────────────────────────────┐
│ 1. Copy files to C:\ShopFloorConnect│
│    (169MB - Java + MTC Service)     │
└──────────────┬──────────────────────┘
               │
               ▼
┌─────────────────────────────────────┐
│ 2. Set Environment Variable         │
│    setx /m TCFITDIR=C:\ShopFloorConnect
│    ✓ Error check: Exit if failed    │
└──────────────┬──────────────────────┘
               │
               ▼
┌─────────────────────────────────────┐
│ 3. Install MTC Service              │
│    cd MachineToolClient_Service     │
│    echo. | call install.bat         │
│    (Ant build creates FIT-MI_Server)│
│    (Registers SFCMTCService)        │
│    ✓ Error check: Exit if failed    │
│    ✓ Auto-respond to pause          │
└──────────────┬──────────────────────┘
               │
               ▼ (Sleep 3 seconds)
               │
┌─────────────────────────────────────┐
│ 3a. Verify FIT-MI_Server Created   │
│     Check folder exists             │
│     ✓ Error: Exit if not found      │
└──────────────┬──────────────────────┘
               │
               ▼
┌─────────────────────────────────────┐
│ 3b. Verify Service Registration    │
│     sc query SFCMTCService          │
│     ✓ Error: Exit if not registered │
└──────────────┬──────────────────────┘
               │
               ▼
┌─────────────────────────────────────┐
│ 4. Configure Site Settings          │
│    cd C:\ShopFloorConnect           │
│    call 3 - West_Jeff_CA_LR_Update_ini_File.bat
│    ✓ Error check: Exit if failed    │
└──────────────┬──────────────────────┘
               │
               ▼
┌─────────────────────────────────────┐
│ 4a. Verify Configuration File      │
│     Check mi_server.ini exists      │
│     ✓ Error: Exit if not found      │
└──────────────┬──────────────────────┘
               │
               ▼
┌─────────────────────────────────────┐
│ ✓ Installation Complete!            │
│   Show success message with:        │
│   - Service name and status         │
│   - Configuration details           │
│   - Instructions to start service   │
└─────────────────────────────────────┘

---

Testing Recommendations

Test Case 1: Successful Installation

1. Run installer on clean Windows PC with admin rights
2. Verify all 3 steps execute without errors
3. Confirm success message appears
4. Check that mi_server.ini file exists and contains correct settings

Test Case 2: Missing Admin Rights

1. Run installer without admin rights
2. Should fail at Step 2 (setx /m)
3. Should show error: "Failed to set TCFITDIR environment variable!"

Test Case 3: Installation Failure Recovery

1. Simulate failure by renaming install.bat temporarily
2. Run installer
3. Should fail at Step 3 with error message
4. Should NOT show "Installation Complete!" message
5. Should provide manual remediation steps

Test Case 4: Configuration File Verification

1. Run installer normally
2. If install.bat fails silently (doesn't create FIT-MI_Server folder)
3. Should catch this at Step 5 (file validation)
4. Should show: "Configuration file not found"

---

Compatibility Notes

• Inno Setup Version: Requires Inno Setup 6 or later
• Windows: Windows 7 and later (x64)
• Admin Rights: Required for setx /m and Windows service installation
• Dependencies: None (all files included in installer)

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Known Limitations

1. Site-Specific: Hardcoded for West Jefferson CA-LR

   • To change sites, must edit line 59 and rebuild installer
   • Future: Could add wizard page for site selection

2. Single Installation Path: Fixed to C:\ShopFloorConnect

   • Cannot be changed by user during installation
   • This is intentional (service expects this path)

3. No Rollback: If installation fails mid-way

   • Files remain in C:\ShopFloorConnect
   • Environment variable may be set
   • User must manually clean up or re-run installer

---

Files Modified

• ShopfloorConnect.iss - Main installer script (improved error handling)
• README.md - Enhanced troubleshooting section
• IMPROVEMENTS.md - This file (new)

Files Unchanged

• Run_ShopfloorConnect_Installer.bat - Batch launcher (still valid)
• ShopFloorConnect/ - Source files (no changes needed)
• *.bmp, *.ico - Image assets (no changes)

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Next Steps (Optional Enhancements)

1. Add Site Selection Wizard Page

   • Let user choose between West Jeff / Rotating Parts / Wilmington
   • Eliminates need to rebuild installer for different sites

2. Add Installation Logging

   • Create C:\ShopFloorConnect\install.log with timestamps
   • Log each step and result code
   • Helpful for troubleshooting

3. Add Pre-Installation Checks

   • Verify Windows version
   • Check available disk space (needs ~200MB)
   • Detect if service already installed

4. Add Uninstaller Enhancements

   • Stop service before uninstalling
   • Remove environment variable
   • Prompt to keep configuration files

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Reviewed By: Claude Code Status: Ready for testing and deployment