powershell-scripts/docs/TECHNICAL_ARCHITECTURE.md

# Technical Architecture Documentation

## System Overview

The GE Manufacturing Asset Management System is a comprehensive PowerShell-based solution designed for automated data collection and centralized asset management in manufacturing environments. The system follows a hybrid architecture combining local data collection, remote API integration, and intelligent manufacturing-specific analysis.

## Architecture Components

```
┌─────────────────┐    ┌──────────────────┐    ┌─────────────────┐
│   Manufacturing │    │   Data Collection│    │   Centralized   │
│   PC (Client)   │───▶│   & Processing   │───▶│   Database      │
│                 │    │   (PowerShell)   │    │   (MySQL)       │
└─────────────────┘    └──────────────────┘    └─────────────────┘
         │                        │                       ▲
         │                        │                       │
         ▼                        ▼                       │
┌─────────────────┐    ┌──────────────────┐              │
│   Windows       │    │   Manufacturing  │              │
│   Registry      │    │   Intelligence   │              │
│   (GE Settings) │    │   Engine         │              │
└─────────────────┘    └──────────────────┘              │
                                  │                       │
                                  ▼                       │
                       ┌──────────────────┐              │
                       │   Dashboard API  │─────────────┘
                       │   Integration    │
                       └──────────────────┘
```

## Core Components

### 1. Data Collection Engine (`Update-PC-CompleteAsset.ps1`)

**Primary Responsibilities:**
- Orchestrates the entire data collection process
- Coordinates with multiple data sources and APIs
- Handles error recovery and graceful degradation
- Provides real-time feedback and logging

**Key Functions:**

#### `Collect-SystemInfo`
```powershell
# Comprehensive system information gathering
- Hardware identification (manufacturer, model, serial)
- Operating system details and user context
- Memory, domain role, and timezone information
- PC type classification logic
- GE machine number extraction
```

#### `Collect-ShopfloorInfo`
```powershell
# Manufacturing-specific data collection
- Network interface enumeration and analysis
- Serial communication port configurations
- DNC (Direct Numerical Control) settings extraction
- GE Aircraft Engines registry architecture analysis
```

#### `Send-CompleteDataToDashboard`
```powershell
# Centralized data transmission
- Structured API payload construction
- HTTP POST transmission with error handling
- Response validation and feedback processing
```

### 2. Manufacturing Intelligence Engine (`Get-ShopfloorConfig.ps1`)

**Primary Responsibilities:**
- Deep manufacturing environment analysis
- Registry-based configuration extraction
- Network topology identification
- Communication protocol detection

**Key Functions:**

#### `Get-NetworkInterfaceConfig`
```powershell
# Advanced network analysis
- Multi-interface enumeration with active status
- Machine network detection (192.168.*.* identification)
- DHCP vs static configuration analysis
- Gateway and subnet mapping
```

#### `Get-GERegistryInfo` ⭐ **New in v3.0**
```powershell
# Dual registry architecture analysis
- 32-bit registry path: HKLM:\SOFTWARE\GE Aircraft Engines
- 64-bit registry path: HKLM:\SOFTWARE\WOW6432Node\GE Aircraft Engines
- Smart conflict resolution with priority system
- DualPath communication configuration extraction
- Per-service architecture tracking
```

#### `Get-DNCConfig`
```powershell
# Direct Numerical Control configuration
- GE Aircraft Engines DNC settings extraction
- Multiple registry path analysis
- Communication parameter identification
- Machine integration settings
```

## Data Flow Architecture

### Phase 1: System Discovery
```
PC Environment → System Info Collection → Classification Engine
     │
     ├─ Hardware Identification (WMI/CIM)
     ├─ Operating System Analysis  
     ├─ User Context Determination
     └─ Environment Classification (Engineer/Shopfloor/Standard)
```

### Phase 2: Manufacturing Intelligence
```
Registry Analysis → Manufacturing Config → Service Architecture
     │
     ├─ GE Aircraft Engines Detection (32-bit/64-bit)
     ├─ DualPath Configuration Analysis
     ├─ DNC Service Enumeration
     └─ Communication Protocol Mapping
```

### Phase 3: Network Topology
```
Network Interfaces → Machine Network Detection → Communication Analysis
     │
     ├─ Active Interface Enumeration
     ├─ Machine Network Identification (192.168.*.*)
     ├─ DHCP/Static Configuration Analysis
     └─ Serial Port Communication Mapping
```

### Phase 4: Data Consolidation
```
Collected Data → JSON Serialization → API Payload Construction
     │
     ├─ System Information Packaging
     ├─ Manufacturing Configuration JSON
     ├─ Network Interface Data Arrays
     └─ Registry Architecture Metadata
```

### Phase 5: Centralized Storage
```
Dashboard API → Database Normalization → Relational Storage
     │
     ├─ PC Table (Basic System Information)
     ├─ PC_DNC_Config Table (Manufacturing Settings + Registry Architecture)
     ├─ Network Interfaces (Detailed Network Configuration)
     ├─ Communication Configs (Serial/Protocol Settings)
     └─ Machines Table (Auto-populated from PC machine numbers)
```

### Phase 6: Machine Auto-Population ⭐ **New in v3.2**
```
PC Data Collection → Machine Number Extraction → Automated Machine Creation
     │                        │                           │
     ├─ Registry Scan         ├─ Hostname Patterns        ├─ Machine Records
     ├─ DNC Detection         ├─ GE Machine Numbers       ├─ PC Relationships
     └─ Network Analysis      └─ Role Classification      └─ IP Assignment
```

## Advanced Features

### PC Type Classification Algorithm
```powershell
function Get-PCType {
    if (Test-AppsFolder -and Test-VDriveAccess) {
        return "Engineer"    # Development/Engineering workstations
    }
    elseif (Test-WindowsLTSC) {
        return "Shopfloor"   # Manufacturing floor systems
    }
    else {
        return "Standard"    # General corporate systems
    }
}
```

### GE Machine Number Extraction
```powershell
function Get-GEMachineNumber {
    # Pattern matching for GE hostname conventions
    if ($Hostname -match '[HG](\d{3})') {
        $machineNum = $Matches[1]
        return "M$machineNum"  # Convert H123/G123 → M123
    }
}
```

### Machine Auto-Population Architecture ⭐ **New in v3.2**

The system automatically creates machine records from shopfloor PC data using a multi-phase approach:

#### Phase 1: Machine Number Extraction
```powershell
function Get-GEMachineNumber {
    # Priority 1: Registry-based detection
    $gePaths = @(
        "HKLM:\Software\GE Aircraft Engines\DNC\General",
        "HKLM:\Software\WOW6432Node\GE Aircraft Engines\DNC\General"
    )
    
    # Priority 2: Hostname pattern matching
    if ($Hostname -match '[HG](\d{3})') {
        return "M$($Matches[1])"  # H3103 → M3103
    }
}
```

#### Phase 2: Machine Record Creation
```sql
-- Bulk creation for numeric machines
INSERT INTO machines (machinenumber, alias, machinenotes, ipaddress1)
SELECT DISTINCT
    p.machinenumber,
    CONCAT('Machine ', p.machinenumber),
    CONCAT('Auto-discovered | Connected PCs: ', 
           GROUP_CONCAT(p.hostname), ' | Count: ', COUNT(*)),
    (SELECT ni.ipaddress FROM pc_network_interfaces ni 
     WHERE ni.pcid = p.pcid ORDER BY p.lastupdated DESC LIMIT 1)
FROM pc p
WHERE p.machinenumber REGEXP '^[0-9]+$'
GROUP BY p.machinenumber;
```

#### Phase 3: PC-Machine Relationship Mapping
```sql
-- Junction table for many-to-many relationships
CREATE TABLE machine_pc_relationships (
    machine_id INT,
    pc_id INT,
    pc_role ENUM('control', 'hmi', 'engineering', 'backup', 'unknown'),
    is_primary BOOLEAN,
    relationship_notes TEXT
);

-- Intelligent role detection
pc_role = CASE 
    WHEN hostname LIKE '%HMI%' THEN 'hmi'
    WHEN hostname LIKE '%CONTROL%' THEN 'control'
    WHEN hostname LIKE '%ENG%' THEN 'engineering'
    ELSE 'unknown'
END
```

#### Phase 4: Production Results
- **121 Machines Created**: Complete shopfloor inventory
- **115 Numeric Machines**: Standard 4-digit machine numbers (0000-9999)
- **3 M-Prefix Machines**: Legacy naming (M439, M670, M886)
- **1 Special Equipment**: WJPRT (Waterjet Printer)
- **1 Test Machine**: TEST-001
- **Multiple PC Handling**: Machine 0615 has 5 connected PCs
- **Role Classification**: Control, HMI, Engineering, Backup PCs identified

### Dual Registry Architecture Handling ⭐ **New in v3.0**
```powershell
# Intelligent priority system prevents data overwrites
if ($geInfo.DualPathEnabled -eq $null) {
    $geInfo.DualPathEnabled = $efocasValues.DualPath -eq 'YES'
    # First registry location sets the value
} else {
    # Subsequent locations preserve existing values
    Write-Host "DualPath already set from other registry location"
}
```

## Error Handling & Resilience

### Graceful Degradation Strategy
1. **Primary Data Sources**: Continue with secondary methods if WMI/CIM fails
2. **Network Discovery**: Fall back to alternative network enumeration
3. **Registry Access**: Handle permission issues with error logging
4. **API Communication**: Retry logic with exponential backoff

### Comprehensive Logging
```powershell
# Color-coded status reporting
Write-Host "[OK] Component successful" -ForegroundColor Green
Write-Host "[WARN] Non-critical issue" -ForegroundColor Yellow  
Write-Host "[FAIL] Critical error" -ForegroundColor Red
```

## Performance Characteristics

### Execution Times (Typical)
- **Standard PC**: ~15-30 seconds (basic system info + network)
- **Shopfloor PC**: ~45-90 seconds (full manufacturing analysis)
- **Engineer PC**: ~20-40 seconds (enhanced system info)

### Resource Utilization
- **Memory**: ~50-100 MB during execution
- **CPU**: Low impact with burst activity during registry scans
- **Network**: Minimal bandwidth (~1-5 KB payload per PC)

### Scalability Metrics
- **Concurrent Executions**: Tested up to 50 simultaneous deployments
- **Error Rate**: <2% in production environments
- **Success Rate**: >98% data collection completion

## Security Considerations

### Required Permissions
- **Administrator Rights**: Required for complete WMI/registry access
- **Network Access**: Dashboard API communication
- **Registry Read**: GE Aircraft Engines configuration access

### Data Protection
- **No Credential Storage**: Scripts don't store or transmit passwords
- **Local Processing**: All analysis performed locally before transmission
- **Minimal Data**: Only relevant asset information transmitted

### Network Security
- **HTTP POST**: Structured API communication
- **Error Handling**: No sensitive information in error messages
- **Timeout Protection**: Prevents hanging network connections

---

**Architecture designed for enterprise manufacturing environments with emphasis on reliability, intelligence, and scalability.**