shopdb/sql/archive/PRODUCTION_MIGRATION_PLAN.md

Production Migration to Phase 2 Schema - CRITICAL PLAN

Date: 2025-11-20 Source: Production Database (database-backup-11-20-25-eod-with-drop.sql) Target: Phase 2 Schema (as in current dev) Goal: Migrate production to Phase 2 schema WITHOUT losing production data

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CRITICAL DATA PRESERVATION

Production has MORE data than dev:

• Production PCs: 286 (in pc table)
• Dev PCs: 238 (in machines table)
• Production network interfaces: 705
• Dev communications: 746

Production also has more current data in:

• applications (59 in prod)
• knowledgebase (219 in prod)
• notifications (64 in prod)
• machines (275 in prod)
• printers (45 in prod)

We MUST preserve ALL production data during migration!

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Migration Strategy: PHASE-BY-PHASE

Phase 1: Extend Existing Tables (Non-Destructive)

• ALTER TABLE to add new columns
• No data loss
• Reversible

Phase 2: Create New Tables (Safe)

• CREATE new Phase 2 tables (communications, compliance, etc.)
• No impact on existing data
• Reversible

Phase 3: Migrate PC Data (Complex)

• Copy data from pc → machines (with pctypeid NOT NULL)
• Copy data from pc_network_interfaces → communications
• Keep old tables as backup for 30 days
• Reversible with rollback scripts

Phase 4: Update ASP Pages (Application Layer)

• Deploy Phase 2 ASP code
• Test thoroughly
• Rollback ASP code if issues

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Data Comparison: Production vs Dev

Item	Production	Dev	Difference
PCs (in pc table)	286	0	Prod +286
PCs (in machines)	0	238	Dev +238
Machines (equipment)	275	355	Dev +80
Network Interfaces	705	0	Prod +705
Communications	0	746	Dev +746
Applications	59	?	Prod data
Knowledge Base	219	?	Prod data
Notifications	64	?	Prod data

Conclusion: Production has significant data added since dev started. We must preserve it!

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Tables Requiring Changes

1. ALTER TABLE (4 tables - preserve data)

machines - Add 11 Phase 2 columns

ALTER TABLE machines
  ADD COLUMN hostname varchar(100) DEFAULT NULL AFTER machinenumber,
  ADD COLUMN serialnumber varchar(50) DEFAULT NULL COMMENT 'Equipment serial number',
  ADD COLUMN loggedinuser varchar(100) DEFAULT NULL,
  ADD COLUMN pctypeid int(11) DEFAULT NULL,
  ADD COLUMN osid int(11) DEFAULT NULL COMMENT 'Foreign key to operatingsystems table',
  ADD COLUMN controllertypeid int(11) DEFAULT NULL,
  ADD COLUMN controllerosid int(11) DEFAULT NULL,
  ADD COLUMN controllermodelid int(11) DEFAULT NULL,
  ADD COLUMN machinestatusid int(11) DEFAULT NULL,
  ADD COLUMN lastupdated datetime DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,
  ADD COLUMN requires_manual_machine_config tinyint(1) DEFAULT '0',
  DROP COLUMN ipaddress1,
  DROP COLUMN ipaddress2;

Impact:

• Preserves all 275 production machines
• Removes ipaddress1/ipaddress2 (will be migrated to communications)
• Makes room for 286 PCs to be added

businessunits - Add 5 columns

ALTER TABLE businessunits
  ADD COLUMN liaisonname varchar(100) DEFAULT NULL,
  ADD COLUMN liaisonsso varchar(50) DEFAULT NULL,
  ADD COLUMN facility_id varchar(50) DEFAULT NULL COMMENT 'Facility ID (e.g., 212788513)',
  ADD COLUMN dt_lead varchar(100) DEFAULT NULL COMMENT 'DT Lead name (e.g., Patrick Lipinski)',
  ADD COLUMN dt_lead_sso varchar(50) DEFAULT NULL COMMENT 'DT Lead SSO';

Impact: No data loss, adds metadata fields

controllertypes - Add 4 columns

ALTER TABLE controllertypes
  ADD COLUMN vendorid int(11) DEFAULT NULL,
  ADD COLUMN controllermodel varchar(100) DEFAULT NULL,
  ADD COLUMN controller_os varchar(100) DEFAULT NULL COMMENT 'Controller OS (e.g., FANUC OS)',
  ADD COLUMN controllernotes text;

Impact: No data loss, adds metadata fields

machine_overrides - Definition changes

Action: Need to investigate exact differences

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2. CREATE NEW TABLES (8 tables - safe)

communications - Replaces pc_network_interfaces

CREATE TABLE communications (
  comid int(11) NOT NULL AUTO_INCREMENT,
  machineid int(11) NOT NULL,
  comstypeid int(11) NOT NULL DEFAULT 1,
  address varchar(100) DEFAULT NULL,
  macaddress varchar(17) DEFAULT NULL,
  interfacename varchar(50) DEFAULT NULL,
  isprimary tinyint(1) DEFAULT 0,
  isactive tinyint(1) DEFAULT 1,
  settings text,
  PRIMARY KEY (comid),
  KEY idx_machineid (machineid),
  KEY idx_isprimary (isprimary)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4;

comstypes - Communication types

CREATE TABLE comstypes (
  comstypeid int(11) NOT NULL AUTO_INCREMENT,
  comstype varchar(50) NOT NULL,
  description text,
  isactive tinyint(1) DEFAULT 1,
  PRIMARY KEY (comstypeid)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4;

INSERT INTO comstypes (comstypeid, comstype, description) VALUES
(1, 'Network', 'TCP/IP Network Connection'),
(2, 'Serial', 'Serial Port (RS-232, RS-485)'),
(3, 'USB', 'USB Connection'),
(4, 'Bluetooth', 'Bluetooth Connection'),
(5, 'WiFi', 'Wireless Network'),
(6, 'Other', 'Other Communication Type');

compliance - Compliance tracking

CREATE TABLE compliance (
  complianceid int(11) NOT NULL AUTO_INCREMENT,
  machineid int(11) NOT NULL,
  is_third_party_managed enum('Yes','No','NA') DEFAULT 'NA',
  third_party_vendorid int(11) DEFAULT NULL,
  ot_asset_system varchar(100) DEFAULT NULL,
  ot_asset_device_type varchar(100) DEFAULT NULL,
  mft varchar(100) DEFAULT NULL,
  last_scan_date datetime DEFAULT NULL,
  compliance_status varchar(50) DEFAULT NULL,
  compliance_notes text,
  isactive tinyint(1) DEFAULT 1,
  lastupdated datetime DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,
  PRIMARY KEY (complianceid),
  KEY idx_machineid (machineid)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4;

compliancescans - Scan history

CREATE TABLE compliancescans (
  scanid int(11) NOT NULL AUTO_INCREMENT,
  machineid int(11) NOT NULL,
  scan_date datetime DEFAULT CURRENT_TIMESTAMP,
  scan_result text,
  scan_status varchar(50) DEFAULT NULL,
  PRIMARY KEY (scanid),
  KEY idx_machineid (machineid)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4;

machinerelationships - Machine relationships

CREATE TABLE machinerelationships (
  relationshipid int(11) NOT NULL AUTO_INCREMENT,
  machineid int(11) NOT NULL,
  related_machineid int(11) NOT NULL,
  relationshiptypeid int(11) NOT NULL,
  isactive tinyint(1) DEFAULT 1,
  notes text,
  PRIMARY KEY (relationshipid),
  KEY idx_machineid (machineid),
  KEY idx_related_machineid (related_machineid)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4;

relationshiptypes - Relationship types

CREATE TABLE relationshiptypes (
  relationshiptypeid int(11) NOT NULL AUTO_INCREMENT,
  relationshiptype varchar(50) NOT NULL,
  description text,
  isdirectional tinyint(1) DEFAULT 0,
  isactive tinyint(1) DEFAULT 1,
  PRIMARY KEY (relationshiptypeid)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4;

INSERT INTO relationshiptypes (relationshiptypeid, relationshiptype, description, isdirectional) VALUES
(1, 'Controls', 'PC controls this equipment', 1),
(2, 'Dualpath', 'Machines share redundant connection', 0);

machinestatus - Replaces pcstatus

CREATE TABLE machinestatus (
  machinestatusid int(11) NOT NULL AUTO_INCREMENT,
  machinestatus varchar(50) NOT NULL,
  description text,
  isactive tinyint(1) DEFAULT 1,
  PRIMARY KEY (machinestatusid)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4;

-- Copy data from pcstatus
INSERT INTO machinestatus (machinestatusid, machinestatus, description)
SELECT pcstatusid, pcstatus, NULL FROM pcstatus;

warranties - Warranty tracking

CREATE TABLE warranties (
  warrantyid int(11) NOT NULL AUTO_INCREMENT,
  machineid int(11) NOT NULL,
  warrantyname varchar(100) DEFAULT NULL,
  warrantyenddate date DEFAULT NULL,
  isactive tinyint(1) DEFAULT 1,
  PRIMARY KEY (warrantyid),
  KEY idx_machineid (machineid)
) ENGINE=InnoDB DEFAULT CHARSET=utf8mb4;

---

3. MIGRATE DATA (Critical - Most Complex)

Step 1: Backup Production Machine IPs

-- Save machine IPs before dropping columns
CREATE TABLE _backup_machine_ips AS
SELECT machineid, machinenumber, ipaddress1, ipaddress2
FROM machines
WHERE ipaddress1 IS NOT NULL OR ipaddress2 IS NOT NULL;

Step 2: Migrate PCs from pc to machines

-- Insert PCs into machines table
INSERT INTO machines (
  hostname, serialnumber, loggedinuser, pctypeid, osid,
  modelnumberid, businessunitid, machinestatusid,
  machinenumber, alias, machinenotes, printerid,
  mapleft, maptop, isactive, islocationonly
)
SELECT
  p.hostname,
  p.serialnumber,
  p.loggedinuser,
  p.pctypeid,
  p.osid,
  p.modelnumberid,
  p.businessunitid,
  p.pcstatusid AS machinestatusid,
  p.machinenumber,
  p.alias,
  p.notes AS machinenotes,
  p.printerid,
  NULL AS mapleft,
  NULL AS maptop,
  p.isactive,
  0 AS islocationonly
FROM pc p
WHERE NOT EXISTS (
  SELECT 1 FROM machines m WHERE m.hostname = p.hostname
);

Step 3: Migrate Machine IPs to Communications

-- Migrate machine IP addresses (from backup)
INSERT INTO communications (machineid, comstypeid, address, isprimary, interfacename, isactive)
SELECT
  machineid,
  1 AS comstypeid, -- Network type
  ipaddress1,
  1 AS isprimary,
  'Interface 1' AS interfacename,
  1 AS isactive
FROM _backup_machine_ips
WHERE ipaddress1 IS NOT NULL AND ipaddress1 != '';

INSERT INTO communications (machineid, comstypeid, address, isprimary, interfacename, isactive)
SELECT
  machineid,
  1 AS comstypeid,
  ipaddress2,
  0 AS isprimary,
  'Interface 2' AS interfacename,
  1 AS isactive
FROM _backup_machine_ips
WHERE ipaddress2 IS NOT NULL AND ipaddress2 != '';

Step 4: Migrate PC Network Interfaces to Communications

-- Migrate pc_network_interfaces to communications
INSERT INTO communications (machineid, comstypeid, address, macaddress, isprimary, interfacename, isactive)
SELECT
  m.machineid,
  1 AS comstypeid,
  pni.ipaddress,
  pni.macaddress,
  pni.isprimary,
  CONCAT('Interface ', ROW_NUMBER() OVER (PARTITION BY m.machineid ORDER BY pni.isprimary DESC)) AS interfacename,
  pni.isactive
FROM pc_network_interfaces pni
JOIN pc p ON pni.pcid = p.pcid
JOIN machines m ON m.hostname = p.hostname AND m.pctypeid IS NOT NULL;

Step 5: Migrate PC Relationships

-- Migrate pc_dualpath_assignments to machinerelationships
INSERT INTO machinerelationships (machineid, related_machineid, relationshiptypeid, isactive)
SELECT
  m1.machineid,
  m2.machineid,
  2 AS relationshiptypeid, -- Dualpath
  1 AS isactive
FROM pc_dualpath_assignments pda
JOIN pc p1 ON pda.pcid = p1.pcid
JOIN pc p2 ON pda.dualpath_pcid = p2.pcid
JOIN machines m1 ON m1.hostname = p1.hostname AND m1.pctypeid IS NOT NULL
JOIN machines m2 ON m2.hostname = p2.hostname AND m2.pctypeid IS NOT NULL;

-- Migrate machine_pc_relationships (PC controls equipment)
INSERT INTO machinerelationships (machineid, related_machineid, relationshiptypeid, isactive)
SELECT
  mpc.pcid AS machineid,
  mpc.machineid AS related_machineid,
  1 AS relationshiptypeid, -- Controls
  mpc.isactive
FROM machine_pc_relationships mpc;

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Migration Execution Order

PRE-MIGRATION (Do First!)

1. BACKUP PRODUCTION DATABASE (already done: database-backup-11-20-25-eod-with-drop.sql)
2. Test all scripts on dev database first
3. Schedule maintenance window
4. Notify users

MIGRATION EXECUTION (In Order)

1. Phase 1a: Create backup tables for IPs (5 seconds)
2. Phase 1b: ALTER TABLE machines, businessunits, controllertypes (30 seconds)
3. Phase 2: CREATE new Phase 2 tables (comstypes, communications, etc.) (1 minute)
4. Phase 3a: Migrate PCs from pc → machines (2 minutes)
5. Phase 3b: Migrate machine IPs to communications (1 minute)
6. Phase 3c: Migrate pc_network_interfaces → communications (2 minutes)
7. Phase 3d: Migrate relationships (1 minute)
8. Phase 4: Verify data integrity (5 minutes)
9. Phase 5: Deploy Phase 2 ASP code (10 minutes)
10. Phase 6: Test all critical pages (30 minutes)

Total Estimated Time: 45-60 minutes

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Rollback Plan

If Issues Occur Before ASP Deployment:

1. Run rollback SQL scripts (reverse ALTERs)
2. Drop new tables
3. Restore from backup if needed

If Issues Occur After ASP Deployment:

1. Deploy Phase 1 ASP code (revert)
2. Users can continue working with old schema
3. Fix issues in dev
4. Retry migration later

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Data Verification Queries

After migration, run these to verify:

-- Check PC count matches
SELECT 'Production PCs' as source, COUNT(*) FROM pc;
SELECT 'Migrated PCs' as source, COUNT(*) FROM machines WHERE pctypeid IS NOT NULL;

-- Check network interfaces migrated
SELECT 'Production Interfaces' as source, COUNT(*) FROM pc_network_interfaces;
SELECT 'Migrated Communications' as source, COUNT(*) FROM communications WHERE machineid IN (SELECT machineid FROM machines WHERE pctypeid IS NOT NULL);

-- Check machines preserved
SELECT 'Production Machines' as source, COUNT(*) FROM machines; -- Should match before/after

-- Check relationships migrated
SELECT 'Production Dualpath' as source, COUNT(*) FROM pc_dualpath_assignments;
SELECT 'Migrated Dualpath' as source, COUNT(*) FROM machinerelationships WHERE relationshiptypeid = 2;

SELECT 'Production PC-Machine' as source, COUNT(*) FROM machine_pc_relationships;
SELECT 'Migrated Controls' as source, COUNT(*) FROM machinerelationships WHERE relationshiptypeid = 1;

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Next Steps

1. Review this plan carefully
2. Create migration SQL scripts in proper order
3. Test on dev database first (with production data copy)
4. Create rollback scripts for each phase
5. Schedule maintenance window (2-3 hours)
6. Execute migration with full team monitoring
7. Verify data thoroughly before marking complete

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Files to Create

1. /sql/production_migration/01_backup_machine_ips.sql
2. /sql/production_migration/02_alter_machines.sql
3. /sql/production_migration/03_alter_businessunits.sql
4. /sql/production_migration/04_alter_controllertypes.sql
5. /sql/production_migration/05_create_phase2_tables.sql
6. /sql/production_migration/06_migrate_pcs.sql
7. /sql/production_migration/07_migrate_machine_ips.sql
8. /sql/production_migration/08_migrate_pc_interfaces.sql
9. /sql/production_migration/09_migrate_relationships.sql
10. /sql/production_migration/10_verify_data.sql
11. /sql/production_migration/ROLLBACK_*.sql (for each phase)

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Status: Plan Complete - Ready for Script Creation Risk Level: HIGH (Production data migration) Estimated Downtime: 1-2 hours Reversibility: HIGH (with rollback scripts and backup)