Bootstrap material state across production runs

tests/test_material_polling_service.py

@@ -16,6 +16,7 @@ from production_analytics.service.material_polling import (
 
 def test_poll_once_starts_at_run_start_without_saved_state() -> None:
     gateway = Mock()
+    gateway.get_production_runs.return_value = []
     state_store = Mock()
     state_store.load.return_value = None
 
@@ -28,6 +29,7 @@ def test_poll_once_starts_at_run_start_without_saved_state() -> None:
         end=None,
     )
     gateway.get_open_production_run.return_value = run
+    gateway.get_production_runs.return_value = [run]
 
     samples = [
         MaterialSample(
@@ -82,6 +84,7 @@ def test_poll_once_starts_at_run_start_without_saved_state() -> None:
 
 def test_poll_once_resumes_from_saved_timestamp_without_double_counting() -> None:
     gateway = Mock()
+    gateway.get_production_runs.return_value = []
     state_store = Mock()
 
     run = EnlyzeProductionRun(
@@ -135,6 +138,7 @@ def test_poll_once_resumes_from_saved_timestamp_without_double_counting() -> Non
     )
 
     assert result is not None
+    gateway.get_production_runs.assert_not_called()
     assert result.state.cumulative_consumption_kg == 20.0
     assert result.state.integrated_running_seconds == 20.0
 
@@ -149,6 +153,7 @@ def test_poll_once_resumes_from_saved_timestamp_without_double_counting() -> Non
 
 def test_poll_once_without_open_run_does_nothing() -> None:
     gateway = Mock()
+    gateway.get_production_runs.return_value = []
     state_store = Mock()
     gateway.get_open_production_run.return_value = None
 
@@ -174,6 +179,7 @@ def test_poll_once_without_open_run_does_nothing() -> None:
 
 def test_new_run_of_same_order_keeps_total_but_restarts_integration_at_run_start() -> None:
     gateway = Mock()
+    gateway.get_production_runs.return_value = []
     state_store = Mock()
 
     run = EnlyzeProductionRun(
@@ -228,6 +234,7 @@ def test_new_run_of_same_order_keeps_total_but_restarts_integration_at_run_start
     )
 
     assert result is not None
+    gateway.get_production_runs.assert_not_called()
     assert result.state.cumulative_consumption_kg == 110.0
     assert result.state.integrated_running_seconds == 370.0
 
@@ -250,6 +257,7 @@ def polling(tmp_path):
     from production_analytics.service.material_state_store import JsonMaterialStateStore
 
     gateway = Mock()
+    gateway.get_production_runs.return_value = []
     gateway.get_open_production_run.return_value = EnlyzeProductionRun(
         "run", "machine", None, "order", datetime(2026, 9, 3, tzinfo=UTC), None,
     )
@@ -291,6 +299,7 @@ def test_different_order_does_not_reuse_state(polling) -> None:
 def test_now_before_run_start_does_not_query_or_save(polling) -> None:
     service, gateway, store = polling
     assert service.poll_once(now=datetime(2026, 9, 2, tzinfo=UTC)) is None
+    gateway.get_production_runs.assert_not_called()
     gateway.get_material_samples.assert_not_called()
     assert store.load("machine", "order") is None
 
@@ -325,3 +334,76 @@ def test_now_before_saved_timestamp_leaves_state_unchanged(polling) -> None:
     assert service.poll_once(now=datetime(2026, 9, 3, 1, tzinfo=UTC)) is None
     gateway.get_material_samples.assert_not_called()
     assert store.load("machine", "order") == saved
+
+
+@pytest.mark.parametrize("order", [
+    "K 7-12026000815", "K 7-12025000074-K 7-12025000075",
+])
+@pytest.mark.parametrize("gap_seconds", [5, 86400])
+def test_bootstrap_replays_exact_order_segments_and_then_resumes(
+    polling, order, gap_seconds,
+) -> None:
+    from dataclasses import replace
+    from datetime import timedelta
+
+    service, gateway, store = polling
+    base = datetime(2026, 9, 3, tzinfo=UTC)
+    runs = [
+        EnlyzeProductionRun(
+            f"run-{i}", "machine", None, order,
+            base + timedelta(seconds=i * (10 + gap_seconds)),
+            base + timedelta(seconds=i * (10 + gap_seconds) + 10) if i < 4 else None,
+        )
+        for i in range(5)
+    ]
+    current = runs[-1]
+    now = current.start + timedelta(seconds=10)
+    gateway.get_open_production_run.return_value = current
+    gateway.get_production_runs.return_value = [
+        current, runs[2], runs[0], runs[3], runs[1],
+        replace(runs[0], uuid="unrelated", production_order=order + "-suffix"),
+        replace(runs[0], uuid="component", production_order="K 7-12025000074"),
+        replace(runs[0], uuid="whitespace", production_order=order + " "),
+        replace(current, uuid="future", start=now + timedelta(days=1)),
+    ]
+
+    def samples(**kwargs):
+        return [
+            MaterialSample(kwargs["start"], 3600, 1),
+            MaterialSample(kwargs["end"], 3600, 1),
+        ]
+
+    gateway.get_material_samples.side_effect = samples
+    result = service.poll_once(now=now)
+    assert result.state.cumulative_consumption_kg == 50
+    assert result.state.integrated_running_seconds == 50
+    assert [
+        (call.kwargs["start"], call.kwargs["end"])
+        for call in gateway.get_material_samples.call_args_list
+    ] == [(run.start, run.end or now) for run in runs]
+    assert store.load("machine", order) == MaterialPollingState(current.uuid, result.state)
+
+    gateway.get_production_runs.reset_mock()
+    gateway.get_material_samples.reset_mock()
+    result = service.poll_once(now=now + timedelta(seconds=10))
+    gateway.get_production_runs.assert_not_called()
+    assert gateway.get_material_samples.call_args.kwargs["start"] == now
+    assert result.state.cumulative_consumption_kg == 60
+    assert result.state.integrated_running_seconds == 60
+
+
+def test_bootstrap_failure_does_not_persist_partial_totals(polling) -> None:
+    from dataclasses import replace
+    from datetime import timedelta
+
+    service, gateway, store = polling
+    current = gateway.get_open_production_run.return_value
+    gateway.get_production_runs.return_value = [
+        replace(current, uuid="old", start=current.start - timedelta(hours=1),
+                end=current.start - timedelta(minutes=30)),
+        current,
+    ]
+    gateway.get_material_samples.side_effect = [[], ValueError("failed page")]
+    with pytest.raises(ValueError, match="failed page"):
+        service.poll_once(now=current.start + timedelta(seconds=10))
+    assert store.load("machine", "order") is None