fix(rev-ops): harden paid order truth, owner alerts, fulfillment queues, and commercial repeat purchase

[QaliAI]

Revenue Operations Hardening Sprint

1. Paid Order Truth & Stripe Webhook Consistency

• Backfills missing stripe_checkout_session_id, stripe_payment_intent_id, and stripe_customer_id on duplicate or subsequent settlement events to eliminate session lookup mismatches for customer order confirmation.
• Automatically associates guest manual_orders with registered customers by email upon payment receipt.
• Idempotently decrements inventory once per order via database row locks; detects oversell conditions and flags oversold orders into the operational exception queue.

2. Owner Alerts & Error Isolation

• Added fulfillmentNextStep to internal order notification emails: distinguishes orders ready to pick/pack from orders waiting on inventory replenishment or documentation.
• Isolated customer and internal email dispatches in dedicated try/catch blocks: email service failure (e.g. Resend rate limit or network glitch) never causes Stripe webhook idempotency rollback or paid order loss.
• Added owner_alert support to /api/admin/orders/resend-email allowing operators to resend internal alerts on demand.

3. Fulfillment Exception Queues

• Replaced raw statuses in the admin dashboard with the exact 6 operational queues:
  • PAID — NEEDS FULFILLMENT
  • WAITING ON INVENTORY
  • WAITING ON DOCUMENTATION
  • SHIPPED
  • DELIVERED/COMPLETED
  • REFUND/EXCEPTION
    (plus ALL and AWAITING PAYMENT).
• Added real-time count badges to tabs and queue pills in table rows.
• Updated NEXT_STATUSES in order detail drawer to support transitioning between waiting_inventory and waiting_documentation.

4. Commercial Repeat Purchase

• Added saveRecentOrder and resolveProductForReorder preserving catalog SKU and configuration.
• Surfaced "Reorder Items" on /order-confirmation/[orderId] and "Reorder Previous Materials" in CartDrawer when empty.
• Strictly commercial language only: zero medical, clinical, dosing, protocol, or human-use claims.

5. Mobile Flow Polish (390px)

• Fixed cart drawer horizontal squeeze on mobile viewports by updating padding from pl-10 to pl-0 sm:pl-10 and p-6 to p-4 sm:p-6.
• Adjusted modal padding in COAModal.tsx to p-4 sm:p-8 for clean viewing on 390px screens.

6. Verification & Quality Gates

• 171/171 tests passing (npm test).
• TypeScript check passing (npm run typecheck).
• ESLint check passing with 0 warnings/errors (npm run lint).
• Production audit passing with 0 failures (npm run check:prod).
• Full Next.js production build succeeded with all 125 static/dynamic routes.

[vercel]

The latest updates on your projects. Learn more about Vercel for GitHub.

Project	Deployment	Actions	Updated
vialfoundry	Building	Preview	Sep 25, 2026 2:34am UTC