Add facility overhead (rent + utilities) to operating costs and pricing engine

Adds MonthlyRent, MonthlyUtilities, and MonthlyBillableHours to CompanyOperatingCosts so fixed shop occupancy costs are recovered on every quote. The pricing engine converts these into a per-hour rate and applies it as a transparent "Facility Overhead" line between oven batch cost and shop supplies. UI added in Company Settings Operating Costs tab and Setup Wizard Step 3; migration AddFacilityOverheadFields applied. Help docs and AI knowledge base updated to cover the new fields and the revised quote pricing calculation order.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

src/PowderCoating.Application/DTOs/Company/CompanySettingsDtos.cs

@@ -140,6 +140,14 @@ namespace PowderCoating.Application.DTOs.Company
         public decimal DerivedBlastRateSqFtPerHour { get; set; }
         /// <summary>Derived coating rate — shown to the user as a sanity-check value.</summary>
         public decimal DerivedCoatingRateSqFtPerHour { get; set; }
+
+        // Facility Overhead
+        public decimal MonthlyRent { get; set; }
+        public decimal MonthlyUtilities { get; set; }
+        public int MonthlyBillableHours { get; set; } = 160;
+
+        /// <summary>Derived facility overhead rate = (MonthlyRent + MonthlyUtilities) / MonthlyBillableHours.</summary>
+        public decimal FacilityOverheadRatePerHour { get; set; }
     }
 
     /// <summary>
@@ -228,6 +236,19 @@ namespace PowderCoating.Application.DTOs.Company
 
         [Range(0, 500)]
         public decimal ComplexityExtremePercent { get; set; } = 25m;
+
+        // Facility Overhead
+        [Range(0, 1000000, ErrorMessage = "Monthly rent must be between 0 and 1,000,000")]
+        [Display(Name = "Monthly Rent ($)")]
+        public decimal MonthlyRent { get; set; } = 0m;
+
+        [Range(0, 1000000, ErrorMessage = "Monthly utilities must be between 0 and 1,000,000")]
+        [Display(Name = "Monthly Utilities ($)")]
+        public decimal MonthlyUtilities { get; set; } = 0m;
+
+        [Range(1, 10000, ErrorMessage = "Billable hours must be between 1 and 10,000")]
+        [Display(Name = "Billable Hours/Month")]
+        public int MonthlyBillableHours { get; set; } = 160;
     }
 
     /// <summary>DTO for updating the company AI profile text used for AI Photo Quote calibration.</summary>

src/PowderCoating.Application/DTOs/Quote/QuoteDtos.cs

@@ -606,6 +606,9 @@ public class QuotePricingBreakdownDto
     public int OvenBatches { get; set; }
     public int OvenCycleMinutes { get; set; }
 
+    public decimal FacilityOverheadCost { get; set; }
+    public decimal FacilityOverheadRatePerHour { get; set; }
+
     public decimal Total { get; set; }
 
     // Cost Breakdown Details
@@ -822,6 +825,10 @@ public class QuotePricingResult
     public int OvenBatches { get; set; }
     public int OvenCycleMinutes { get; set; }
 
+    // Facility overhead (rent + utilities apportioned by estimated job hours)
+    public decimal FacilityOverheadCost { get; set; }
+    public decimal FacilityOverheadRatePerHour { get; set; }
+
     // Detailed breakdown for transparency
     public decimal MaterialCosts { get; set; }
     public decimal LaborCosts { get; set; }

src/PowderCoating.Application/DTOs/Wizard/WizardDtos.cs

@@ -112,6 +112,19 @@ public class WizardStep2Dto
 
     [Display(Name = "Shop Capability Tier")]
     public ShopCapabilityTier ShopCapabilityTier { get; set; } = ShopCapabilityTier.Small;
+
+    // Facility Overhead
+    [Range(0, 1000000)]
+    [Display(Name = "Monthly Rent ($)")]
+    public decimal MonthlyRent { get; set; } = 0m;
+
+    [Range(0, 1000000)]
+    [Display(Name = "Monthly Utilities ($)")]
+    public decimal MonthlyUtilities { get; set; } = 0m;
+
+    [Range(1, 10000)]
+    [Display(Name = "Billable Hours/Month")]
+    public int MonthlyBillableHours { get; set; } = 160;
 }
 
 // ─── Step 3: Branding & Numbering ───────────────────────────────────────────

src/PowderCoating.Application/Mappings/CompanyProfile.cs

@@ -37,7 +37,11 @@ public class CompanyProfile : Profile
             .ForMember(dest => dest.DerivedBlastRateSqFtPerHour,
                 opt => opt.MapFrom(src => ShopCapabilityCalculator.GetBlastRateSqFtPerHour(src)))
             .ForMember(dest => dest.DerivedCoatingRateSqFtPerHour,
-                opt => opt.MapFrom(src => ShopCapabilityCalculator.GetCoatingRateSqFtPerHour(src)));
+                opt => opt.MapFrom(src => ShopCapabilityCalculator.GetCoatingRateSqFtPerHour(src)))
+            .ForMember(dest => dest.FacilityOverheadRatePerHour,
+                opt => opt.MapFrom(src => src.MonthlyBillableHours > 0
+                    ? (src.MonthlyRent + src.MonthlyUtilities) / src.MonthlyBillableHours
+                    : 0m));
         CreateMap<UpdateOperatingCostsDto, CompanyOperatingCosts>();
         CreateMap<UpdateBlastProfileDto, CompanyOperatingCosts>();
 

src/PowderCoating.Application/Services/PricingCalculationService.cs

@@ -542,6 +542,8 @@ public class PricingCalculationService : IPricingCalculationService
                 ItemsSubtotal = 0,
                 ShopSuppliesAmount = 0,
                 ShopSuppliesPercent = 0,
+                FacilityOverheadCost = 0,
+                FacilityOverheadRatePerHour = 0,
                 OverheadCosts = 0,
                 OverheadPercent = 0,
                 ProfitMargin = 0,
@@ -683,14 +685,27 @@ public class PricingCalculationService : IPricingCalculationService
 
         var itemsAndOvenSubtotal = itemsSubtotal + ovenBatchCost;
 
-        // 5. SHOP SUPPLIES (percentage of items + oven subtotal)
+        // 5. FACILITY OVERHEAD (rent + utilities apportioned by estimated job hours)
+        var facilityOverheadRatePerHour = 0m;
+        var facilityOverheadCost = 0m;
+        if (costs.MonthlyBillableHours > 0 && (costs.MonthlyRent + costs.MonthlyUtilities) > 0)
+        {
+            facilityOverheadRatePerHour = (costs.MonthlyRent + costs.MonthlyUtilities) / costs.MonthlyBillableHours;
+            var totalEstimatedMinutes = items.Sum(i => (decimal)i.EstimatedMinutes * i.Quantity);
+            facilityOverheadCost = facilityOverheadRatePerHour * (totalEstimatedMinutes / 60m);
+            _logger.LogInformation(
+                "Facility overhead: ${Rate:F2}/hr × {Min:F0} min = ${Cost:F2}",
+                facilityOverheadRatePerHour, totalEstimatedMinutes, facilityOverheadCost);
+        }
+
+        // 6. SHOP SUPPLIES (percentage of items + oven subtotal — does not include facility overhead)
         var shopSuppliesPercent = costs.ShopSuppliesRate;
         var shopSuppliesAmount = itemsAndOvenSubtotal * (shopSuppliesPercent / 100m);
 
-        // 6. SUBTOTAL BEFORE DISCOUNT (items + oven + shop supplies)
-        var subtotalBeforeDiscount = itemsAndOvenSubtotal + shopSuppliesAmount;
+        // 7. SUBTOTAL BEFORE DISCOUNT (items + oven + facility overhead + shop supplies)
+        var subtotalBeforeDiscount = itemsAndOvenSubtotal + facilityOverheadCost + shopSuppliesAmount;
 
-        // 7. CUSTOMER PRICING TIER DISCOUNT (if applicable)
+        // 8. CUSTOMER PRICING TIER DISCOUNT (if applicable)
         var pricingTierDiscountPercent = 0m;
         var pricingTierDiscountAmount = 0m;
 
@@ -782,6 +797,8 @@ public class PricingCalculationService : IPricingCalculationService
             OvenBatchCost = Math.Round(ovenBatchCost, 2),
             OvenBatches = effectiveBatches,
             OvenCycleMinutes = effectiveCycleMinutes,
+            FacilityOverheadCost = Math.Round(facilityOverheadCost, 2),
+            FacilityOverheadRatePerHour = Math.Round(facilityOverheadRatePerHour, 4),
             ShopSuppliesAmount = Math.Round(shopSuppliesAmount, 2),
             ShopSuppliesPercent = Math.Round(shopSuppliesPercent, 2),
             OverheadCosts = Math.Round(overheadCosts, 2),