Merge dev into master: churned account filter, powder catalog lookup fixes

- CatalogLookup now returns all partial color name matches ranked by
  specificity (exact vendor+color first, same-vendor partial, cross-vendor)
  with isExact flag so JS can decide to auto-fill vs show modal
- Removed cross-vendor fallback that was silently overwriting manufacturer
  field with wrong brand when vendor-scoped search found nothing
- Picker modal now includes "Not listed — search online" option that
  triggers AI lookup as an escape hatch from the catalog results

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

src/PowderCoating.Core/Interfaces/Services/ICompanyListService.cs

@@ -31,10 +31,13 @@ public interface ICompanyListService
 {
     /// <summary>
     /// Returns a paged, searched, and sorted slice of non-deleted companies together with the
-    /// total unfiltered count for pagination.
+    /// total count for pagination and the count of churned accounts that are currently hidden.
+    /// When <paramref name="hideChurned"/> is true, Expired/Canceled companies whose subscription
+    /// ended more than 14 days ago are excluded from results (but still counted for the banner).
     /// </summary>
-    Task<(List<Company> Companies, int TotalCount)> GetPagedAsync(
-        string? searchTerm, string sortColumn, string sortDirection, int page, int pageSize);
+    Task<(List<Company> Companies, int TotalCount, int ChurnedCount)> GetPagedAsync(
+        string? searchTerm, string sortColumn, string sortDirection, int page, int pageSize,
+        bool hideChurned = true);
 
     /// <summary>
     /// Returns job, quote, customer, and wizard completion counts for each of the supplied

src/PowderCoating.Infrastructure/Services/CompanyListService.cs

@@ -1,5 +1,6 @@
 using Microsoft.EntityFrameworkCore;
 using PowderCoating.Core.Entities;
+using PowderCoating.Core.Enums;
 using PowderCoating.Core.Interfaces.Services;
 using PowderCoating.Infrastructure.Data;
 
@@ -21,15 +22,34 @@ public class CompanyListService : ICompanyListService
     }
 
     /// <inheritdoc/>
-    public async Task<(List<Company> Companies, int TotalCount)> GetPagedAsync(
-        string? searchTerm, string sortColumn, string sortDirection, int page, int pageSize)
+    public async Task<(List<Company> Companies, int TotalCount, int ChurnedCount)> GetPagedAsync(
+        string? searchTerm, string sortColumn, string sortDirection, int page, int pageSize,
+        bool hideChurned = true)
     {
+        var cutoff = DateTime.UtcNow.AddDays(-14);
+
+        // Always count churned regardless of hideChurned so the banner can show a number.
+        var churnedCount = await _context.Companies
+            .AsNoTracking()
+            .IgnoreQueryFilters()
+            .Where(c => !c.IsDeleted
+                && (c.SubscriptionStatus == SubscriptionStatus.Expired || c.SubscriptionStatus == SubscriptionStatus.Canceled)
+                && c.SubscriptionEndDate != null
+                && c.SubscriptionEndDate < cutoff)
+            .CountAsync();
+
         var query = _context.Companies
             .AsNoTracking()
             .IgnoreQueryFilters()
             .Where(c => !c.IsDeleted)
             .AsQueryable();
 
+        if (hideChurned)
+            query = query.Where(c =>
+                !((c.SubscriptionStatus == SubscriptionStatus.Expired || c.SubscriptionStatus == SubscriptionStatus.Canceled)
+                  && c.SubscriptionEndDate != null
+                  && c.SubscriptionEndDate < cutoff));
+
         if (!string.IsNullOrWhiteSpace(searchTerm))
         {
             var s = searchTerm.ToLower();
@@ -61,7 +81,7 @@ public class CompanyListService : ICompanyListService
             .Take(pageSize)
             .ToListAsync();
 
-        return (companies, totalCount);
+        return (companies, totalCount, churnedCount);
     }
 
     /// <inheritdoc/>

src/PowderCoating.Web/Controllers/CompaniesController.cs

@@ -66,15 +66,16 @@ public class CompaniesController : Controller
         string sortColumn = "CompanyName",
         string sortDirection = "asc",
         int pageNumber = 1,
-        int pageSize = 25)
+        int pageSize = 25,
+        bool showChurned = false)
     {
         try
         {
             pageNumber = Math.Max(1, pageNumber);
             pageSize = pageSize is 10 or 25 or 50 or 100 ? pageSize : 25;
 
-            var (companies, totalCount) = await _companyList.GetPagedAsync(
-                searchTerm, sortColumn, sortDirection, pageNumber, pageSize);
+            var (companies, totalCount, churnedCount) = await _companyList.GetPagedAsync(
+                searchTerm, sortColumn, sortDirection, pageNumber, pageSize, hideChurned: !showChurned);
 
             var companyDtos = _mapper.Map<List<CompanyListDto>>(companies);
 
@@ -128,6 +129,8 @@ public class CompaniesController : Controller
             ViewBag.PageSize = pageSize;
             ViewBag.TotalPages = (int)Math.Ceiling(totalCount / (double)pageSize);
             ViewBag.ImpersonatingCompanyId = HttpContext.Session.GetInt32("ImpersonatingCompanyId");
+            ViewBag.ShowChurned = showChurned;
+            ViewBag.ChurnedCount = churnedCount;
 
             return View(companyDtos);
         }

src/PowderCoating.Web/Controllers/CompanyHealthController.cs

@@ -45,18 +45,30 @@ public class CompanyHealthController : Controller
     /// user's risk/search filters, so the KPI cards always show platform-wide totals.
     /// </para>
     /// </summary>
-    public async Task<IActionResult> Index(string? risk, string? search, bool configIssuesOnly = false)
+    public async Task<IActionResult> Index(string? risk, string? search, bool configIssuesOnly = false, bool showChurned = false)
     {
         var now = DateTime.UtcNow;
         var d30 = now.AddDays(-30);
         var d90 = now.AddDays(-90);
+        var churnedCutoff = now.AddDays(-14);
 
         // One query per signal — all keyed by CompanyId
-        var companies = await _db.Companies
+        var allCompanies = await _db.Companies
             .AsNoTracking().IgnoreQueryFilters()
             .Where(c => !c.IsDeleted)
             .ToListAsync();
 
+        var churnedCount = allCompanies.Count(c =>
+            (c.SubscriptionStatus == SubscriptionStatus.Expired || c.SubscriptionStatus == SubscriptionStatus.Canceled)
+            && c.SubscriptionEndDate.HasValue && c.SubscriptionEndDate.Value < churnedCutoff);
+
+        var companies = showChurned
+            ? allCompanies
+            : allCompanies.Where(c =>
+                !((c.SubscriptionStatus == SubscriptionStatus.Expired || c.SubscriptionStatus == SubscriptionStatus.Canceled)
+                  && c.SubscriptionEndDate.HasValue && c.SubscriptionEndDate.Value < churnedCutoff))
+              .ToList();
+
         var lastLogins = await _db.Users
             .AsNoTracking().IgnoreQueryFilters()
             .Where(u => u.LastLoginDate != null)
@@ -163,6 +175,8 @@ public class CompanyHealthController : Controller
         ViewBag.Risk              = risk;
         ViewBag.Search            = search;
         ViewBag.ConfigIssuesOnly  = configIssuesOnly;
+        ViewBag.ShowChurned       = showChurned;
+        ViewBag.ChurnedCount      = churnedCount;
 
         if (!string.IsNullOrWhiteSpace(search))
             all = all.Where(h =>

src/PowderCoating.Web/Controllers/InventoryController.cs

@@ -304,6 +304,32 @@ public class InventoryController : Controller
                 await _unitOfWork.SaveChangesAsync();
             }
 
+            // Contribute/sync to the platform powder catalog if we have enough identity data.
+            // Runs silently — a failure here never blocks the inventory save.
+            if (!string.IsNullOrWhiteSpace(dto.Manufacturer) && !string.IsNullOrWhiteSpace(dto.ManufacturerPartNumber))
+            {
+                var catalogResult = new InventoryAiLookupResult
+                {
+                    Manufacturer           = dto.Manufacturer,
+                    ManufacturerPartNumber = dto.ManufacturerPartNumber,
+                    ColorName              = dto.ColorName ?? item.Name,
+                    Finish                 = dto.Finish,
+                    CureTemperatureF       = dto.CureTemperatureF,
+                    CureTimeMinutes        = dto.CureTimeMinutes,
+                    ColorFamilies          = dto.ColorFamilies,
+                    RequiresClearCoat      = dto.RequiresClearCoat ? true : (bool?)null,
+                    CoverageSqFtPerLb      = dto.CoverageSqFtPerLb,
+                    SpecificGravity        = dto.SpecificGravity,
+                    TransferEfficiency     = dto.TransferEfficiency,
+                    UnitCostPerLb          = dto.UnitCost > 0 ? dto.UnitCost : null,
+                    SpecPageUrl            = dto.SpecPageUrl,
+                    ImageUrl               = dto.ImageUrl,
+                    SdsUrl                 = dto.SdsUrl,
+                    TdsUrl                 = dto.TdsUrl,
+                };
+                await EnrichFromCatalogAsync(catalogResult, autoContribute: true);
+            }
+
             TempData["Success"] = "Inventory item created successfully.";
             return RedirectToAction(nameof(Details), new { id = item.Id });
         }
@@ -704,6 +730,8 @@ public class InventoryController : Controller
             return Json(new { success = false, errorMessage = "No product URL provided." });
 
         var result = await _aiLookupService.LookupByUrlAsync(productUrl, colorName);
+        if (result.Success)
+            await EnrichFromCatalogAsync(result, autoContribute: true);
         return Json(result);
     }
 
@@ -750,6 +778,39 @@ public class InventoryController : Controller
             result.SdsUrl      ??= match.SdsUrl;
             result.TdsUrl      ??= match.TdsUrl;
             if (match.UnitPrice > 0) result.UnitCostPerLb ??= match.UnitPrice;
+
+            // Back-sync: fill NULL catalog fields from the incoming result so the catalog
+            // gets richer over time without overwriting anything already stored.
+            bool catalogDirty = false;
+            if (match.Finish             == null && !string.IsNullOrWhiteSpace(result.Finish))       { match.Finish             = result.Finish;             catalogDirty = true; }
+            if (match.CureTemperatureF   == null && result.CureTemperatureF  != null)                { match.CureTemperatureF   = result.CureTemperatureF;   catalogDirty = true; }
+            if (match.CureTimeMinutes    == null && result.CureTimeMinutes   != null)                { match.CureTimeMinutes    = result.CureTimeMinutes;     catalogDirty = true; }
+            if (match.ColorFamilies      == null && !string.IsNullOrWhiteSpace(result.ColorFamilies)){ match.ColorFamilies      = result.ColorFamilies;       catalogDirty = true; }
+            if (match.RequiresClearCoat  == null && result.RequiresClearCoat != null)                { match.RequiresClearCoat  = result.RequiresClearCoat;   catalogDirty = true; }
+            if (match.CoverageSqFtPerLb  == null && result.CoverageSqFtPerLb != null)               { match.CoverageSqFtPerLb  = result.CoverageSqFtPerLb;  catalogDirty = true; }
+            if (match.SpecificGravity    == null && result.SpecificGravity   != null)                { match.SpecificGravity    = result.SpecificGravity;     catalogDirty = true; }
+            if (match.TransferEfficiency == null && result.TransferEfficiency != null)               { match.TransferEfficiency = result.TransferEfficiency;  catalogDirty = true; }
+            if (string.IsNullOrWhiteSpace(match.ImageUrl)   && !string.IsNullOrWhiteSpace(result.ImageUrl))   { match.ImageUrl   = result.ImageUrl;   catalogDirty = true; }
+            if (string.IsNullOrWhiteSpace(match.ProductUrl) && !string.IsNullOrWhiteSpace(result.SpecPageUrl)){ match.ProductUrl = result.SpecPageUrl; catalogDirty = true; }
+            if (string.IsNullOrWhiteSpace(match.SdsUrl)     && !string.IsNullOrWhiteSpace(result.SdsUrl))     { match.SdsUrl     = result.SdsUrl;     catalogDirty = true; }
+            if (string.IsNullOrWhiteSpace(match.TdsUrl)     && !string.IsNullOrWhiteSpace(result.TdsUrl))     { match.TdsUrl     = result.TdsUrl;     catalogDirty = true; }
+            if (match.UnitPrice == 0 && (result.UnitCostPerLb ?? 0) > 0)                            { match.UnitPrice  = result.UnitCostPerLb!.Value;        catalogDirty = true; }
+
+            if (catalogDirty)
+            {
+                match.UpdatedAt = DateTime.UtcNow;
+                try
+                {
+                    await _unitOfWork.PowderCatalog.UpdateAsync(match);
+                    await _unitOfWork.CompleteAsync();
+                    _logger.LogInformation("Back-synced catalog gaps for {VendorName} {Sku}", match.VendorName, match.Sku);
+                }
+                catch (Exception ex)
+                {
+                    _logger.LogWarning(ex, "Failed to back-sync catalog entry {Id}", match.Id);
+                }
+            }
+
             return (true, false);
         }
 
@@ -767,6 +828,7 @@ public class InventoryController : Controller
                 VendorName         = manufacturer,
                 Sku                = sku,
                 ColorName          = colorName,
+                UnitPrice          = result.UnitCostPerLb ?? 0m,
                 CureTemperatureF   = result.CureTemperatureF,
                 CureTimeMinutes    = result.CureTimeMinutes,
                 Finish             = result.Finish,
@@ -1050,61 +1112,50 @@ public class InventoryController : Controller
             .Select(i => i.ManufacturerPartNumber!.Trim().ToLower())
             .ToHashSet();
 
-        // When a vendor is specified, search vendor-scoped first. Only widen to all vendors
-        // if the scoped search returns nothing — prevents a cross-vendor color match from
-        // being returned as the only result when the user clearly intended a specific manufacturer.
-        IEnumerable<PowderCatalogItem> matches;
-        if (!string.IsNullOrEmpty(vendorTerm))
-        {
-            matches = await _unitOfWork.PowderCatalog.FindAsync(p =>
-                p.VendorName.ToLower().Contains(vendorTerm) && (
-                    p.Sku.ToLower() == term ||
-                    p.ColorName.ToLower().Contains(term) ||
-                    p.Sku.ToLower().Contains(term)));
-
-            // Fall back to all vendors only when the scoped search finds nothing
-            if (!matches.Any())
-            {
-                matches = await _unitOfWork.PowderCatalog.FindAsync(p =>
-                    p.Sku.ToLower() == term ||
-                    p.ColorName.ToLower().Contains(term) ||
-                    p.Sku.ToLower().Contains(term));
-            }
-        }
-        else
-        {
-            matches = await _unitOfWork.PowderCatalog.FindAsync(p =>
-                p.Sku.ToLower() == term ||
-                p.ColorName.ToLower().Contains(term) ||
-                p.Sku.ToLower().Contains(term));
-        }
+        // Single query — all partial color/SKU matches across all vendors.
+        // Results are ranked: exact vendor + exact color (isExact=true) sorts first and
+        // triggers auto-fill in the JS. Everything else goes to the picker modal.
+        // This means a user who typed "Columbia Coatings" + "Lime Green" gets auto-fill
+        // only when that exact product is in the catalog; otherwise they see a ranked modal
+        // with same-vendor results at the top and a "Not Listed — Search Online" escape hatch.
+        var matches = await _unitOfWork.PowderCatalog.FindAsync(p =>
+            p.ColorName.ToLower().Contains(term) ||
+            p.Sku.ToLower() == term ||
+            p.Sku.ToLower().Contains(term));
 
         var results = matches
             .Where(p => !existingSkus.Contains(p.Sku.ToLower()))
-            .OrderBy(p => p.Sku.ToLower() == term ? 0 : 1)
-            .ThenBy(p => p.ColorName)
-            .Select(p => new
+            .Select(p =>
             {
-                id = p.Id,
-                vendorName = p.VendorName,
-                sku = p.Sku,
-                colorName = p.ColorName,
-                description = p.Description,
-                unitPrice = p.UnitPrice,
-                imageUrl = p.ImageUrl,
-                sdsUrl = p.SdsUrl,
-                tdsUrl = p.TdsUrl,
-                applicationGuideUrl = p.ApplicationGuideUrl,
-                productUrl = p.ProductUrl,
-                isDiscontinued = p.IsDiscontinued,
-                cureTemperatureF = p.CureTemperatureF,
-                cureTimeMinutes = p.CureTimeMinutes,
-                finish = p.Finish,
-                colorFamilies = p.ColorFamilies,
-                requiresClearCoat = p.RequiresClearCoat,
-                coverageSqFtPerLb = p.CoverageSqFtPerLb,
-                specificGravity = p.SpecificGravity,
-                transferEfficiency = GetEffectiveTransferEfficiency(p.TransferEfficiency)
+                var vendorMatch = string.IsNullOrEmpty(vendorTerm) || p.VendorName.ToLower().Contains(vendorTerm);
+                var colorExact  = p.ColorName.ToLower() == term;
+                return (p, isExact: vendorMatch && colorExact, vendorMatch, colorExact);
+            })
+            .OrderBy(x => x.isExact ? 0 : x.vendorMatch ? 1 : x.colorExact ? 2 : 3)
+            .ThenBy(x => x.p.ColorName)
+            .Select(x => new
+            {
+                id = x.p.Id,
+                vendorName = x.p.VendorName,
+                sku = x.p.Sku,
+                colorName = x.p.ColorName,
+                description = x.p.Description,
+                unitPrice = x.p.UnitPrice,
+                imageUrl = x.p.ImageUrl,
+                sdsUrl = x.p.SdsUrl,
+                tdsUrl = x.p.TdsUrl,
+                applicationGuideUrl = x.p.ApplicationGuideUrl,
+                productUrl = x.p.ProductUrl,
+                isDiscontinued = x.p.IsDiscontinued,
+                isExact = x.isExact,
+                cureTemperatureF = x.p.CureTemperatureF,
+                cureTimeMinutes = x.p.CureTimeMinutes,
+                finish = x.p.Finish,
+                colorFamilies = x.p.ColorFamilies,
+                requiresClearCoat = x.p.RequiresClearCoat,
+                coverageSqFtPerLb = x.p.CoverageSqFtPerLb,
+                specificGravity = x.p.SpecificGravity,
+                transferEfficiency = GetEffectiveTransferEfficiency(x.p.TransferEfficiency)
             })
             .ToList();
 

src/PowderCoating.Web/Views/Companies/Index.cshtml

@@ -26,11 +26,13 @@
     var totalPages    = (int)(ViewBag.TotalPages ?? 1);
     var totalCount    = (int)(ViewBag.TotalCount ?? 0);
     var impersonatingId = (int?)(ViewBag.ImpersonatingCompanyId);
+    var showChurned   = (bool)(ViewBag.ShowChurned ?? false);
+    var churnedCount  = (int)(ViewBag.ChurnedCount ?? 0);
 
     string SortLink(string col)
     {
         var dir = (sortColumn == col && sortDirection == "asc") ? "desc" : "asc";
-        return Url.Action("Index", new { searchTerm, sortColumn = col, sortDirection = dir, pageNumber = 1, pageSize })!;
+        return Url.Action("Index", new { searchTerm, sortColumn = col, sortDirection = dir, pageNumber = 1, pageSize, showChurned })!;
     }
 
     string SortIcon(string col)
@@ -54,6 +56,7 @@
                 <input type="hidden" name="sortColumn" value="@sortColumn" />
                 <input type="hidden" name="sortDirection" value="@sortDirection" />
                 <input type="hidden" name="pageSize" value="@pageSize" />
+                <input type="hidden" name="showChurned" value="@showChurned.ToString().ToLower()" />
                 <div class="col-md-6">
                     <div class="input-group">
                         <span class="input-group-text"><i class="bi bi-search"></i></span>
@@ -75,6 +78,25 @@
         </div>
     </div>
 
+    @if (churnedCount > 0 && !showChurned)
+    {
+        <div class="alert alert-secondary alert-permanent d-flex align-items-center gap-2 mb-3 py-2">
+            <i class="bi bi-eye-slash text-muted"></i>
+            <span class="small"><strong>@churnedCount</strong> churned @(churnedCount == 1 ? "account" : "accounts") (expired or canceled 14+ days ago) hidden.</span>
+            <a href="@Url.Action("Index", new { searchTerm, sortColumn, sortDirection, pageNumber = 1, pageSize, showChurned = true })"
+               class="btn btn-sm btn-outline-secondary ms-auto py-0">Show churned</a>
+        </div>
+    }
+    else if (showChurned && churnedCount > 0)
+    {
+        <div class="alert alert-warning alert-permanent d-flex align-items-center gap-2 mb-3 py-2">
+            <i class="bi bi-eye text-warning"></i>
+            <span class="small">Showing all accounts including <strong>@churnedCount</strong> churned.</span>
+            <a href="@Url.Action("Index", new { searchTerm, sortColumn, sortDirection, pageNumber = 1, pageSize, showChurned = false })"
+               class="btn btn-sm btn-outline-secondary ms-auto py-0">Hide churned</a>
+        </div>
+    }
+
     <div class="card shadow-sm">
         <div class="card-body p-0">
             @if (Model != null && Model.Any())
@@ -313,18 +335,18 @@
                             <nav>
                                 <ul class="pagination pagination-sm mb-0">
                                     <li class="page-item @(pageNumber == 1 ? "disabled" : "")">
-                                        <a class="page-link" href="@Url.Action("Index", new { searchTerm, sortColumn, sortDirection, pageNumber = pageNumber - 1, pageSize })">
+                                        <a class="page-link" href="@Url.Action("Index", new { searchTerm, sortColumn, sortDirection, pageNumber = pageNumber - 1, pageSize, showChurned })">
                                             <i class="bi bi-chevron-left"></i>
                                         </a>
                                     </li>
                                     @for (int p = Math.Max(1, pageNumber - 2); p <= Math.Min(totalPages, pageNumber + 2); p++)
                                     {
                                         <li class="page-item @(p == pageNumber ? "active" : "")">
-                                            <a class="page-link" href="@Url.Action("Index", new { searchTerm, sortColumn, sortDirection, pageNumber = p, pageSize })">@p</a>
+                                            <a class="page-link" href="@Url.Action("Index", new { searchTerm, sortColumn, sortDirection, pageNumber = p, pageSize, showChurned })">@p</a>
                                         </li>
                                     }
                                     <li class="page-item @(pageNumber == totalPages ? "disabled" : "")">
-                                        <a class="page-link" href="@Url.Action("Index", new { searchTerm, sortColumn, sortDirection, pageNumber = pageNumber + 1, pageSize })">
+                                        <a class="page-link" href="@Url.Action("Index", new { searchTerm, sortColumn, sortDirection, pageNumber = pageNumber + 1, pageSize, showChurned })">
                                             <i class="bi bi-chevron-right"></i>
                                         </a>
                                     </li>
@@ -464,6 +486,7 @@
             const url = new URL(window.location.href);
             url.searchParams.set('pageSize', size);
             url.searchParams.set('pageNumber', '1');
+            url.searchParams.set('showChurned', '@showChurned.ToString().ToLower()');
             window.location.href = url.toString();
         }
 

src/PowderCoating.Web/Views/CompanyHealth/Index.cshtml

@@ -4,6 +4,9 @@
 @{
     ViewData["Title"] = "Company Health";
 
+    var showChurned  = (bool)(ViewBag.ShowChurned ?? false);
+    var churnedCount = (int)(ViewBag.ChurnedCount ?? 0);
+
     string RiskBadge(ChurnRisk r) => r switch {
         ChurnRisk.Healthy        => "bg-success",
         ChurnRisk.AtRisk         => "bg-warning text-dark",
@@ -73,6 +76,26 @@
         </div>
     </div>
 
+    @* Churned account visibility banner *@
+    @if (churnedCount > 0 && !showChurned)
+    {
+        <div class="alert alert-secondary alert-permanent d-flex align-items-center gap-2 mb-3 py-2">
+            <i class="bi bi-eye-slash text-muted"></i>
+            <span class="small"><strong>@churnedCount</strong> churned @(churnedCount == 1 ? "account" : "accounts") (expired or canceled 14+ days ago) hidden from scores and totals.</span>
+            <a href="@Url.Action("Index", new { risk = ViewBag.Risk, search = ViewBag.Search, configIssuesOnly = ViewBag.ConfigIssuesOnly, showChurned = true })"
+               class="btn btn-sm btn-outline-secondary ms-auto py-0">Show churned</a>
+        </div>
+    }
+    else if (showChurned && churnedCount > 0)
+    {
+        <div class="alert alert-warning alert-permanent d-flex align-items-center gap-2 mb-3 py-2">
+            <i class="bi bi-eye text-warning"></i>
+            <span class="small">Showing all accounts including <strong>@churnedCount</strong> churned.</span>
+            <a href="@Url.Action("Index", new { risk = ViewBag.Risk, search = ViewBag.Search, configIssuesOnly = ViewBag.ConfigIssuesOnly, showChurned = false })"
+               class="btn btn-sm btn-outline-secondary ms-auto py-0">Hide churned</a>
+        </div>
+    }
+
     @* Summary stat cards *@
     <div class="row g-3 mb-3">
         <div class="col-6 col-lg-3">
@@ -193,6 +216,7 @@
                         <label class="form-check-label small" for="configOnly">Config issues only</label>
                     </div>
                 </div>
+                <input type="hidden" name="showChurned" value="@showChurned.ToString().ToLower()" />
                 <div class="col-auto">
                     <button class="btn btn-sm btn-primary">Filter</button>
                     <a asp-action="Index" class="btn btn-sm btn-outline-secondary ms-1">Clear</a>

src/PowderCoating.Web/wwwroot/js/inventory-catalog-lookup.js

@@ -62,23 +62,25 @@
             const items = await resp.json();
 
             if (items.length === 0) {
-                // No catalog match — fall back to AI if available
-                hideStatus();
-                if (typeof window._runInventoryAiLookup === 'function') {
-                    showStatus('info', '<span class="spinner-border spinner-border-sm me-1"></span>Not in catalog — searching with AI…');
-                    await window._runInventoryAiLookup();
-                } else {
-                    showStatus('warning', 'No match found in the catalog. Enter details manually or enable AI Lookup.');
-                }
+                // Nothing in catalog — go straight to AI
+                await runAiOrWarn();
                 return;
             }
 
-            if (items.length === 1) {
+            // Single exact match (vendor + color name both match precisely) — auto-fill
+            if (items.length === 1 && items[0].isExact) {
                 await fillFields(items[0]);
                 return;
             }
 
-            // Multiple matches — let the user pick via modal
+            // Exact match exists but so do other results — auto-fill the exact one
+            const exactMatches = items.filter(i => i.isExact);
+            if (exactMatches.length === 1) {
+                await fillFields(exactMatches[0]);
+                return;
+            }
+
+            // No exact match (or ambiguous) — show picker modal with "Not Listed" escape hatch
             hideStatus();
             showPickerModal(items);
 
@@ -89,6 +91,18 @@
         }
     });
 
+    // ── AI fallback helper ───────────────────────────────────────────────────
+
+    async function runAiOrWarn() {
+        hideStatus();
+        if (typeof window._runInventoryAiLookup === 'function') {
+            showStatus('info', '<span class="spinner-border spinner-border-sm me-1"></span>Not in catalog — searching online with AI…');
+            await window._runInventoryAiLookup();
+        } else {
+            showStatus('warning', 'No match found in the catalog. Enter details manually or enable AI Lookup.');
+        }
+    }
+
     // ── Fill fields from a catalog result ────────────────────────────────────
 
     async function fillFields(item) {
@@ -368,6 +382,12 @@
               <div class="modal-body p-0">
                 <div class="list-group list-group-flush">${rows}</div>
               </div>
+              <div class="modal-footer py-2 justify-content-start">
+                <button type="button" class="btn btn-sm btn-outline-secondary" id="catalogPickerNotListed">
+                  <i class="bi bi-search me-1"></i>Not listed — search online
+                </button>
+                <span class="text-muted small ms-2">Uses AI to look up the exact product</span>
+              </div>
             </div>
           </div>
         </div>`;
@@ -383,6 +403,11 @@
             });
         });
 
+        document.getElementById('catalogPickerNotListed').addEventListener('click', function () {
+            bsModal.hide();
+            runAiOrWarn();
+        });
+
         bsModal.show();
     }