feat: repair-POS integration, receipt formats, manager overrides, price adjustments

- Add thermal/full-page receipt format toggle (per-device, localStorage)
- Full-page receipt uses clean invoice layout matching repair PDF style
- Settings page reorganized into tabbed sections (Store, Locations, Modules, Receipt, POS Security, Advanced)
- Manager override system: configurable PIN prompt for void, refund, discount, cash in/out
- Discount threshold setting: require manager approval above X%
- Consumable product type: tracked for internal job costing, excluded from POS search, receipts, and customer-facing totals
- Repair line item dialog: product picker dropdown for parts/consumables from inventory
- Repair → POS checkout: load ready-for-pickup tickets into repair_payment transactions with proper tax categories (labor=service, parts=goods)
- Transaction completion auto-updates repair ticket status to picked_up
- POS Repairs dialog with Pickup and New Intake tabs, customer account lookup
- Inline price adjustment on cart items: % off, $ off, or set price with live preview
- Order-level discount button with same three input modes
- Backend: migration 0043 (consumable enum + is_consumable flag), createFromRepairTicket service, ready-for-pickup endpoint
- Fix: backend dev script uses --env-file for turbo compatibility

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

packages/admin/src/components/inventory/product-form.tsx

@@ -34,6 +34,7 @@ export function ProductForm({ defaultValues, onSubmit, loading }: Props) {
       isSerialized: defaultValues?.isSerialized ?? false,
       isRental: defaultValues?.isRental ?? false,
       isDualUseRepair: defaultValues?.isDualUseRepair ?? false,
+      isConsumable: defaultValues?.isConsumable ?? false,
       isActive: defaultValues?.isActive ?? true,
     },
   })
@@ -42,6 +43,7 @@ export function ProductForm({ defaultValues, onSubmit, loading }: Props) {
   const isRental = watch('isRental')
   const isSerialized = watch('isSerialized')
   const isDualUseRepair = watch('isDualUseRepair')
+  const isConsumable = watch('isConsumable')
   const isActive = watch('isActive')
 
   function handleFormSubmit(data: Record<string, unknown>) {
@@ -61,6 +63,7 @@ export function ProductForm({ defaultValues, onSubmit, loading }: Props) {
       isSerialized: data.isSerialized,
       isRental: data.isRental,
       isDualUseRepair: data.isDualUseRepair,
+      isConsumable: data.isConsumable,
       isActive: data.isActive,
     })
   }
@@ -158,6 +161,10 @@ export function ProductForm({ defaultValues, onSubmit, loading }: Props) {
             <input type="checkbox" checked={isDualUseRepair} onChange={(e) => setValue('isDualUseRepair', e.target.checked)} className="h-4 w-4" />
             Available as Repair Line Item
           </label>
+          <label className="flex items-center gap-2 text-sm cursor-pointer">
+            <input type="checkbox" checked={isConsumable} onChange={(e) => setValue('isConsumable', e.target.checked)} className="h-4 w-4" />
+            Consumable (internal use, not sold at POS)
+          </label>
           <label className="flex items-center gap-2 text-sm cursor-pointer">
             <input type="checkbox" checked={isActive} onChange={(e) => setValue('isActive', e.target.checked)} className="h-4 w-4" />
             Active

packages/admin/src/components/pos/pos-cart-panel.tsx

@@ -3,11 +3,16 @@ import { usePOSStore } from '@/stores/pos.store'
 import { posMutations, posKeys, type Transaction } from '@/api/pos'
 import { Button } from '@/components/ui/button'
 import { Separator } from '@/components/ui/separator'
-import { X, Banknote, CreditCard, FileText, Ban, UserRound } from 'lucide-react'
+import { Input } from '@/components/ui/input'
+import { Label } from '@/components/ui/label'
+import { Popover, PopoverContent, PopoverTrigger } from '@/components/ui/popover'
+import { X, Banknote, CreditCard, FileText, Ban, UserRound, Tag } from 'lucide-react'
 import { toast } from 'sonner'
 import { useState } from 'react'
 import { POSPaymentDialog } from './pos-payment-dialog'
 import { POSCustomerDialog } from './pos-customer-dialog'
+import { ManagerOverrideDialog, requiresOverride, requiresDiscountOverride } from './pos-manager-override'
+import type { TransactionLineItem } from '@/api/pos'
 
 interface POSCartPanelProps {
   transaction: Transaction | null
@@ -18,6 +23,10 @@ export function POSCartPanel({ transaction }: POSCartPanelProps) {
   const { currentTransactionId, setTransaction, accountName, accountPhone, accountEmail } = usePOSStore()
   const [paymentMethod, setPaymentMethod] = useState<string | null>(null)
   const [customerOpen, setCustomerOpen] = useState(false)
+  const [overrideOpen, setOverrideOpen] = useState(false)
+  const [priceItemId, setPriceItemId] = useState<string | null>(null)
+  const [pendingDiscount, setPendingDiscount] = useState<{ lineItemId: string; amount: number; reason: string } | null>(null)
+  const [discountOverrideOpen, setDiscountOverrideOpen] = useState(false)
   const lineItems = transaction?.lineItems ?? []
 
   const drawerSessionId = usePOSStore((s) => s.drawerSessionId)
@@ -32,6 +41,17 @@ export function POSCartPanel({ transaction }: POSCartPanelProps) {
     onError: (err) => toast.error(err.message),
   })
 
+  const discountMutation = useMutation({
+    mutationFn: (data: { lineItemId: string; amount: number; reason: string }) =>
+      posMutations.applyDiscount(currentTransactionId!, data),
+    onSuccess: () => {
+      queryClient.invalidateQueries({ queryKey: posKeys.transaction(currentTransactionId!) })
+      setPriceItemId(null)
+      toast.success('Price adjusted')
+    },
+    onError: (err) => toast.error(err.message),
+  })
+
   const voidMutation = useMutation({
     mutationFn: () => posMutations.void(currentTransactionId!),
     onSuccess: () => {
@@ -93,33 +113,61 @@ export function POSCartPanel({ transaction }: POSCartPanelProps) {
           </div>
         ) : (
           <div className="divide-y divide-border">
-            {lineItems.map((item) => (
-              <div key={item.id} className="flex items-center gap-2 px-3 py-2.5 group">
-                <div className="flex-1 min-w-0">
-                  <p className="text-sm font-medium truncate">{item.description}</p>
-                  <p className="text-xs text-muted-foreground">
-                    {item.qty} x ${parseFloat(item.unitPrice).toFixed(2)}
-                    {parseFloat(item.taxAmount) > 0 && (
-                      <span className="ml-2">tax ${parseFloat(item.taxAmount).toFixed(2)}</span>
-                    )}
-                  </p>
+            {lineItems.map((item) => {
+              const unitPrice = parseFloat(item.unitPrice)
+              const discount = parseFloat(item.discountAmount)
+              const hasDiscount = discount > 0
+              const listTotal = unitPrice * item.qty
+              const discountPct = listTotal > 0 ? Math.round((discount / listTotal) * 100) : 0
+
+              return (
+                <div key={item.id} className="flex items-center gap-2 px-3 py-2.5 group">
+                  <div className="flex-1 min-w-0">
+                    <p className="text-sm font-medium truncate">{item.description}</p>
+                    <div className="text-xs text-muted-foreground flex items-center gap-2">
+                      <span>{item.qty} x ${unitPrice.toFixed(2)}</span>
+                      {hasDiscount && (
+                        <span className="text-green-600">-${discount.toFixed(2)} ({discountPct}%)</span>
+                      )}
+                      {parseFloat(item.taxAmount) > 0 && (
+                        <span>tax ${parseFloat(item.taxAmount).toFixed(2)}</span>
+                      )}
+                    </div>
+                  </div>
+                  <span className="text-sm font-medium tabular-nums">
+                    ${parseFloat(item.lineTotal).toFixed(2)}
+                  </span>
+                  {isPending && (
+                    <div className="flex items-center gap-0.5 opacity-0 group-hover:opacity-100 shrink-0">
+                      <PriceAdjuster
+                        item={item}
+                        open={priceItemId === item.id}
+                        onOpenChange={(o) => setPriceItemId(o ? item.id : null)}
+                        onApply={(amount, reason) => {
+                          const pct = listTotal > 0 ? (amount / listTotal) * 100 : 0
+                          if (requiresDiscountOverride(pct)) {
+                            setPendingDiscount({ lineItemId: item.id, amount, reason })
+                            setDiscountOverrideOpen(true)
+                          } else {
+                            discountMutation.mutate({ lineItemId: item.id, amount, reason })
+                          }
+                        }}
+                        isPending={discountMutation.isPending}
+                      />
+                      <Button
+                        variant="ghost"
+                        size="icon"
+                        className="h-8 w-8"
+                        onClick={() => removeItemMutation.mutate(item.id)}
+                        disabled={removeItemMutation.isPending}
+                      >
+                        <X className="h-4 w-4 text-destructive" />
+                      </Button>
+                    </div>
+                  )}
                 </div>
-                <span className="text-sm font-medium tabular-nums">
-                  ${parseFloat(item.lineTotal).toFixed(2)}
-                </span>
-                {isPending && (
-                  <Button
-                    variant="ghost"
-                    size="icon"
-                    className="h-8 w-8 opacity-0 group-hover:opacity-100 shrink-0"
-                    onClick={() => removeItemMutation.mutate(item.id)}
-                    disabled={removeItemMutation.isPending}
-                  >
-                    <X className="h-4 w-4 text-destructive" />
-                  </Button>
-                )}
-              </div>
-            ))}
+              )
+            })}
           </div>
         )}
       </div>
@@ -148,6 +196,25 @@ export function POSCartPanel({ transaction }: POSCartPanelProps) {
           </div>
         </div>
 
+        {/* Order discount button */}
+        {hasItems && isPending && (
+          <div className="px-3 pb-1">
+            <OrderDiscountButton
+              subtotal={subtotal}
+              onApply={(amount, reason) => {
+                const pct = subtotal > 0 ? (amount / subtotal) * 100 : 0
+                if (requiresDiscountOverride(pct)) {
+                  setPendingDiscount({ lineItemId: lineItems[0].id, amount, reason })
+                  setDiscountOverrideOpen(true)
+                } else {
+                  discountMutation.mutate({ lineItemId: lineItems[0].id, amount, reason })
+                }
+              }}
+              isPending={discountMutation.isPending}
+            />
+          </div>
+        )}
+
         {/* Payment buttons */}
         <div className="p-3 space-y-2">
           {!drawerOpen && hasItems && (
@@ -183,7 +250,13 @@ export function POSCartPanel({ transaction }: POSCartPanelProps) {
               variant="destructive"
               className="h-12 text-sm gap-2"
               disabled={!hasItems || !isPending}
-              onClick={() => voidMutation.mutate()}
+              onClick={() => {
+                if (requiresOverride('void_transaction')) {
+                  setOverrideOpen(true)
+                } else {
+                  voidMutation.mutate()
+                }
+              }}
             >
               <Ban className="h-4 w-4" />
               Void
@@ -205,6 +278,220 @@ export function POSCartPanel({ transaction }: POSCartPanelProps) {
 
       {/* Customer dialog */}
       <POSCustomerDialog open={customerOpen} onOpenChange={setCustomerOpen} />
+
+      {/* Manager override for void */}
+      <ManagerOverrideDialog
+        open={overrideOpen}
+        onOpenChange={setOverrideOpen}
+        action="Void transaction"
+        onAuthorized={() => voidMutation.mutate()}
+      />
+
+      {/* Manager override for discount */}
+      <ManagerOverrideDialog
+        open={discountOverrideOpen}
+        onOpenChange={setDiscountOverrideOpen}
+        action="Price adjustment"
+        onAuthorized={() => {
+          if (pendingDiscount) {
+            discountMutation.mutate(pendingDiscount)
+            setPendingDiscount(null)
+          }
+        }}
+      />
     </div>
   )
 }
+
+// --- Order Discount Button ---
+
+function OrderDiscountButton({ subtotal, onApply, isPending }: {
+  subtotal: number
+  onApply: (amount: number, reason: string) => void
+  isPending: boolean
+}) {
+  const [open, setOpen] = useState(false)
+  const [mode, setMode] = useState<AdjustMode>('percent')
+  const [value, setValue] = useState('')
+
+  function calculate() {
+    const v = parseFloat(value) || 0
+    if (mode === 'amount_off') return Math.min(v, subtotal)
+    if (mode === 'set_price') return Math.max(0, subtotal - v)
+    return Math.round(subtotal * (v / 100) * 100) / 100
+  }
+
+  const discountAmount = calculate()
+
+  function handleApply() {
+    if (discountAmount <= 0) return
+    const reason = mode === 'percent' ? `${parseFloat(value)}% order discount` : mode === 'set_price' ? `Order total set to $${parseFloat(value).toFixed(2)}` : `$${parseFloat(value).toFixed(2)} order discount`
+    onApply(discountAmount, reason)
+    setValue('')
+    setOpen(false)
+  }
+
+  return (
+    <Popover open={open} onOpenChange={(o) => { setOpen(o); if (!o) setValue('') }}>
+      <PopoverTrigger asChild>
+        <Button variant="outline" size="sm" className="w-full gap-2 text-xs h-8">
+          <Tag className="h-3 w-3" />Order Discount
+        </Button>
+      </PopoverTrigger>
+      <PopoverContent className="w-64 p-3" side="top" align="center">
+        <div className="space-y-3">
+          <div className="text-xs text-muted-foreground">
+            Subtotal: <span className="font-medium text-foreground">${subtotal.toFixed(2)}</span>
+          </div>
+          <div className="flex rounded-md border overflow-hidden text-xs">
+            {([
+              { key: 'percent' as const, label: '% Off' },
+              { key: 'amount_off' as const, label: '$ Off' },
+              { key: 'set_price' as const, label: 'Set Total' },
+            ]).map((m) => (
+              <button
+                key={m.key}
+                type="button"
+                className={`flex-1 py-1.5 transition-colors ${mode === m.key ? 'bg-primary text-primary-foreground' : 'hover:bg-muted'}`}
+                onClick={() => { setMode(m.key); setValue('') }}
+              >
+                {m.label}
+              </button>
+            ))}
+          </div>
+          <Input
+            type="number"
+            step="0.01"
+            min="0"
+            placeholder={mode === 'percent' ? 'e.g. 10' : '0.00'}
+            value={value}
+            onChange={(e) => setValue(e.target.value)}
+            className="h-9"
+            autoFocus
+            onKeyDown={(e) => { if (e.key === 'Enter') handleApply() }}
+          />
+          {value && discountAmount > 0 && (
+            <div className="text-xs flex justify-between font-medium">
+              <span className="text-green-600">-${discountAmount.toFixed(2)}</span>
+              <span>New total: ${(subtotal - discountAmount).toFixed(2)}</span>
+            </div>
+          )}
+          <Button size="sm" className="w-full" onClick={handleApply} disabled={isPending || discountAmount <= 0}>
+            {isPending ? 'Applying...' : 'Apply Discount'}
+          </Button>
+        </div>
+      </PopoverContent>
+    </Popover>
+  )
+}
+
+// --- Price Adjuster Popover ---
+
+type AdjustMode = 'amount_off' | 'set_price' | 'percent'
+
+function PriceAdjuster({ item, open, onOpenChange, onApply, isPending }: {
+  item: TransactionLineItem
+  open: boolean
+  onOpenChange: (open: boolean) => void
+  onApply: (amount: number, reason: string) => void
+  isPending: boolean
+}) {
+  const [mode, setMode] = useState<AdjustMode>('percent')
+  const [value, setValue] = useState('')
+
+  const unitPrice = parseFloat(item.unitPrice)
+  const listTotal = unitPrice * item.qty
+
+  function calculate(): { discountAmount: number; salePrice: number; pct: number } {
+    const v = parseFloat(value) || 0
+    if (mode === 'amount_off') {
+      const d = Math.min(v, listTotal)
+      return { discountAmount: d, salePrice: listTotal - d, pct: listTotal > 0 ? (d / listTotal) * 100 : 0 }
+    }
+    if (mode === 'set_price') {
+      const d = Math.max(0, listTotal - v)
+      return { discountAmount: d, salePrice: v, pct: listTotal > 0 ? (d / listTotal) * 100 : 0 }
+    }
+    // percent
+    const d = Math.round(listTotal * (v / 100) * 100) / 100
+    return { discountAmount: d, salePrice: listTotal - d, pct: v }
+  }
+
+  const calc = calculate()
+
+  function handleApply() {
+    if (calc.discountAmount <= 0) return
+    const reason = mode === 'percent' ? `${parseFloat(value)}% off` : mode === 'set_price' ? `Price set to $${parseFloat(value).toFixed(2)}` : `$${parseFloat(value).toFixed(2)} off`
+    onApply(calc.discountAmount, reason)
+    setValue('')
+  }
+
+  return (
+    <Popover open={open} onOpenChange={(o) => { onOpenChange(o); if (!o) setValue('') }}>
+      <PopoverTrigger asChild>
+        <Button variant="ghost" size="icon" className="h-8 w-8">
+          <Tag className="h-4 w-4" />
+        </Button>
+      </PopoverTrigger>
+      <PopoverContent className="w-64 p-3" side="left" align="start">
+        <div className="space-y-3">
+          <div className="text-xs text-muted-foreground">
+            List: <span className="font-medium text-foreground">${listTotal.toFixed(2)}</span>
+          </div>
+
+          {/* Mode tabs */}
+          <div className="flex rounded-md border overflow-hidden text-xs">
+            {([
+              { key: 'percent' as const, label: '% Off' },
+              { key: 'amount_off' as const, label: '$ Off' },
+              { key: 'set_price' as const, label: 'Set Price' },
+            ]).map((m) => (
+              <button
+                key={m.key}
+                type="button"
+                className={`flex-1 py-1.5 transition-colors ${mode === m.key ? 'bg-primary text-primary-foreground' : 'hover:bg-muted'}`}
+                onClick={() => { setMode(m.key); setValue('') }}
+              >
+                {m.label}
+              </button>
+            ))}
+          </div>
+
+          <Input
+            type="number"
+            step="0.01"
+            min="0"
+            placeholder={mode === 'percent' ? 'e.g. 10' : '0.00'}
+            value={value}
+            onChange={(e) => setValue(e.target.value)}
+            className="h-9"
+            autoFocus
+            onKeyDown={(e) => { if (e.key === 'Enter') handleApply() }}
+          />
+
+          {value && parseFloat(value) > 0 && (
+            <div className="text-xs space-y-0.5">
+              <div className="flex justify-between">
+                <span className="text-muted-foreground">Discount</span>
+                <span className="text-green-600">-${calc.discountAmount.toFixed(2)} ({calc.pct.toFixed(0)}%)</span>
+              </div>
+              <div className="flex justify-between font-medium">
+                <span>Sale Price</span>
+                <span>${calc.salePrice.toFixed(2)}</span>
+              </div>
+            </div>
+          )}
+
+          <Button
+            size="sm"
+            className="w-full"
+            onClick={handleApply}
+            disabled={isPending || !value || calc.discountAmount <= 0}
+          >
+            {isPending ? 'Applying...' : 'Apply'}
+          </Button>
+        </div>
+      </PopoverContent>
+    </Popover>
+  )
+}

packages/admin/src/components/pos/pos-drawer-dialog.tsx

@@ -10,6 +10,7 @@ import { Separator } from '@/components/ui/separator'
 import { Badge } from '@/components/ui/badge'
 import { ArrowDownToLine, ArrowUpFromLine } from 'lucide-react'
 import { toast } from 'sonner'
+import { ManagerOverrideDialog, requiresOverride } from './pos-manager-override'
 
 interface POSDrawerDialogProps {
   open: boolean
@@ -28,6 +29,8 @@ export function POSDrawerDialog({ open, onOpenChange, drawer }: POSDrawerDialogP
   const [adjustView, setAdjustView] = useState<'cash_in' | 'cash_out' | null>(null)
   const [adjAmount, setAdjAmount] = useState('')
   const [adjReason, setAdjReason] = useState('')
+  const [overrideOpen, setOverrideOpen] = useState(false)
+  const [pendingAdjustView, setPendingAdjustView] = useState<'cash_in' | 'cash_out' | null>(null)
 
   // Fetch adjustments for open drawer
   const { data: adjData } = useQuery({
@@ -93,6 +96,7 @@ export function POSDrawerDialog({ open, onOpenChange, drawer }: POSDrawerDialogP
   if (adjustView && isOpen) {
     const isCashIn = adjustView === 'cash_in'
     return (
+      <>
       <Dialog open={open} onOpenChange={onOpenChange}>
         <DialogContent className="max-w-sm">
           <DialogHeader>
@@ -136,10 +140,12 @@ export function POSDrawerDialog({ open, onOpenChange, drawer }: POSDrawerDialogP
           </div>
         </DialogContent>
       </Dialog>
+      </>
     )
   }
 
   return (
+    <>
     <Dialog open={open} onOpenChange={onOpenChange}>
       <DialogContent className="max-w-sm">
         <DialogHeader>
@@ -164,7 +170,14 @@ export function POSDrawerDialog({ open, onOpenChange, drawer }: POSDrawerDialogP
               <Button
                 variant="outline"
                 className="h-11 gap-2"
-                onClick={() => setAdjustView('cash_in')}
+                onClick={() => {
+                  if (requiresOverride('cash_in_out')) {
+                    setPendingAdjustView('cash_in')
+                    setOverrideOpen(true)
+                  } else {
+                    setAdjustView('cash_in')
+                  }
+                }}
               >
                 <ArrowDownToLine className="h-4 w-4 text-green-600" />
                 Cash In
@@ -172,7 +185,14 @@ export function POSDrawerDialog({ open, onOpenChange, drawer }: POSDrawerDialogP
               <Button
                 variant="outline"
                 className="h-11 gap-2"
-                onClick={() => setAdjustView('cash_out')}
+                onClick={() => {
+                  if (requiresOverride('cash_in_out')) {
+                    setPendingAdjustView('cash_out')
+                    setOverrideOpen(true)
+                  } else {
+                    setAdjustView('cash_out')
+                  }
+                }}
               >
                 <ArrowUpFromLine className="h-4 w-4 text-red-600" />
                 Cash Out
@@ -260,5 +280,16 @@ export function POSDrawerDialog({ open, onOpenChange, drawer }: POSDrawerDialogP
         )}
       </DialogContent>
     </Dialog>
+
+    <ManagerOverrideDialog
+      open={overrideOpen}
+      onOpenChange={setOverrideOpen}
+      action={pendingAdjustView === 'cash_in' ? 'Cash In' : 'Cash Out'}
+      onAuthorized={() => {
+        if (pendingAdjustView) setAdjustView(pendingAdjustView)
+        setPendingAdjustView(null)
+      }}
+    />
+    </>
   )
 }

packages/admin/src/components/pos/pos-item-panel.tsx

@@ -10,6 +10,7 @@ import { Skeleton } from '@/components/ui/skeleton'
 import { Search, ScanBarcode, Wrench, PenLine, ClipboardList } from 'lucide-react'
 import { toast } from 'sonner'
 import { POSTransactionsDialog } from './pos-transactions-dialog'
+import { POSRepairDialog } from './pos-repair-dialog'
 
 interface POSItemPanelProps {
   transaction: Transaction | null
@@ -21,6 +22,7 @@ export function POSItemPanel({ transaction: _transaction }: POSItemPanelProps) {
   const [search, setSearch] = useState('')
   const [customOpen, setCustomOpen] = useState(false)
   const [txnDialogOpen, setTxnDialogOpen] = useState(false)
+  const [repairOpen, setRepairOpen] = useState(false)
   const [customDesc, setCustomDesc] = useState('')
   const [customPrice, setCustomPrice] = useState('')
   const [customQty, setCustomQty] = useState('1')
@@ -200,7 +202,7 @@ export function POSItemPanel({ transaction: _transaction }: POSItemPanelProps) {
         <Button
           variant="outline"
           className="flex-1 h-11 text-sm gap-2"
-          disabled
+          onClick={() => setRepairOpen(true)}
         >
           <Wrench className="h-4 w-4" />
           Repairs
@@ -277,6 +279,7 @@ export function POSItemPanel({ transaction: _transaction }: POSItemPanelProps) {
 
       {/* Transactions dialog */}
       <POSTransactionsDialog open={txnDialogOpen} onOpenChange={setTxnDialogOpen} />
+      <POSRepairDialog open={repairOpen} onOpenChange={setRepairOpen} />
     </div>
   )
 }

packages/admin/src/components/pos/pos-manager-override.tsx

@@ -0,0 +1,199 @@
+import { useState, useCallback, useEffect, useRef } from 'react'
+import { Dialog, DialogContent, DialogTitle } from '@/components/ui/dialog'
+import { Button } from '@/components/ui/button'
+import { api } from '@/lib/api-client'
+import { Delete, ShieldCheck } from 'lucide-react'
+
+interface ManagerOverrideDialogProps {
+  open: boolean
+  onOpenChange: (open: boolean) => void
+  action: string
+  onAuthorized: () => void
+}
+
+interface PinUser {
+  id: string
+  role: string
+  firstName: string
+  lastName: string
+}
+
+export function ManagerOverrideDialog({ open, onOpenChange, action, onAuthorized }: ManagerOverrideDialogProps) {
+  const [code, setCode] = useState('')
+  const [error, setError] = useState('')
+  const [loading, setLoading] = useState(false)
+  const containerRef = useRef<HTMLDivElement>(null)
+
+  useEffect(() => {
+    if (open) {
+      setCode('')
+      setError('')
+      containerRef.current?.focus()
+    }
+  }, [open])
+
+  const handleDigit = useCallback((digit: string) => {
+    setError('')
+    setCode((p) => (p.length >= 10 ? p : p + digit))
+  }, [])
+
+  const handleBackspace = useCallback(() => {
+    setError('')
+    setCode((p) => p.slice(0, -1))
+  }, [])
+
+  const handleClear = useCallback(() => {
+    setError('')
+    setCode('')
+  }, [])
+
+  const handleSubmit = useCallback(async (submitCode: string) => {
+    if (submitCode.length < 8) {
+      setError('Enter manager employee # + PIN')
+      return
+    }
+    setLoading(true)
+    setError('')
+    try {
+      const res = await api.post<{ user: PinUser; token: string }>('/v1/auth/pin-login', { code: submitCode })
+      if (res.user.role === 'admin' || res.user.role === 'manager') {
+        onAuthorized()
+        onOpenChange(false)
+      } else {
+        setError('Manager or admin access required')
+        setCode('')
+      }
+    } catch {
+      setError('Invalid code')
+      setCode('')
+    } finally {
+      setLoading(false)
+    }
+  }, [onAuthorized, onOpenChange])
+
+  useEffect(() => {
+    if (code.length === 8) {
+      handleSubmit(code)
+    }
+  }, [code, handleSubmit])
+
+  const handleKeyDown = useCallback((e: React.KeyboardEvent) => {
+    if (e.key >= '0' && e.key <= '9') handleDigit(e.key)
+    else if (e.key === 'Backspace') handleBackspace()
+    else if (e.key === 'Enter' && code.length >= 8) handleSubmit(code)
+    else if (e.key === 'Escape') handleClear()
+  }, [handleDigit, handleBackspace, handleSubmit, handleClear, code])
+
+  return (
+    <Dialog open={open} onOpenChange={onOpenChange}>
+      <DialogContent className="max-w-xs">
+        <div
+          ref={containerRef}
+          onKeyDown={handleKeyDown}
+          tabIndex={0}
+          className="outline-none space-y-4"
+        >
+          <div className="text-center space-y-1">
+            <ShieldCheck className="h-8 w-8 mx-auto text-amber-500" />
+            <DialogTitle className="text-base">Manager Override</DialogTitle>
+            <p className="text-xs text-muted-foreground">{action}</p>
+          </div>
+
+          {/* Code dots */}
+          <div className="flex justify-center items-center gap-2">
+            <div className="flex gap-1.5">
+              {Array.from({ length: 4 }).map((_, i) => (
+                <div
+                  key={`e${i}`}
+                  className={`w-3 h-3 rounded-full border-2 ${
+                    i < Math.min(code.length, 4) ? 'bg-foreground border-foreground' : 'border-muted-foreground/30'
+                  }`}
+                />
+              ))}
+            </div>
+            <span className="text-muted-foreground/40">-</span>
+            <div className="flex gap-1.5">
+              {Array.from({ length: 4 }).map((_, i) => (
+                <div
+                  key={`p${i}`}
+                  className={`w-3 h-3 rounded-full border-2 ${
+                    i < Math.max(0, code.length - 4) ? 'bg-foreground border-foreground' : 'border-muted-foreground/30'
+                  }`}
+                />
+              ))}
+            </div>
+          </div>
+
+          {error && <p className="text-xs text-destructive text-center">{error}</p>}
+
+          {/* Numpad */}
+          <div className="grid grid-cols-3 gap-1.5">
+            {['1', '2', '3', '4', '5', '6', '7', '8', '9'].map((d) => (
+              <Button key={d} variant="outline" className="h-12 text-lg font-medium" onClick={() => handleDigit(d)} disabled={loading}>
+                {d}
+              </Button>
+            ))}
+            <Button variant="outline" className="h-12 text-xs" onClick={handleClear} disabled={loading}>Clear</Button>
+            <Button variant="outline" className="h-12 text-lg font-medium" onClick={() => handleDigit('0')} disabled={loading}>0</Button>
+            <Button variant="outline" className="h-12" onClick={handleBackspace} disabled={loading}>
+              <Delete className="h-4 w-4" />
+            </Button>
+          </div>
+
+          {loading && <p className="text-xs text-muted-foreground text-center">Verifying...</p>}
+        </div>
+      </DialogContent>
+    </Dialog>
+  )
+}
+
+// --- Config types & helpers ---
+
+export const OVERRIDE_ACTIONS = [
+  { key: 'void_transaction', label: 'Void Transaction', description: 'Cancel an in-progress sale' },
+  { key: 'refund', label: 'Refund', description: 'Process a return or refund' },
+  { key: 'manual_discount', label: 'Manual Discount', description: 'Apply a discount not from a preset' },
+  { key: 'price_override', label: 'Price Override', description: 'Change an item price at the register' },
+  { key: 'no_sale_drawer', label: 'No-Sale Drawer Open', description: 'Open the drawer without a transaction' },
+  { key: 'cash_in_out', label: 'Cash In / Cash Out', description: 'Add or remove cash from the drawer' },
+] as const
+
+export type OverrideAction = typeof OVERRIDE_ACTIONS[number]['key']
+
+const STORAGE_KEY = 'pos_manager_overrides'
+
+export function getRequiredOverrides(): Set<OverrideAction> {
+  try {
+    const stored = localStorage.getItem(STORAGE_KEY)
+    if (!stored) return new Set()
+    return new Set(JSON.parse(stored) as OverrideAction[])
+  } catch {
+    return new Set()
+  }
+}
+
+export function setRequiredOverrides(actions: Set<OverrideAction>) {
+  localStorage.setItem(STORAGE_KEY, JSON.stringify([...actions]))
+}
+
+export function requiresOverride(action: OverrideAction): boolean {
+  return getRequiredOverrides().has(action)
+}
+
+// Discount threshold — discounts above this percentage require manager override
+const DISCOUNT_THRESHOLD_KEY = 'pos_discount_threshold_pct'
+
+export function getDiscountThreshold(): number {
+  const stored = localStorage.getItem(DISCOUNT_THRESHOLD_KEY)
+  return stored ? parseInt(stored, 10) : 0 // 0 = disabled
+}
+
+export function setDiscountThreshold(pct: number) {
+  localStorage.setItem(DISCOUNT_THRESHOLD_KEY, String(pct))
+}
+
+export function requiresDiscountOverride(discountPct: number): boolean {
+  const threshold = getDiscountThreshold()
+  if (threshold <= 0) return requiresOverride('manual_discount')
+  return discountPct >= threshold
+}

packages/admin/src/components/pos/pos-payment-dialog.tsx

@@ -71,6 +71,7 @@ export function POSPaymentDialog({ open, onOpenChange, paymentMethod, transactio
     queryFn: () => api.get<{ data: AppConfigEntry[] }>('/v1/config'),
     enabled: !!result?.id,
   })
+  const receiptFormat = usePOSStore((s) => s.receiptFormat)
   const receiptConfig = {
     header: configData?.data?.find((c) => c.key === 'receipt_header')?.value || undefined,
     footer: configData?.data?.find((c) => c.key === 'receipt_footer')?.value || undefined,
@@ -98,11 +99,11 @@ export function POSPaymentDialog({ open, onOpenChange, paymentMethod, transactio
     if (showReceipt && receiptData) {
       return (
         <Dialog open={open} onOpenChange={() => { setShowReceipt(false); handleDone() }}>
-          <DialogContent className="max-w-sm max-h-[90vh] overflow-y-auto print:max-w-none print:max-h-none print:overflow-visible print:shadow-none print:border-none">
+          <DialogContent className={`${receiptFormat === 'full' ? 'max-w-2xl' : 'max-w-sm'} max-h-[90vh] overflow-y-auto print:max-w-none print:max-h-none print:overflow-visible print:shadow-none print:border-none`}>
             <div className="flex justify-between items-center mb-2">
               <Button variant="ghost" size="sm" onClick={() => setShowReceipt(false)}>Back</Button>
               <div className="flex gap-2">
-                <Button variant="outline" size="sm" onClick={() => downloadReceiptPDF(result.transactionNumber)} className="gap-2">
+                <Button variant="outline" size="sm" onClick={() => downloadReceiptPDF(result.transactionNumber, receiptFormat)} className="gap-2">
                   Save PDF
                 </Button>
                 <Button size="sm" onClick={printReceipt} className="gap-2">
@@ -111,7 +112,7 @@ export function POSPaymentDialog({ open, onOpenChange, paymentMethod, transactio
               </div>
             </div>
             <div id="pos-receipt-print">
-              <POSReceipt data={receiptData} config={receiptConfig} />
+              <POSReceipt data={receiptData} size={receiptFormat} config={receiptConfig} />
             </div>
           </DialogContent>
         </Dialog>

packages/admin/src/components/pos/pos-receipt.tsx

@@ -100,23 +100,28 @@ function useStoreLogo(companyId?: string) {
 }
 
 export function POSReceipt({ data, size = 'thermal', footerText, config }: POSReceiptProps) {
-  const barcodeRef = useRef<SVGSVGElement>(null)
   const { transaction: txn, company, location } = data
   const isThermal = size === 'thermal'
+
+  if (!isThermal) {
+    return <FullPageReceipt data={data} config={config} footerText={footerText} />
+  }
+
+  return <ThermalReceipt data={data} config={config} footerText={footerText} />
+}
+
+function ThermalReceipt({ data, config, footerText }: { data: POSReceiptProps['data']; config?: ReceiptConfig; footerText?: string }) {
+  const barcodeRef = useRef<SVGSVGElement>(null)
+  const { transaction: txn, company, location } = data
   const logoSrc = useStoreLogo()
 
   useEffect(() => {
     if (barcodeRef.current) {
       JsBarcode(barcodeRef.current, txn.transactionNumber, {
-        format: 'CODE128',
-        width: isThermal ? 1.5 : 2,
-        height: isThermal ? 40 : 50,
-        displayValue: true,
-        fontSize: isThermal ? 10 : 12,
-        margin: 4,
+        format: 'CODE128', width: 1.5, height: 40, displayValue: true, fontSize: 10, margin: 4,
       })
     }
-  }, [txn.transactionNumber, isThermal])
+  }, [txn.transactionNumber])
 
   const date = new Date(txn.completedAt ?? txn.createdAt)
   const subtotal = parseFloat(txn.subtotal)
@@ -143,16 +148,14 @@ export function POSReceipt({ data, size = 'thermal', footerText, config }: POSRe
   return (
     <div style={{
       background: '#fff', color: '#000', fontFamily: 'monospace',
-      width: isThermal ? 260 : '100%', maxWidth: isThermal ? 260 : 480,
-      fontSize: isThermal ? 10 : 14, lineHeight: isThermal ? '1.3' : '1.6',
-      margin: '0 auto',
+      width: 260, maxWidth: 260, fontSize: 10, lineHeight: '1.3', margin: '0 auto',
     }}>
       {/* Store header */}
       <div style={{ ...s.section, ...s.center }}>
         {logoSrc ? (
-          <img src={logoSrc} alt={company.name} style={{ display: 'block', margin: '0 auto 4px', maxHeight: isThermal ? 48 : 64, maxWidth: isThermal ? 200 : 280, objectFit: 'contain' }} />
+          <img src={logoSrc} alt={company.name} style={{ display: 'block', margin: '0 auto 4px', maxHeight: 48, maxWidth: 200, objectFit: 'contain' }} />
         ) : (
-          <div style={{ ...s.bold, fontSize: isThermal ? 14 : 18 }}>{company.name}</div>
+          <div style={{ ...s.bold, fontSize: 14 }}>{company.name}</div>
         )}
         {location.name !== company.name && <div style={s.gray}>{location.name}</div>}
         {addr?.street && <div>{addr.street}</div>}
@@ -205,7 +208,7 @@ export function POSReceipt({ data, size = 'thermal', footerText, config }: POSRe
         {rounding !== 0 && (
           <div style={{ ...s.row, ...s.gray }}><span>Rounding</span><span style={s.nums}>{rounding > 0 ? '+' : ''}{rounding.toFixed(2)}</span></div>
         )}
-        <div style={{ ...s.row, ...s.bold, fontSize: isThermal ? 14 : 16, paddingTop: 4 }}>
+        <div style={{ ...s.row, ...s.bold, fontSize: 14, paddingTop: 4 }}>
           <span>TOTAL</span><span style={s.nums}>${total.toFixed(2)}</span>
         </div>
       </div>
@@ -240,6 +243,152 @@ export function POSReceipt({ data, size = 'thermal', footerText, config }: POSRe
   )
 }
 
+function FullPageReceipt({ data, config, footerText }: { data: POSReceiptProps['data']; config?: ReceiptConfig; footerText?: string }) {
+  const barcodeRef = useRef<SVGSVGElement>(null)
+  const { transaction: txn, company, location } = data
+  const logoSrc = useStoreLogo()
+
+  useEffect(() => {
+    if (barcodeRef.current) {
+      JsBarcode(barcodeRef.current, txn.transactionNumber, {
+        format: 'CODE128', width: 2, height: 50, displayValue: true, fontSize: 12, margin: 4,
+      })
+    }
+  }, [txn.transactionNumber])
+
+  const date = new Date(txn.completedAt ?? txn.createdAt)
+  const subtotal = parseFloat(txn.subtotal)
+  const discountTotal = parseFloat(txn.discountTotal)
+  const taxTotal = parseFloat(txn.taxTotal)
+  const total = parseFloat(txn.total)
+  const rounding = parseFloat(txn.roundingAdjustment)
+  const tendered = txn.amountTendered ? parseFloat(txn.amountTendered) : null
+  const change = txn.changeGiven ? parseFloat(txn.changeGiven) : null
+
+  const addr = location.address ?? company.address
+  const phone = location.phone ?? company.phone
+  const email = location.email ?? company.email
+
+  const f = (n: number) => `$${n.toFixed(2)}`
+
+  return (
+    <div style={{
+      background: '#fff', color: '#000', fontFamily: 'Helvetica, Arial, sans-serif',
+      width: '100%', maxWidth: 600, margin: '0 auto', fontSize: 13, lineHeight: '1.5',
+    }}>
+      {/* Header — company left, transaction right */}
+      <div style={{ display: 'flex', justifyContent: 'space-between', alignItems: 'flex-start', paddingBottom: 16 }}>
+        <div>
+          {logoSrc ? (
+            <img src={logoSrc} alt={company.name} style={{ maxHeight: 56, maxWidth: 200, objectFit: 'contain', marginBottom: 4 }} />
+          ) : (
+            <div style={{ fontSize: 20, fontWeight: 'bold' }}>{company.name}</div>
+          )}
+          {location.name !== company.name && <div style={{ color: '#555', fontSize: 12 }}>{location.name}</div>}
+          {addr?.street && <div style={{ fontSize: 12 }}>{addr.street}</div>}
+          {(addr?.city || addr?.state || addr?.zip) && (
+            <div style={{ fontSize: 12 }}>{[addr?.city, addr?.state].filter(Boolean).join(', ')} {addr?.zip}</div>
+          )}
+          {phone && <div style={{ fontSize: 12 }}>{phone}</div>}
+          {email && <div style={{ fontSize: 12 }}>{email}</div>}
+          {config?.header && <div style={{ fontSize: 12, color: '#555', marginTop: 2 }}>{config.header}</div>}
+        </div>
+        <div style={{ textAlign: 'right' }}>
+          <div style={{ fontSize: 16, fontWeight: 'bold' }}>{txn.transactionNumber}</div>
+          <div style={{ fontSize: 12, color: '#555', textTransform: 'capitalize' }}>{txn.transactionType.replace('_', ' ')}</div>
+          <div style={{ fontSize: 12, color: '#555' }}>{date.toLocaleDateString()}</div>
+          <div style={{ fontSize: 12, color: '#555' }}>{date.toLocaleTimeString()}</div>
+        </div>
+      </div>
+
+      {/* Divider */}
+      <div style={{ borderBottom: '1px solid #ddd', marginBottom: 16 }} />
+
+      {/* Line items table */}
+      <table style={{ width: '100%', borderCollapse: 'collapse', fontSize: 13 }}>
+        <thead>
+          <tr style={{ background: '#f5f5f5' }}>
+            <th style={{ textAlign: 'left', padding: '6px 8px', fontWeight: 600, fontSize: 11, textTransform: 'uppercase', color: '#555' }}>Item</th>
+            <th style={{ textAlign: 'right', padding: '6px 8px', fontWeight: 600, fontSize: 11, textTransform: 'uppercase', color: '#555', width: 50 }}>Qty</th>
+            <th style={{ textAlign: 'right', padding: '6px 8px', fontWeight: 600, fontSize: 11, textTransform: 'uppercase', color: '#555', width: 80 }}>Price</th>
+            <th style={{ textAlign: 'right', padding: '6px 8px', fontWeight: 600, fontSize: 11, textTransform: 'uppercase', color: '#555', width: 80 }}>Total</th>
+          </tr>
+        </thead>
+        <tbody>
+          {txn.lineItems.map((item, i) => (
+            <tr key={i} style={{ borderBottom: '1px solid #eee' }}>
+              <td style={{ padding: '6px 8px' }}>
+                {item.description}
+                {parseFloat(item.discountAmount ?? '0') > 0 && (
+                  <div style={{ fontSize: 11, color: '#999' }}>Discount: -{f(parseFloat(item.discountAmount!))}</div>
+                )}
+              </td>
+              <td style={{ padding: '6px 8px', textAlign: 'right', fontVariantNumeric: 'tabular-nums' }}>{item.qty}</td>
+              <td style={{ padding: '6px 8px', textAlign: 'right', fontVariantNumeric: 'tabular-nums' }}>{f(parseFloat(item.unitPrice))}</td>
+              <td style={{ padding: '6px 8px', textAlign: 'right', fontVariantNumeric: 'tabular-nums' }}>{f(parseFloat(item.lineTotal))}</td>
+            </tr>
+          ))}
+        </tbody>
+      </table>
+
+      {/* Totals — right aligned */}
+      <div style={{ display: 'flex', justifyContent: 'flex-end', marginTop: 12 }}>
+        <div style={{ width: 220 }}>
+          <div style={{ display: 'flex', justifyContent: 'space-between', padding: '3px 0' }}>
+            <span>Subtotal</span><span style={{ fontVariantNumeric: 'tabular-nums' }}>{f(subtotal)}</span>
+          </div>
+          {discountTotal > 0 && (
+            <div style={{ display: 'flex', justifyContent: 'space-between', padding: '3px 0', color: '#555' }}>
+              <span>Discount</span><span style={{ fontVariantNumeric: 'tabular-nums' }}>-{f(discountTotal)}</span>
+            </div>
+          )}
+          <div style={{ display: 'flex', justifyContent: 'space-between', padding: '3px 0' }}>
+            <span>Tax</span><span style={{ fontVariantNumeric: 'tabular-nums' }}>{f(taxTotal)}</span>
+          </div>
+          {rounding !== 0 && (
+            <div style={{ display: 'flex', justifyContent: 'space-between', padding: '3px 0', color: '#888', fontSize: 12 }}>
+              <span>Rounding</span><span style={{ fontVariantNumeric: 'tabular-nums' }}>{rounding > 0 ? '+' : ''}{rounding.toFixed(2)}</span>
+            </div>
+          )}
+          <div style={{ borderTop: '1px solid #ddd', marginTop: 4, paddingTop: 6, display: 'flex', justifyContent: 'space-between', fontWeight: 'bold', fontSize: 16 }}>
+            <span>Total</span><span style={{ fontVariantNumeric: 'tabular-nums' }}>{f(total)}</span>
+          </div>
+        </div>
+      </div>
+
+      {/* Payment info */}
+      <div style={{ marginTop: 16, padding: '12px 0', borderTop: '1px solid #ddd' }}>
+        <div style={{ display: 'flex', justifyContent: 'space-between' }}>
+          <span>Payment Method</span>
+          <span style={{ textTransform: 'capitalize', fontWeight: 500 }}>{txn.paymentMethod?.replace('_', ' ') ?? 'N/A'}</span>
+        </div>
+        {tendered !== null && (
+          <div style={{ display: 'flex', justifyContent: 'space-between', color: '#555', fontSize: 12, marginTop: 2 }}>
+            <span>Tendered</span><span style={{ fontVariantNumeric: 'tabular-nums' }}>{f(tendered)}</span>
+          </div>
+        )}
+        {change !== null && change > 0 && (
+          <div style={{ display: 'flex', justifyContent: 'space-between', fontWeight: 'bold', marginTop: 2 }}>
+            <span>Change</span><span style={{ fontVariantNumeric: 'tabular-nums' }}>{f(change)}</span>
+          </div>
+        )}
+      </div>
+
+      {/* Barcode */}
+      <div style={{ display: 'flex', justifyContent: 'center', padding: '16px 0' }}>
+        <svg ref={barcodeRef} />
+      </div>
+
+      {/* Footer */}
+      <div style={{ borderTop: '1px solid #eee', paddingTop: 12, textAlign: 'center', fontSize: 11, color: '#999' }}>
+        {(config?.footer || footerText) && <div>{config?.footer || footerText}</div>}
+        {config?.returnPolicy && <div style={{ marginTop: 4 }}>{config.returnPolicy}</div>}
+        {config?.social && <div style={{ marginTop: 4 }}>{config.social}</div>}
+      </div>
+    </div>
+  )
+}
+
 export function printReceipt() {
   const el = document.getElementById('pos-receipt-print')
   if (!el) return
@@ -269,23 +418,36 @@ export function printReceipt() {
   }, 300)
 }
 
-export async function downloadReceiptPDF(txnNumber?: string) {
+export async function downloadReceiptPDF(txnNumber?: string, format: 'thermal' | 'full' = 'thermal') {
   const el = document.getElementById('pos-receipt-print')
   if (!el) return
 
-  // Calculate height from actual content
-  const heightPx = el.scrollHeight + 16 // 16px padding
-  const heightMm = Math.ceil(heightPx * 0.265) + 8 // px to mm + margin
-
   const html2pdf = (await import('html2pdf.js')).default
-  html2pdf()
-    .set({
-      margin: [2, 2, 2, 2],
-      filename: `receipt-${txnNumber ?? 'unknown'}.pdf`,
-      image: { type: 'jpeg', quality: 0.95 },
-      html2canvas: { scale: 2, useCORS: true, width: 280 },
-      jsPDF: { unit: 'mm', format: [72, heightMm], orientation: 'portrait' },
-    })
-    .from(el)
-    .save()
+
+  if (format === 'full') {
+    html2pdf()
+      .set({
+        margin: [10, 10, 10, 10],
+        filename: `receipt-${txnNumber ?? 'unknown'}.pdf`,
+        image: { type: 'jpeg', quality: 0.95 },
+        html2canvas: { scale: 2, useCORS: true },
+        jsPDF: { unit: 'mm', format: 'letter', orientation: 'portrait' },
+      })
+      .from(el)
+      .save()
+  } else {
+    // Thermal — dynamic height based on content
+    const heightPx = el.scrollHeight + 16
+    const heightMm = Math.ceil(heightPx * 0.265) + 8
+    html2pdf()
+      .set({
+        margin: [2, 2, 2, 2],
+        filename: `receipt-${txnNumber ?? 'unknown'}.pdf`,
+        image: { type: 'jpeg', quality: 0.95 },
+        html2canvas: { scale: 2, useCORS: true, width: 280 },
+        jsPDF: { unit: 'mm', format: [72, heightMm], orientation: 'portrait' },
+      })
+      .from(el)
+      .save()
+  }
 }

packages/admin/src/components/pos/pos-repair-dialog.tsx

@@ -0,0 +1,263 @@
+import { useState } from 'react'
+import { useQuery, useMutation, useQueryClient } from '@tanstack/react-query'
+import { usePOSStore } from '@/stores/pos.store'
+import { api } from '@/lib/api-client'
+import { posMutations, posKeys } from '@/api/pos'
+import { Dialog, DialogContent, DialogHeader, DialogTitle } from '@/components/ui/dialog'
+import { Tabs, TabsContent, TabsList, TabsTrigger } from '@/components/ui/tabs'
+import { Input } from '@/components/ui/input'
+import { Label } from '@/components/ui/label'
+import { Textarea } from '@/components/ui/textarea'
+import { Button } from '@/components/ui/button'
+import { Badge } from '@/components/ui/badge'
+import { Search, Wrench, Plus } from 'lucide-react'
+import { toast } from 'sonner'
+
+interface Account {
+  id: string
+  name: string
+  email: string | null
+  phone: string | null
+  accountNumber: string | null
+}
+
+interface RepairTicketSummary {
+  id: string
+  ticketNumber: string | null
+  customerName: string
+  customerPhone: string | null
+  itemDescription: string | null
+  estimatedCost: string | null
+  status: string
+}
+
+interface POSRepairDialogProps {
+  open: boolean
+  onOpenChange: (open: boolean) => void
+}
+
+export function POSRepairDialog({ open, onOpenChange }: POSRepairDialogProps) {
+  const queryClient = useQueryClient()
+  const { locationId, setTransaction, setAccount } = usePOSStore()
+  const [search, setSearch] = useState('')
+  const [tab, setTab] = useState('pickup')
+
+  // --- Pickup tab ---
+  const { data, isLoading } = useQuery({
+    queryKey: ['pos', 'repair-tickets-ready', search],
+    queryFn: () => api.get<{ data: RepairTicketSummary[] }>('/v1/repair-tickets/ready', { q: search || undefined, limit: 20 }),
+    enabled: open && tab === 'pickup',
+  })
+  const tickets = data?.data ?? []
+
+  const pickupMutation = useMutation({
+    mutationFn: (ticketId: string) => posMutations.createFromRepair(ticketId, locationId ?? undefined),
+    onSuccess: (txn) => {
+      setTransaction(txn.id)
+      if (txn.accountId) {
+        const ticket = tickets.find((t) => t.id === pickupMutation.variables)
+        if (ticket) setAccount(txn.accountId, ticket.customerName, ticket.customerPhone)
+      }
+      queryClient.invalidateQueries({ queryKey: posKeys.transaction(txn.id) })
+      toast.success(`Repair payment loaded — ${txn.transactionNumber}`)
+      close()
+    },
+    onError: (err) => toast.error(err.message),
+  })
+
+  // --- New intake tab ---
+  const [customerName, setCustomerName] = useState('')
+  const [customerPhone, setCustomerPhone] = useState('')
+  const [itemDescription, setItemDescription] = useState('')
+  const [problemDescription, setProblemDescription] = useState('')
+  const [estimatedCost, setEstimatedCost] = useState('')
+  const [accountId, setAccountId] = useState<string | null>(null)
+  const [customerSearch, setCustomerSearch] = useState('')
+  const [showCustomers, setShowCustomers] = useState(false)
+
+  const { data: customerData } = useQuery({
+    queryKey: ['pos', 'accounts', customerSearch],
+    queryFn: () => api.get<{ data: Account[] }>('/v1/accounts', { q: customerSearch, limit: 10 }),
+    enabled: customerSearch.length >= 2 && tab === 'intake',
+  })
+  const customerResults = customerData?.data ?? []
+
+  function selectCustomer(account: Account) {
+    setAccountId(account.id)
+    setCustomerName(account.name)
+    setCustomerPhone(account.phone ?? '')
+    setCustomerSearch('')
+    setShowCustomers(false)
+  }
+
+  function clearCustomer() {
+    setAccountId(null)
+    setCustomerName('')
+    setCustomerPhone('')
+  }
+
+  const intakeMutation = useMutation({
+    mutationFn: (data: Record<string, unknown>) =>
+      api.post<{ id: string; ticketNumber: string }>('/v1/repair-tickets', data),
+    onSuccess: (ticket) => {
+      toast.success(`Repair ticket #${ticket.ticketNumber} created`)
+      close()
+    },
+    onError: (err) => toast.error(err.message),
+  })
+
+  function handleIntakeSubmit(e: React.FormEvent) {
+    e.preventDefault()
+    intakeMutation.mutate({
+      customerName,
+      customerPhone: customerPhone || undefined,
+      accountId: accountId ?? undefined,
+      itemDescription: itemDescription || undefined,
+      problemDescription,
+      estimatedCost: estimatedCost ? parseFloat(estimatedCost) : undefined,
+      locationId: locationId ?? undefined,
+    })
+  }
+
+  function close() {
+    onOpenChange(false)
+    setSearch('')
+    setCustomerName('')
+    setCustomerPhone('')
+    setItemDescription('')
+    setProblemDescription('')
+    setEstimatedCost('')
+    setAccountId(null)
+    setCustomerSearch('')
+    setShowCustomers(false)
+  }
+
+  return (
+    <Dialog open={open} onOpenChange={(o) => { if (!o) close(); else onOpenChange(true) }}>
+      <DialogContent className="max-w-md">
+        <DialogHeader>
+          <DialogTitle className="flex items-center gap-2">
+            <Wrench className="h-5 w-5" />Repairs
+          </DialogTitle>
+        </DialogHeader>
+
+        <Tabs value={tab} onValueChange={setTab}>
+          <TabsList className="w-full">
+            <TabsTrigger value="pickup" className="flex-1">Pickup</TabsTrigger>
+            <TabsTrigger value="intake" className="flex-1">New Intake</TabsTrigger>
+          </TabsList>
+
+          <TabsContent value="pickup" className="mt-3 space-y-3">
+            <div className="relative">
+              <Search className="absolute left-3 top-1/2 -translate-y-1/2 h-4 w-4 text-muted-foreground" />
+              <Input
+                placeholder="Search by ticket #, name, or phone..."
+                value={search}
+                onChange={(e) => setSearch(e.target.value)}
+                className="pl-9"
+                autoFocus={tab === 'pickup'}
+              />
+            </div>
+
+            <div className="max-h-64 overflow-y-auto space-y-1">
+              {isLoading ? (
+                <p className="text-sm text-muted-foreground text-center py-4">Loading...</p>
+              ) : tickets.length === 0 ? (
+                <p className="text-sm text-muted-foreground text-center py-4">
+                  {search ? 'No ready tickets found' : 'No tickets ready for pickup'}
+                </p>
+              ) : (
+                tickets.map((ticket) => (
+                  <button
+                    key={ticket.id}
+                    type="button"
+                    className="w-full text-left rounded-md border p-3 hover:bg-accent transition-colors"
+                    onClick={() => pickupMutation.mutate(ticket.id)}
+                    disabled={pickupMutation.isPending}
+                  >
+                    <div className="flex items-center justify-between">
+                      <span className="font-medium text-sm">#{ticket.ticketNumber}</span>
+                      <Badge variant="outline" className="text-xs">Ready</Badge>
+                    </div>
+                    <div className="text-sm mt-0.5">{ticket.customerName}</div>
+                    {ticket.itemDescription && (
+                      <div className="text-xs text-muted-foreground mt-0.5 truncate">{ticket.itemDescription}</div>
+                    )}
+                    {ticket.estimatedCost && (
+                      <div className="text-xs text-muted-foreground mt-0.5">Est: ${ticket.estimatedCost}</div>
+                    )}
+                  </button>
+                ))
+              )}
+            </div>
+          </TabsContent>
+
+          <TabsContent value="intake" className="mt-3">
+            <form onSubmit={handleIntakeSubmit} className="space-y-3">
+              {/* Customer lookup */}
+              <div className="relative space-y-1">
+                <Label className="text-xs">Customer Lookup</Label>
+                <div className="relative">
+                  <Search className="absolute left-3 top-1/2 -translate-y-1/2 h-3.5 w-3.5 text-muted-foreground" />
+                  <Input
+                    placeholder="Search by name, phone, or email..."
+                    value={customerSearch}
+                    onChange={(e) => { setCustomerSearch(e.target.value); setShowCustomers(true) }}
+                    onFocus={() => customerSearch.length >= 2 && setShowCustomers(true)}
+                    className="pl-9 h-8 text-sm"
+                  />
+                </div>
+                {accountId && (
+                  <div className="flex items-center gap-1 text-xs text-muted-foreground">
+                    <Badge variant="secondary" className="text-[10px]">Linked</Badge>
+                    <span>{customerName}</span>
+                    <button type="button" className="underline text-destructive ml-1" onClick={clearCustomer}>clear</button>
+                  </div>
+                )}
+                {showCustomers && customerSearch.length >= 2 && (
+                  <div className="absolute z-50 mt-1 w-full rounded-md border bg-popover shadow-lg max-h-40 overflow-auto">
+                    {customerResults.length === 0 ? (
+                      <div className="p-2 text-xs text-muted-foreground">No accounts found</div>
+                    ) : customerResults.map((a) => (
+                      <button key={a.id} type="button" className="w-full text-left px-3 py-2 text-sm hover:bg-accent" onClick={() => selectCustomer(a)}>
+                        <div className="font-medium">{a.name}</div>
+                        <div className="text-xs text-muted-foreground">{[a.phone, a.email].filter(Boolean).join(' · ')}</div>
+                      </button>
+                    ))}
+                  </div>
+                )}
+              </div>
+
+              <div className="grid grid-cols-2 gap-3">
+                <div className="space-y-1">
+                  <Label className="text-xs">Customer Name *</Label>
+                  <Input value={customerName} onChange={(e) => setCustomerName(e.target.value)} required />
+                </div>
+                <div className="space-y-1">
+                  <Label className="text-xs">Phone</Label>
+                  <Input value={customerPhone} onChange={(e) => setCustomerPhone(e.target.value)} />
+                </div>
+              </div>
+              <div className="space-y-1">
+                <Label className="text-xs">Item Description</Label>
+                <Input value={itemDescription} onChange={(e) => setItemDescription(e.target.value)} placeholder="e.g. Violin, iPhone 12, Trek bicycle" />
+              </div>
+              <div className="space-y-1">
+                <Label className="text-xs">Problem *</Label>
+                <Textarea value={problemDescription} onChange={(e) => setProblemDescription(e.target.value)} rows={2} placeholder="What needs to be fixed?" required />
+              </div>
+              <div className="space-y-1">
+                <Label className="text-xs">Estimated Cost</Label>
+                <Input type="number" step="0.01" min="0" value={estimatedCost} onChange={(e) => setEstimatedCost(e.target.value)} placeholder="0.00" />
+              </div>
+              <Button type="submit" className="w-full gap-2" disabled={intakeMutation.isPending}>
+                <Plus className="h-4 w-4" />
+                {intakeMutation.isPending ? 'Creating...' : 'Create Repair Ticket'}
+              </Button>
+            </form>
+          </TabsContent>
+        </Tabs>
+      </DialogContent>
+    </Dialog>
+  )
+}

packages/admin/src/components/pos/pos-top-bar.tsx

@@ -3,7 +3,7 @@ import { usePOSStore } from '@/stores/pos.store'
 import { Button } from '@/components/ui/button'
 import { Badge } from '@/components/ui/badge'
 import { Select, SelectContent, SelectItem, SelectTrigger, SelectValue } from '@/components/ui/select'
-import { ArrowLeft, Lock, DollarSign } from 'lucide-react'
+import { ArrowLeft, Lock, DollarSign, Receipt, FileText } from 'lucide-react'
 import type { DrawerSession } from '@/api/pos'
 import { useState } from 'react'
 import { POSDrawerDialog } from './pos-drawer-dialog'
@@ -18,9 +18,12 @@ interface POSTopBarProps {
 export function POSTopBar({ locations, locationId, onLocationChange, drawer }: POSTopBarProps) {
   const cashier = usePOSStore((s) => s.cashier)
   const lockFn = usePOSStore((s) => s.lock)
+  const receiptFormat = usePOSStore((s) => s.receiptFormat)
+  const setReceiptFormat = usePOSStore((s) => s.setReceiptFormat)
   const [drawerDialogOpen, setDrawerDialogOpen] = useState(false)
 
   const drawerOpen = drawer?.status === 'open'
+  const isThermal = receiptFormat === 'thermal'
 
   return (
     <>
@@ -46,6 +49,17 @@ export function POSTopBar({ locations, locationId, onLocationChange, drawer }: P
           ) : locations.length === 1 ? (
             <span className="text-sm font-medium">{locations[0].name}</span>
           ) : null}
+
+          <Button
+            variant="ghost"
+            size="sm"
+            className="h-8 gap-1.5 text-xs text-muted-foreground hover:text-foreground"
+            onClick={() => setReceiptFormat(isThermal ? 'full' : 'thermal')}
+            title={isThermal ? 'Receipt: Thermal — click to switch to Full Page' : 'Receipt: Full Page — click to switch to Thermal'}
+          >
+            {isThermal ? <Receipt className="h-3.5 w-3.5" /> : <FileText className="h-3.5 w-3.5" />}
+            <span className="hidden sm:inline">{isThermal ? 'Thermal' : 'Full Page'}</span>
+          </Button>
         </div>
 
         {/* Center: drawer status */}

packages/admin/src/components/pos/pos-transactions-dialog.tsx

@@ -2,6 +2,7 @@ import { useState } from 'react'
 import { useQuery } from '@tanstack/react-query'
 import { queryOptions } from '@tanstack/react-query'
 import { api } from '@/lib/api-client'
+import { usePOSStore } from '@/stores/pos.store'
 import { Dialog, DialogContent, DialogHeader, DialogTitle } from '@/components/ui/dialog'
 import { Input } from '@/components/ui/input'
 import { Button } from '@/components/ui/button'
@@ -57,6 +58,7 @@ export function POSTransactionsDialog({ open, onOpenChange }: POSTransactionsDia
     queryFn: () => api.get<{ data: AppConfigEntry[] }>('/v1/config'),
     enabled: !!receiptTxnId,
   })
+  const receiptFormat = usePOSStore((s) => s.receiptFormat)
   const receiptConfig = {
     header: configData?.data?.find((c) => c.key === 'receipt_header')?.value || undefined,
     footer: configData?.data?.find((c) => c.key === 'receipt_footer')?.value || undefined,
@@ -68,11 +70,11 @@ export function POSTransactionsDialog({ open, onOpenChange }: POSTransactionsDia
   if (receiptTxnId && receiptData) {
     return (
       <Dialog open={open} onOpenChange={onOpenChange}>
-        <DialogContent className="max-w-sm max-h-[90vh] overflow-y-auto">
+        <DialogContent className={`${receiptFormat === 'full' ? 'max-w-2xl' : 'max-w-sm'} max-h-[90vh] overflow-y-auto`}>
           <div className="flex justify-between items-center mb-2">
             <Button variant="ghost" size="sm" onClick={() => setReceiptTxnId(null)}>Back</Button>
             <div className="flex gap-2">
-              <Button variant="outline" size="sm" onClick={() => downloadReceiptPDF(receiptData.transaction.transactionNumber)}>
+              <Button variant="outline" size="sm" onClick={() => downloadReceiptPDF(receiptData.transaction.transactionNumber, receiptFormat)}>
                 Save PDF
               </Button>
               <Button size="sm" onClick={printReceipt} className="gap-2">
@@ -81,7 +83,7 @@ export function POSTransactionsDialog({ open, onOpenChange }: POSTransactionsDia
             </div>
           </div>
           <div id="pos-receipt-print">
-            <POSReceipt data={receiptData} config={receiptConfig} />
+            <POSReceipt data={receiptData} size={receiptFormat} config={receiptConfig} />
           </div>
         </DialogContent>
       </Dialog>

packages/admin/src/components/repairs/generate-pdf.ts

@@ -85,8 +85,9 @@ export function generateRepairPdf({ ticket, lineItems, notes, includeNotes, comp
   doc.text(dateInfo, 14, y)
   y += 8
 
-  // Line items table
-  if (lineItems.length > 0) {
+  // Line items table (exclude consumables — internal only)
+  const billableItems = lineItems.filter((i) => i.itemType !== 'consumable')
+  if (billableItems.length > 0) {
     doc.setDrawColor(200)
     doc.line(14, y, 196, y)
     y += 6
@@ -109,7 +110,7 @@ export function generateRepairPdf({ ticket, lineItems, notes, includeNotes, comp
 
     // Table rows
     doc.setFont('helvetica', 'normal')
-    for (const item of lineItems) {
+    for (const item of billableItems) {
       if (y > 270) { doc.addPage(); y = 20 }
       doc.text(item.itemType.replace('_', ' '), 16, y)
       const descLines = doc.splitTextToSize(item.description, 85)
@@ -127,7 +128,7 @@ export function generateRepairPdf({ ticket, lineItems, notes, includeNotes, comp
     y += 5
     doc.setFont('helvetica', 'bold')
     doc.setFontSize(10)
-    const total = lineItems.reduce((sum, i) => sum + parseFloat(i.totalPrice), 0)
+    const total = billableItems.reduce((sum, i) => sum + parseFloat(i.totalPrice), 0)
     doc.text('Total:', 155, y, { align: 'right' })
     doc.text(`$${total.toFixed(2)}`, 190, y, { align: 'right' })
     y += 4

packages/admin/src/components/ui/popover.tsx

@@ -0,0 +1,46 @@
+import * as React from "react"
+import { Popover as PopoverPrimitive } from "radix-ui"
+
+import { cn } from "@/lib/utils"
+
+function Popover({
+  ...props
+}: React.ComponentProps<typeof PopoverPrimitive.Root>) {
+  return <PopoverPrimitive.Root data-slot="popover" {...props} />
+}
+
+function PopoverTrigger({
+  ...props
+}: React.ComponentProps<typeof PopoverPrimitive.Trigger>) {
+  return <PopoverPrimitive.Trigger data-slot="popover-trigger" {...props} />
+}
+
+function PopoverContent({
+  className,
+  align = "center",
+  sideOffset = 4,
+  ...props
+}: React.ComponentProps<typeof PopoverPrimitive.Content>) {
+  return (
+    <PopoverPrimitive.Portal>
+      <PopoverPrimitive.Content
+        data-slot="popover-content"
+        align={align}
+        sideOffset={sideOffset}
+        className={cn(
+          "bg-popover text-popover-foreground data-[state=open]:animate-in data-[state=closed]:animate-out data-[state=closed]:fade-out-0 data-[state=open]:fade-in-0 data-[state=closed]:zoom-out-95 data-[state=open]:zoom-in-95 data-[side=bottom]:slide-in-from-top-2 data-[side=left]:slide-in-from-right-2 data-[side=right]:slide-in-from-left-2 data-[side=top]:slide-in-from-bottom-2 z-50 w-72 rounded-md border p-4 shadow-md outline-hidden",
+          className
+        )}
+        {...props}
+      />
+    </PopoverPrimitive.Portal>
+  )
+}
+
+function PopoverAnchor({
+  ...props
+}: React.ComponentProps<typeof PopoverPrimitive.Anchor>) {
+  return <PopoverPrimitive.Anchor data-slot="popover-anchor" {...props} />
+}
+
+export { Popover, PopoverTrigger, PopoverContent, PopoverAnchor }