mail templates reviewd and checked for the tat breach and pause resume workflow

src/controllers/document.controller.ts

@@ -96,16 +96,84 @@ export class DocumentController {
         }
       }
 
-      const doc = await Document.create({
+      // Check if storageUrl exceeds database column limit (500 chars)
+      // GCS signed URLs can be very long (500-1000+ chars)
+      const MAX_STORAGE_URL_LENGTH = 500;
+      let finalStorageUrl = storageUrl;
+      if (storageUrl && storageUrl.length > MAX_STORAGE_URL_LENGTH) {
+        logWithContext('warn', 'Storage URL exceeds database column limit, truncating', {
+          originalLength: storageUrl.length,
+          maxLength: MAX_STORAGE_URL_LENGTH,
+          urlPrefix: storageUrl.substring(0, 100),
+        });
+        // For signed URLs, we can't truncate as it will break the URL
+        // Instead, store null and generate signed URLs on-demand when needed
+        // The filePath is sufficient to generate a new signed URL later
+        finalStorageUrl = null as any;
+        logWithContext('info', 'Storing null storageUrl - will generate signed URL on-demand', {
+          filePath: gcsFilePath,
+          reason: 'Signed URL too long for database column',
+        });
+      }
+
+      // Truncate file names if they exceed database column limits (255 chars)
+      const MAX_FILE_NAME_LENGTH = 255;
+      const originalFileName = file.originalname;
+      let truncatedOriginalFileName = originalFileName;
+      
+      if (originalFileName.length > MAX_FILE_NAME_LENGTH) {
+        // Preserve file extension when truncating
+        const ext = path.extname(originalFileName);
+        const nameWithoutExt = path.basename(originalFileName, ext);
+        const maxNameLength = MAX_FILE_NAME_LENGTH - ext.length;
+        
+        if (maxNameLength > 0) {
+          truncatedOriginalFileName = nameWithoutExt.substring(0, maxNameLength) + ext;
+        } else {
+          // If extension itself is too long, just use the extension
+          truncatedOriginalFileName = ext.substring(0, MAX_FILE_NAME_LENGTH);
+        }
+        
+        logWithContext('warn', 'File name truncated to fit database column', {
+          originalLength: originalFileName.length,
+          truncatedLength: truncatedOriginalFileName.length,
+          originalName: originalFileName.substring(0, 100) + '...',
+          truncatedName: truncatedOriginalFileName,
+        });
+      }
+
+      // Generate fileName (basename of the generated file name in GCS)
+      const generatedFileName = path.basename(gcsFilePath);
+      let truncatedFileName = generatedFileName;
+      
+      if (generatedFileName.length > MAX_FILE_NAME_LENGTH) {
+        const ext = path.extname(generatedFileName);
+        const nameWithoutExt = path.basename(generatedFileName, ext);
+        const maxNameLength = MAX_FILE_NAME_LENGTH - ext.length;
+        
+        if (maxNameLength > 0) {
+          truncatedFileName = nameWithoutExt.substring(0, maxNameLength) + ext;
+        } else {
+          truncatedFileName = ext.substring(0, MAX_FILE_NAME_LENGTH);
+        }
+        
+        logWithContext('warn', 'Generated file name truncated', {
+          originalLength: generatedFileName.length,
+          truncatedLength: truncatedFileName.length,
+        });
+      }
+
+      // Prepare document data
+      const documentData = {
         requestId,
         uploadedBy: userId,
-        fileName: path.basename(file.filename || file.originalname),
-        originalFileName: file.originalname,
+        fileName: truncatedFileName,
+        originalFileName: truncatedOriginalFileName,
         fileType: extension,
         fileExtension: extension,
         fileSize: file.size,
         filePath: gcsFilePath, // Store GCS path or local path
-        storageUrl: storageUrl, // Store GCS URL or local URL
+        storageUrl: finalStorageUrl, // Store GCS URL or local URL (null if too long)
         mimeType: file.mimetype,
         checksum,
         isGoogleDoc: false,
@@ -115,7 +183,43 @@ export class DocumentController {
         parentDocumentId: null as any,
         isDeleted: false,
         downloadCount: 0,
-      } as any);
+      };
+
+      logWithContext('info', 'Creating document record', {
+        requestId,
+        userId,
+        fileName: file.originalname,
+        filePath: gcsFilePath,
+        storageUrl: storageUrl,
+        documentData: JSON.stringify(documentData, null, 2),
+      });
+
+      let doc;
+      try {
+        doc = await Document.create(documentData as any);
+        logWithContext('info', 'Document record created successfully', {
+          documentId: doc.documentId,
+          requestId,
+          fileName: file.originalname,
+        });
+      } catch (createError) {
+        const createErrorMessage = createError instanceof Error ? createError.message : 'Unknown error';
+        const createErrorStack = createError instanceof Error ? createError.stack : undefined;
+        // Check if it's a Sequelize validation error
+        const sequelizeError = (createError as any)?.errors || (createError as any)?.parent;
+        logWithContext('error', 'Document.create() failed', {
+          error: createErrorMessage,
+          stack: createErrorStack,
+          sequelizeErrors: sequelizeError,
+          requestId,
+          userId,
+          fileName: file.originalname,
+          filePath: gcsFilePath,
+          storageUrl: storageUrl,
+          documentData: JSON.stringify(documentData, null, 2),
+        });
+        throw createError; // Re-throw to be caught by outer catch block
+      }
 
       // Log document upload event
       logDocumentEvent('uploaded', doc.documentId, {

src/controllers/workflow.controller.ts

@@ -279,27 +279,114 @@ export class WorkflowController {
             }
           }
 
-          const doc = await Document.create({
-            requestId: workflow.requestId,
-            uploadedBy: userId,
-            fileName: path.basename(file.filename || file.originalname),
-            originalFileName: file.originalname,
-            fileType: extension,
-            fileExtension: extension,
-            fileSize: file.size,
-            filePath: gcsFilePath, // Store GCS path or local path
-            storageUrl: storageUrl, // Store GCS URL or local URL
-            mimeType: file.mimetype,
-            checksum,
-            isGoogleDoc: false,
-            googleDocUrl: null as any,
-            category: category || 'OTHER',
-            version: 1,
-            parentDocumentId: null as any,
-            isDeleted: false,
-            downloadCount: 0,
-          } as any);
-          docs.push(doc);
+          // Truncate file names if they exceed database column limits (255 chars)
+          const MAX_FILE_NAME_LENGTH = 255;
+          const originalFileName = file.originalname;
+          let truncatedOriginalFileName = originalFileName;
+          
+          if (originalFileName.length > MAX_FILE_NAME_LENGTH) {
+            // Preserve file extension when truncating
+            const ext = path.extname(originalFileName);
+            const nameWithoutExt = path.basename(originalFileName, ext);
+            const maxNameLength = MAX_FILE_NAME_LENGTH - ext.length;
+            
+            if (maxNameLength > 0) {
+              truncatedOriginalFileName = nameWithoutExt.substring(0, maxNameLength) + ext;
+            } else {
+              // If extension itself is too long, just use the extension
+              truncatedOriginalFileName = ext.substring(0, MAX_FILE_NAME_LENGTH);
+            }
+            
+            logger.warn('[Workflow] File name truncated to fit database column', {
+              originalLength: originalFileName.length,
+              truncatedLength: truncatedOriginalFileName.length,
+              originalName: originalFileName.substring(0, 100) + '...',
+              truncatedName: truncatedOriginalFileName,
+            });
+          }
+
+          // Generate fileName (basename of the generated file name in GCS)
+          const generatedFileName = path.basename(gcsFilePath);
+          let truncatedFileName = generatedFileName;
+          
+          if (generatedFileName.length > MAX_FILE_NAME_LENGTH) {
+            const ext = path.extname(generatedFileName);
+            const nameWithoutExt = path.basename(generatedFileName, ext);
+            const maxNameLength = MAX_FILE_NAME_LENGTH - ext.length;
+            
+            if (maxNameLength > 0) {
+              truncatedFileName = nameWithoutExt.substring(0, maxNameLength) + ext;
+            } else {
+              truncatedFileName = ext.substring(0, MAX_FILE_NAME_LENGTH);
+            }
+            
+            logger.warn('[Workflow] Generated file name truncated', {
+              originalLength: generatedFileName.length,
+              truncatedLength: truncatedFileName.length,
+            });
+          }
+
+          // Check if storageUrl exceeds database column limit (500 chars)
+          const MAX_STORAGE_URL_LENGTH = 500;
+          let finalStorageUrl = storageUrl;
+          if (storageUrl && storageUrl.length > MAX_STORAGE_URL_LENGTH) {
+            logger.warn('[Workflow] Storage URL exceeds database column limit, storing null', {
+              originalLength: storageUrl.length,
+              maxLength: MAX_STORAGE_URL_LENGTH,
+              urlPrefix: storageUrl.substring(0, 100),
+              filePath: gcsFilePath,
+            });
+            // For signed URLs, store null and generate on-demand later
+            finalStorageUrl = null as any;
+          }
+
+          logger.info('[Workflow] Creating document record', {
+            fileName: truncatedOriginalFileName,
+            filePath: gcsFilePath,
+            storageUrl: finalStorageUrl ? 'present' : 'null (too long)',
+            requestId: workflow.requestId
+          });
+          
+          try {
+            const doc = await Document.create({
+              requestId: workflow.requestId,
+              uploadedBy: userId,
+              fileName: truncatedFileName,
+              originalFileName: truncatedOriginalFileName,
+              fileType: extension,
+              fileExtension: extension,
+              fileSize: file.size,
+              filePath: gcsFilePath, // Store GCS path or local path
+              storageUrl: finalStorageUrl, // Store GCS URL or local URL (null if too long)
+              mimeType: file.mimetype,
+              checksum,
+              isGoogleDoc: false,
+              googleDocUrl: null as any,
+              category: category || 'OTHER',
+              version: 1,
+              parentDocumentId: null as any,
+              isDeleted: false,
+              downloadCount: 0,
+            } as any);
+            docs.push(doc);
+            logger.info('[Workflow] Document record created successfully', {
+              documentId: doc.documentId,
+              fileName: file.originalname,
+            });
+          } catch (docError) {
+            const docErrorMessage = docError instanceof Error ? docError.message : 'Unknown error';
+            const docErrorStack = docError instanceof Error ? docError.stack : undefined;
+            logger.error('[Workflow] Failed to create document record', {
+              error: docErrorMessage,
+              stack: docErrorStack,
+              fileName: file.originalname,
+              requestId: workflow.requestId,
+              filePath: gcsFilePath,
+              storageUrl: storageUrl,
+            });
+            // Re-throw to be caught by outer catch block
+            throw docError;
+          }
           
           // Log document upload activity
           const requestMeta = getRequestMetadata(req);
@@ -320,6 +407,13 @@ export class WorkflowController {
       ResponseHandler.success(res, { requestId: workflow.requestId, documents: docs }, 'Workflow created with documents', 201);
     } catch (error) {
       const errorMessage = error instanceof Error ? error.message : 'Unknown error';
+      const errorStack = error instanceof Error ? error.stack : undefined;
+      logger.error('[WorkflowController] createWorkflowMultipart failed', {
+        error: errorMessage,
+        stack: errorStack,
+        userId: req.user?.userId,
+        filesCount: (req as any).files?.length || 0,
+      });
       ResponseHandler.error(res, 'Failed to create workflow', 400, errorMessage);
     }
   }
@@ -587,10 +681,27 @@ export class WorkflowController {
       }
 
       // Update workflow
-      const workflow = await workflowService.updateWorkflow(id, updateData);
-      if (!workflow) {
-        ResponseHandler.notFound(res, 'Workflow not found');
-        return;
+      let workflow;
+      try {
+        workflow = await workflowService.updateWorkflow(id, updateData);
+        if (!workflow) {
+          ResponseHandler.notFound(res, 'Workflow not found');
+          return;
+        }
+        logger.info('[WorkflowController] Workflow updated successfully', {
+          requestId: id,
+          workflowId: (workflow as any).requestId,
+        });
+      } catch (updateError) {
+        const updateErrorMessage = updateError instanceof Error ? updateError.message : 'Unknown error';
+        const updateErrorStack = updateError instanceof Error ? updateError.stack : undefined;
+        logger.error('[WorkflowController] updateWorkflow failed', {
+          error: updateErrorMessage,
+          stack: updateErrorStack,
+          requestId: id,
+          updateData: JSON.stringify(updateData, null, 2),
+        });
+        throw updateError; // Re-throw to be caught by outer catch block
       }
 
       // Attach new files as documents
@@ -627,40 +738,129 @@ export class WorkflowController {
             }
           }
 
+          // Truncate file names if they exceed database column limits (255 chars)
+          const MAX_FILE_NAME_LENGTH = 255;
+          const originalFileName = file.originalname;
+          let truncatedOriginalFileName = originalFileName;
+          
+          if (originalFileName.length > MAX_FILE_NAME_LENGTH) {
+            // Preserve file extension when truncating
+            const ext = path.extname(originalFileName);
+            const nameWithoutExt = path.basename(originalFileName, ext);
+            const maxNameLength = MAX_FILE_NAME_LENGTH - ext.length;
+            
+            if (maxNameLength > 0) {
+              truncatedOriginalFileName = nameWithoutExt.substring(0, maxNameLength) + ext;
+            } else {
+              // If extension itself is too long, just use the extension
+              truncatedOriginalFileName = ext.substring(0, MAX_FILE_NAME_LENGTH);
+            }
+            
+            logger.warn('[Workflow] File name truncated to fit database column', {
+              originalLength: originalFileName.length,
+              truncatedLength: truncatedOriginalFileName.length,
+              originalName: originalFileName.substring(0, 100) + '...',
+              truncatedName: truncatedOriginalFileName,
+            });
+          }
+
+          // Generate fileName (basename of the generated file name in GCS)
+          const generatedFileName = path.basename(gcsFilePath);
+          let truncatedFileName = generatedFileName;
+          
+          if (generatedFileName.length > MAX_FILE_NAME_LENGTH) {
+            const ext = path.extname(generatedFileName);
+            const nameWithoutExt = path.basename(generatedFileName, ext);
+            const maxNameLength = MAX_FILE_NAME_LENGTH - ext.length;
+            
+            if (maxNameLength > 0) {
+              truncatedFileName = nameWithoutExt.substring(0, maxNameLength) + ext;
+            } else {
+              truncatedFileName = ext.substring(0, MAX_FILE_NAME_LENGTH);
+            }
+            
+            logger.warn('[Workflow] Generated file name truncated', {
+              originalLength: generatedFileName.length,
+              truncatedLength: truncatedFileName.length,
+            });
+          }
+
+          // Check if storageUrl exceeds database column limit (500 chars)
+          const MAX_STORAGE_URL_LENGTH = 500;
+          let finalStorageUrl = storageUrl;
+          if (storageUrl && storageUrl.length > MAX_STORAGE_URL_LENGTH) {
+            logger.warn('[Workflow] Storage URL exceeds database column limit, storing null', {
+              originalLength: storageUrl.length,
+              maxLength: MAX_STORAGE_URL_LENGTH,
+              urlPrefix: storageUrl.substring(0, 100),
+              filePath: gcsFilePath,
+            });
+            // For signed URLs, store null and generate on-demand later
+            finalStorageUrl = null as any;
+          }
+
           logger.info('[Workflow] Creating document record', {
-            fileName: file.originalname,
+            fileName: truncatedOriginalFileName,
             filePath: gcsFilePath,
-            storageUrl: storageUrl,
+            storageUrl: finalStorageUrl ? 'present' : 'null (too long)',
             requestId: actualRequestId
           });
           
-          const doc = await Document.create({
-            requestId: actualRequestId,
-            uploadedBy: userId,
-            fileName: path.basename(file.filename || file.originalname),
-            originalFileName: file.originalname,
-            fileType: extension,
-            fileExtension: extension,
-            fileSize: file.size,
-            filePath: gcsFilePath, // Store GCS path or local path
-            storageUrl: storageUrl, // Store GCS URL or local URL
-            mimeType: file.mimetype,
-            checksum,
-            isGoogleDoc: false,
-            googleDocUrl: null as any,
-            category: category || 'OTHER',
-            version: 1,
-            parentDocumentId: null as any,
-            isDeleted: false,
-            downloadCount: 0,
-          } as any);
-          docs.push(doc);
+          try {
+            const doc = await Document.create({
+              requestId: actualRequestId,
+              uploadedBy: userId,
+              fileName: truncatedFileName,
+              originalFileName: truncatedOriginalFileName,
+              fileType: extension,
+              fileExtension: extension,
+              fileSize: file.size,
+              filePath: gcsFilePath, // Store GCS path or local path
+              storageUrl: finalStorageUrl, // Store GCS URL or local URL (null if too long)
+              mimeType: file.mimetype,
+              checksum,
+              isGoogleDoc: false,
+              googleDocUrl: null as any,
+              category: category || 'OTHER',
+              version: 1,
+              parentDocumentId: null as any,
+              isDeleted: false,
+              downloadCount: 0,
+            } as any);
+            docs.push(doc);
+            logger.info('[Workflow] Document record created successfully', {
+              documentId: doc.documentId,
+              fileName: file.originalname,
+            });
+          } catch (docError) {
+            const docErrorMessage = docError instanceof Error ? docError.message : 'Unknown error';
+            const docErrorStack = docError instanceof Error ? docError.stack : undefined;
+            logger.error('[Workflow] Failed to create document record', {
+              error: docErrorMessage,
+              stack: docErrorStack,
+              fileName: file.originalname,
+              requestId: actualRequestId,
+              filePath: gcsFilePath,
+              storageUrl: storageUrl,
+            });
+            // Continue with other files, but log the error
+            // Don't throw here - let the workflow update complete
+          }
         }
       }
 
       ResponseHandler.success(res, { workflow, newDocuments: docs }, 'Workflow updated with documents', 200);
     } catch (error) {
       const errorMessage = error instanceof Error ? error.message : 'Unknown error';
+      const errorStack = error instanceof Error ? error.stack : undefined;
+      logger.error('[WorkflowController] updateWorkflowMultipart failed', {
+        error: errorMessage,
+        stack: errorStack,
+        requestId: req.params.id,
+        userId: req.user?.userId,
+        hasFiles: !!(req as any).files && (req as any).files.length > 0,
+        fileCount: (req as any).files ? (req as any).files.length : 0,
+      });
       ResponseHandler.error(res, 'Failed to update workflow', 400, errorMessage);
     }
   }

src/emailtemplates/approvalConfirmation.template.ts

@@ -21,21 +21,24 @@ export function getApprovalConfirmationEmail(data: ApprovalConfirmationData): st
 <html lang="en">
 <head>
     <meta charset="UTF-8">
-    <meta name="viewport" content="width=device-width, initial-scale=1.0">
+    <meta name="viewport" content="width=device-width, initial-scale=1.0, maximum-scale=1.0, user-scalable=no">
+    <meta http-equiv="X-UA-Compatible" content="IE=edge">
+    <meta name="format-detection" content="telephone=no">
     <title>Request Approved</title>
+    ${getResponsiveStyles()}
 </head>
 <body style="margin: 0; padding: 0; font-family: Arial, Helvetica, sans-serif; background-color: #f4f4f4;">
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" style="width: 600px; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Request Approved',
                       ...HeaderStyles.success
                     }))}
                     
                     <tr>
-                        <td style="padding: 40px 30px;">
+                        <td class="email-content">
                             <p style="margin: 0 0 20px; color: #333333; font-size: 16px; line-height: 1.6;">
                                 Dear <strong style="color: #28a745;">${data.initiatorName}</strong>,
                             </p>
@@ -46,47 +49,47 @@ export function getApprovalConfirmationEmail(data: ApprovalConfirmationData): st
                             
                             <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #d4edda; border: 1px solid #c3e6cb; border-radius: 6px; margin-bottom: 30px;" cellpadding="0" cellspacing="0">
                                 <tr>
-                                    <td style="padding: 25px;">
-                                        <h2 style="margin: 0 0 20px; color: #155724; font-size: 18px; font-weight: 600;">Request Summary</h2>
+                                    <td class="detail-box" style="padding: 30px;">
+                                        <h2 style="margin: 0 0 25px; color: #155724; font-size: 20px; font-weight: 600;">Request Summary</h2>
                                         
-                                        <table role="presentation" style="width: 100%; border-collapse: collapse;" cellpadding="0" cellspacing="0">
+                                        <table role="presentation" class="detail-table" style="width: 100%; border-collapse: collapse;" cellpadding="0" cellspacing="0">
                                             <tr>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px; width: 140px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     <strong>Request ID:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     ${data.requestId}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     <strong>Approved By:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     ${data.approverName}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     <strong>Approved On:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     ${data.approvalDate}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     <strong>Time:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     ${data.approvalTime}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     <strong>Request Type:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #155724; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #155724; font-size: 15px;">
                                                     ${data.requestType}
                                                 </td>
                                             </tr>

src/emailtemplates/approvalRequest.template.ts

@@ -22,7 +22,7 @@ export function getApprovalRequestEmail(data: ApprovalRequestData): string {
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" class="email-container" style="width: 600px; max-width: 100%; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     <!-- Header -->
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Approval Request',

src/emailtemplates/approverSkipped.template.ts

@@ -12,14 +12,17 @@ export function getApproverSkippedEmail(data: ApproverSkippedData): string {
 <html lang="en">
 <head>
     <meta charset="UTF-8">
-    <meta name="viewport" content="width=device-width, initial-scale=1.0">
+    <meta name="viewport" content="width=device-width, initial-scale=1.0, maximum-scale=1.0, user-scalable=no">
+    <meta http-equiv="X-UA-Compatible" content="IE=edge">
+    <meta name="format-detection" content="telephone=no">
     <title>Approver Skipped</title>
+    ${getResponsiveStyles()}
 </head>
 <body style="margin: 0; padding: 0; font-family: Arial, Helvetica, sans-serif; background-color: #f4f4f4;">
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" style="width: 600px; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Approval Level Skipped',
                       ...HeaderStyles.infoSecondary

src/emailtemplates/helpers.ts

@@ -146,7 +146,7 @@ export function wrapRichText(htmlContent: string): string {
 
 /**
  * Generate all email styles (responsive + rich text)
- * Optimized for screens up to 600px width
+ * Desktop-first design (optimized for browser) with mobile responsive breakpoints
  */
 export function getResponsiveStyles(): string {
   return `
@@ -173,6 +173,86 @@ export function getResponsiveStyles(): string {
         border-collapse: collapse !important;
       }
       
+      /* Desktop-first base styles */
+      .email-container {
+        width: 95%;
+        max-width: 1200px;
+      }
+      
+      .email-content {
+        padding: 50px 40px;
+      }
+      
+      .email-header {
+        padding: 40px 40px 35px;
+      }
+      
+      .email-footer {
+        padding: 30px 40px;
+      }
+      
+      /* Desktop typography */
+      .header-title {
+        font-size: 24px;
+        letter-spacing: 0.5px;
+        line-height: 1.3;
+      }
+      
+      .header-subtitle {
+        font-size: 14px;
+      }
+      
+      /* Desktop detail tables - side by side */
+      .detail-table {
+        width: 100%;
+      }
+      
+      .detail-table td {
+        font-size: 15px;
+        padding: 10px 0;
+        display: table-cell;
+        width: auto;
+        vertical-align: top;
+      }
+      
+      .detail-label {
+        width: 200px;
+        font-weight: 600;
+        color: #666666;
+      }
+      
+      .detail-box {
+        padding: 30px;
+      }
+      
+      /* Desktop button styles */
+      .cta-button {
+        display: inline-block;
+        padding: 16px 45px;
+        font-size: 16px;
+        min-width: 220px;
+      }
+      
+      /* Tablet responsive styles */
+      @media only screen and (max-width: 1200px) {
+        .email-container {
+          width: 95% !important;
+          max-width: 95% !important;
+        }
+        
+        .email-content {
+          padding: 40px 30px !important;
+        }
+        
+        .email-header {
+          padding: 35px 30px 30px !important;
+        }
+        
+        .email-footer {
+          padding: 25px 30px !important;
+        }
+      }
+      
       /* Mobile responsive styles */
       @media only screen and (max-width: 600px) {
         /* Container adjustments */
@@ -180,11 +260,12 @@ export function getResponsiveStyles(): string {
           width: 100% !important;
           max-width: 100% !important;
           margin: 0 !important;
+          border-radius: 0 !important;
         }
         
         /* Header adjustments */
         .email-header {
-          padding: 25px 15px 30px !important;
+          padding: 25px 20px 30px !important;
         }
         
         /* Content adjustments */
@@ -207,7 +288,7 @@ export function getResponsiveStyles(): string {
         /* Typography adjustments */
         .header-title {
           font-size: 20px !important;
-          letter-spacing: 1px !important;
+          letter-spacing: 0.5px !important;
           line-height: 1.4 !important;
         }
         
@@ -215,21 +296,22 @@ export function getResponsiveStyles(): string {
           font-size: 12px !important;
         }
         
-        /* Detail tables */
+        /* Detail tables - stack on mobile */
         .detail-box {
           padding: 20px 15px !important;
         }
         
         .detail-table td {
-          font-size: 13px !important;
-          padding: 6px 0 !important;
+          font-size: 14px !important;
+          padding: 8px 0 !important;
           display: block !important;
           width: 100% !important;
         }
         
         .detail-label {
           font-weight: 600 !important;
-          margin-bottom: 2px !important;
+          margin-bottom: 4px !important;
+          width: 100% !important;
         }
         
         /* Button adjustments */
@@ -240,27 +322,28 @@ export function getResponsiveStyles(): string {
           padding: 16px 20px !important;
           font-size: 16px !important;
           box-sizing: border-box !important;
+          min-width: auto !important;
         }
         
         /* Section adjustments */
         .info-section {
-          padding: 15px !important;
+          padding: 18px 15px !important;
           margin-bottom: 20px !important;
         }
         
         .section-title {
-          font-size: 15px !important;
+          font-size: 16px !important;
         }
         
         .section-text {
-          font-size: 13px !important;
+          font-size: 14px !important;
           line-height: 1.6 !important;
         }
         
         /* List items */
         .info-section ul {
-          padding-left: 15px !important;
-          font-size: 13px !important;
+          padding-left: 20px !important;
+          font-size: 14px !important;
         }
         
         .info-section li {

src/emailtemplates/multiApproverRequest.template.ts

@@ -22,7 +22,7 @@ export function getMultiApproverRequestEmail(data: MultiApproverRequestData): st
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" style="width: 600px; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     <!-- Header -->
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Multi-Level Approval Request',

src/emailtemplates/participantAdded.template.ts

@@ -12,14 +12,17 @@ export function getParticipantAddedEmail(data: ParticipantAddedData): string {
 <html lang="en">
 <head>
     <meta charset="UTF-8">
-    <meta name="viewport" content="width=device-width, initial-scale=1.0">
+    <meta name="viewport" content="width=device-width, initial-scale=1.0, maximum-scale=1.0, user-scalable=no">
+    <meta http-equiv="X-UA-Compatible" content="IE=edge">
+    <meta name="format-detection" content="telephone=no">
     <title>Added to Request</title>
+    ${getResponsiveStyles()}
 </head>
 <body style="margin: 0; padding: 0; font-family: Arial, Helvetica, sans-serif; background-color: #f4f4f4;">
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" style="width: 600px; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: `You've Been Added as ${data.participantRole}`,
                       ...HeaderStyles.info

src/emailtemplates/rejectionNotification.template.ts

@@ -12,14 +12,17 @@ export function getRejectionNotificationEmail(data: RejectionNotificationData):
 <html lang="en">
 <head>
     <meta charset="UTF-8">
-    <meta name="viewport" content="width=device-width, initial-scale=1.0">
+    <meta name="viewport" content="width=device-width, initial-scale=1.0, maximum-scale=1.0, user-scalable=no">
+    <meta http-equiv="X-UA-Compatible" content="IE=edge">
+    <meta name="format-detection" content="telephone=no">
     <title>Request Rejected</title>
+    ${getResponsiveStyles()}
 </head>
 <body style="margin: 0; padding: 0; font-family: Arial, Helvetica, sans-serif; background-color: #f4f4f4;">
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" style="width: 600px; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Request Rejected',
                       ...HeaderStyles.error

src/emailtemplates/requestClosed.template.ts

@@ -22,7 +22,7 @@ export function getRequestClosedEmail(data: RequestClosedData): string {
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" class="email-container" style="width: 600px; max-width: 100%; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Request Closed',
                       ...HeaderStyles.complete

src/emailtemplates/requestCreated.template.ts

@@ -22,7 +22,7 @@ export function getRequestCreatedEmail(data: RequestCreatedData): string {
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" class="email-container" style="width: 600px; max-width: 100%; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     <!-- Header -->
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Request Created Successfully',
@@ -31,7 +31,7 @@ export function getRequestCreatedEmail(data: RequestCreatedData): string {
                     
                     <!-- Content -->
                     <tr>
-                        <td class="email-content" style="padding: 40px 30px;">
+                        <td class="email-content">
                             <p style="margin: 0 0 20px; color: #333333; font-size: 16px; line-height: 1.6;">
                                 Dear <strong style="color: #667eea;">${data.initiatorName}</strong>,
                             </p>
@@ -43,55 +43,55 @@ export function getRequestCreatedEmail(data: RequestCreatedData): string {
                             <!-- Request Details Box -->
                             <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f8f9fa; border-radius: 6px; margin-bottom: 30px;" cellpadding="0" cellspacing="0">
                                 <tr>
-                                    <td style="padding: 25px;">
-                                        <h2 style="margin: 0 0 20px; color: #333333; font-size: 18px; font-weight: 600;">Request Summary</h2>
+                                    <td class="detail-box" style="padding: 30px;">
+                                        <h2 style="margin: 0 0 25px; color: #333333; font-size: 20px; font-weight: 600;">Request Summary</h2>
                                         
-                                        <table role="presentation" style="width: 100%; border-collapse: collapse;" cellpadding="0" cellspacing="0">
+                                        <table role="presentation" class="detail-table" style="width: 100%; border-collapse: collapse;" cellpadding="0" cellspacing="0">
                                             <tr>
-                                                <td style="padding: 8px 0; color: #666666; font-size: 14px; width: 140px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #666666; font-size: 15px;">
                                                     <strong>Request ID:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #333333; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #333333; font-size: 15px;">
                                                     ${data.requestId}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #666666; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #666666; font-size: 15px;">
                                                     <strong>Title:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #333333; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #333333; font-size: 15px;">
                                                     ${data.requestTitle || 'N/A'}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #666666; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #666666; font-size: 15px;">
                                                     <strong>Request Type:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #333333; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #333333; font-size: 15px;">
                                                     ${data.requestType}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #666666; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #666666; font-size: 15px;">
                                                     <strong>Priority:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #333333; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #333333; font-size: 15px;">
                                                     ${data.priority}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #666666; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #666666; font-size: 15px;">
                                                     <strong>Created On:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #333333; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #333333; font-size: 15px;">
                                                     ${data.requestDate} at ${data.requestTime}
                                                 </td>
                                             </tr>
                                             <tr>
-                                                <td style="padding: 8px 0; color: #666666; font-size: 14px;">
+                                                <td class="detail-label" style="padding: 10px 0; color: #666666; font-size: 15px;">
                                                     <strong>Total Approvers:</strong>
                                                 </td>
-                                                <td style="padding: 8px 0; color: #333333; font-size: 14px;">
+                                                <td style="padding: 10px 0; color: #333333; font-size: 15px;">
                                                     ${data.totalApprovers}
                                                 </td>
                                             </tr>

src/emailtemplates/tatBreached.template.ts

@@ -3,7 +3,7 @@
  */
 
 import { TATBreachedData } from './types';
-import { getEmailFooter, getEmailHeader, HeaderStyles } from './helpers';
+import { getEmailFooter, getEmailHeader, HeaderStyles, getResponsiveStyles } from './helpers';
 import { getBrandedHeader } from './branding.config';
 
 export function getTATBreachedEmail(data: TATBreachedData): string {
@@ -12,14 +12,17 @@ export function getTATBreachedEmail(data: TATBreachedData): string {
 <html lang="en">
 <head>
     <meta charset="UTF-8">
-    <meta name="viewport" content="width=device-width, initial-scale=1.0">
+    <meta name="viewport" content="width=device-width, initial-scale=1.0, maximum-scale=1.0, user-scalable=no">
+    <meta http-equiv="X-UA-Compatible" content="IE=edge">
+    <meta name="format-detection" content="telephone=no">
     <title>TAT Breached - Urgent Action Required</title>
+    ${getResponsiveStyles()}
 </head>
 <body style="margin: 0; padding: 0; font-family: Arial, Helvetica, sans-serif; background-color: #f4f4f4;">
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" style="width: 600px; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: 'TAT Breached',
                       subtitle: 'Immediate Action Required',

src/emailtemplates/tatReminder.template.ts

@@ -52,7 +52,7 @@ export function getTATReminderEmail(data: TATReminderData): string {
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" class="email-container" style="width: 600px; max-width: 100%; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: 'TAT Reminder',
                       subtitle: `${data.thresholdPercentage}% Elapsed - ${urgencyStyle.title}`,

src/emailtemplates/workflowPaused.template.ts

@@ -12,14 +12,17 @@ export function getWorkflowPausedEmail(data: WorkflowPausedData): string {
 <html lang="en">
 <head>
     <meta charset="UTF-8">
-    <meta name="viewport" content="width=device-width, initial-scale=1.0">
+    <meta name="viewport" content="width=device-width, initial-scale=1.0, maximum-scale=1.0, user-scalable=no">
+    <meta http-equiv="X-UA-Compatible" content="IE=edge">
+    <meta name="format-detection" content="telephone=no">
     <title>Workflow Paused</title>
+    ${getResponsiveStyles()}
 </head>
 <body style="margin: 0; padding: 0; font-family: Arial, Helvetica, sans-serif; background-color: #f4f4f4;">
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" style="width: 600px; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Workflow Paused',
                       ...HeaderStyles.neutral

src/emailtemplates/workflowResumed.template.ts

@@ -3,7 +3,7 @@
  */
 
 import { WorkflowResumedData } from './types';
-import { getEmailFooter, getEmailHeader, HeaderStyles, getActionRequiredSection } from './helpers';
+import { getEmailFooter, getEmailHeader, HeaderStyles, getActionRequiredSection, getResponsiveStyles } from './helpers';
 import { getBrandedHeader } from './branding.config';
 
 export function getWorkflowResumedEmail(data: WorkflowResumedData): string {
@@ -12,14 +12,17 @@ export function getWorkflowResumedEmail(data: WorkflowResumedData): string {
 <html lang="en">
 <head>
     <meta charset="UTF-8">
-    <meta name="viewport" content="width=device-width, initial-scale=1.0">
+    <meta name="viewport" content="width=device-width, initial-scale=1.0, maximum-scale=1.0, user-scalable=no">
+    <meta http-equiv="X-UA-Compatible" content="IE=edge">
+    <meta name="format-detection" content="telephone=no">
     <title>Workflow Resumed</title>
+    ${getResponsiveStyles()}
 </head>
 <body style="margin: 0; padding: 0; font-family: Arial, Helvetica, sans-serif; background-color: #f4f4f4;">
     <table role="presentation" style="width: 100%; border-collapse: collapse; background-color: #f4f4f4;" cellpadding="0" cellspacing="0">
         <tr>
             <td style="padding: 40px 0;">
-                <table role="presentation" style="width: 600px; margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
+                <table role="presentation" class="email-container" style="margin: 0 auto; background-color: #ffffff; border-radius: 8px; box-shadow: 0 2px 4px rgba(0,0,0,0.1);" cellpadding="0" cellspacing="0">
                     ${getEmailHeader(getBrandedHeader({
                       title: 'Workflow Resumed',
                       ...HeaderStyles.success

src/queues/tatProcessor.ts

@@ -210,6 +210,13 @@ export async function handleTatJob(job: Job<TatJobData>) {
       type === 'threshold2' ? 'HIGH' :
       'MEDIUM';
 
+    // Format time remaining/overdue for email
+    const timeRemainingText = remainingHours > 0 
+      ? `${remainingHours.toFixed(1)} hours remaining`
+      : type === 'breach' 
+        ? `${Math.abs(remainingHours).toFixed(1)} hours overdue`
+        : 'Time exceeded';
+
     // Send notification to approver (with error handling to prevent job failure)
     try {
       await notificationService.sendToUsers([approverId], {
@@ -220,7 +227,17 @@ export async function handleTatJob(job: Job<TatJobData>) {
         url: `/request/${requestNumber}`,
         type: type,
         priority: notificationPriority,
-        actionRequired: type === 'breach' || type === 'threshold2' // Require action for critical alerts
+        actionRequired: type === 'breach' || type === 'threshold2', // Require action for critical alerts
+        metadata: {
+          thresholdPercentage: thresholdPercentage,
+          tatInfo: {
+            thresholdPercentage: thresholdPercentage,
+            timeRemaining: timeRemainingText,
+            tatDeadline: expectedCompletionTime,
+            assignedDate: levelStartTime,
+            timeOverdue: type === 'breach' ? timeRemainingText : undefined
+          }
+        }
       });
       logger.info(`[TAT Processor] ✅ Notification sent to approver ${approverId} for ${type} (${threshold}%)`);
     } catch (notificationError: any) {

src/routes/workflow.routes.ts

@@ -21,6 +21,33 @@ import { pauseController } from '../controllers/pause.controller';
 import logger from '@utils/logger';
 
 const router = Router();
+
+/**
+ * Helper function to create proper Content-Disposition header
+ * Returns clean filename header that browsers handle correctly
+ */
+function createContentDisposition(disposition: 'inline' | 'attachment', filename: string): string {
+  // Clean filename: only remove truly problematic characters for HTTP headers
+  // Keep spaces, dots, hyphens, underscores - these are safe
+  const cleanFilename = filename
+    .replace(/[<>:"|?*\x00-\x1F\x7F]/g, '_') // Only replace truly problematic chars
+    .replace(/\\/g, '_') // Replace backslashes
+    .trim();
+  
+  // For ASCII-only filenames, use simple format (browsers prefer this)
+  // Only use filename* for non-ASCII characters
+  const hasNonASCII = /[^\x00-\x7F]/.test(filename);
+  
+  if (hasNonASCII) {
+    // Use RFC 5987 encoding for non-ASCII characters
+    const encodedFilename = encodeURIComponent(filename);
+    return `${disposition}; filename="${cleanFilename}"; filename*=UTF-8''${encodedFilename}`;
+  } else {
+    // Simple ASCII filename - use clean version (no filename* needed)
+    // This prevents browsers from showing both filename and filename*
+    return `${disposition}; filename="${cleanFilename}"`;
+  }
+}
 const workflowController = new WorkflowController();
 const approvalController = new ApprovalController();
 const workNoteController = new WorkNoteController();
@@ -223,6 +250,89 @@ router.get('/documents/:documentId/preview',
       return;
     }
     
+    // If storageUrl is null but filePath indicates GCS storage, stream file directly from GCS
+    if (!storageUrl && filePath && filePath.startsWith('requests/')) {
+      try {
+        // Use the existing GCS storage service instance
+        if (!gcsStorageService.isConfigured()) {
+          throw new Error('GCS not configured');
+        }
+        
+        // Access the storage instance from the service
+        const { Storage } = require('@google-cloud/storage');
+        const keyFilePath = process.env.GCP_KEY_FILE || '';
+        const bucketName = process.env.GCP_BUCKET_NAME || '';
+        const path = require('path');
+        const resolvedKeyPath = path.isAbsolute(keyFilePath)
+          ? keyFilePath
+          : path.resolve(process.cwd(), keyFilePath);
+        
+        const storage = new Storage({
+          projectId: process.env.GCP_PROJECT_ID || '',
+          keyFilename: resolvedKeyPath,
+        });
+        
+        const bucket = storage.bucket(bucketName);
+        const file = bucket.file(filePath);
+        
+        // Check if file exists
+        const [exists] = await file.exists();
+        if (!exists) {
+          res.status(404).json({ success: false, error: 'File not found in GCS' });
+          return;
+        }
+        
+        // Get file metadata for content type
+        const [metadata] = await file.getMetadata();
+        const contentType = metadata.contentType || fileType || 'application/octet-stream';
+        
+        // Set CORS headers
+        const origin = req.headers.origin;
+        if (origin) {
+          res.setHeader('Access-Control-Allow-Origin', origin);
+          res.setHeader('Access-Control-Allow-Credentials', 'true');
+        }
+        res.setHeader('Access-Control-Expose-Headers', 'Content-Type, Content-Disposition');
+        res.setHeader('Content-Type', contentType);
+        
+        // For images and PDFs, allow inline viewing
+        const isPreviewable = fileType && (fileType.includes('image') || fileType.includes('pdf'));
+        const disposition = isPreviewable ? 'inline' : 'attachment';
+        res.setHeader('Content-Disposition', createContentDisposition(disposition, fileName));
+        
+        // Stream file from GCS to response
+        file.createReadStream()
+          .on('error', (streamError: Error) => {
+            const logger = require('../utils/logger').default;
+            logger.error('[Workflow] Failed to stream file from GCS', {
+              documentId,
+              filePath,
+              error: streamError.message,
+            });
+            if (!res.headersSent) {
+              res.status(500).json({ 
+                success: false, 
+                error: 'Failed to stream file from storage' 
+              });
+            }
+          })
+          .pipe(res);
+        return;
+      } catch (gcsError) {
+        const logger = require('../utils/logger').default;
+        logger.error('[Workflow] Failed to access GCS file for preview', {
+          documentId,
+          filePath,
+          error: gcsError instanceof Error ? gcsError.message : 'Unknown error',
+        });
+        res.status(500).json({ 
+          success: false, 
+          error: 'Failed to access file. Please try again.' 
+        });
+        return;
+      }
+    }
+    
     // Local file handling - check if storageUrl is a local path (starts with /uploads/)
     if (storageUrl && storageUrl.startsWith('/uploads/')) {
       // File is served by express.static middleware, redirect to the storage URL
@@ -296,6 +406,87 @@ router.get('/documents/:documentId/download',
       return;
     }
     
+    // If storageUrl is null but filePath indicates GCS storage, stream file directly from GCS
+    if (!storageUrl && filePath && filePath.startsWith('requests/')) {
+      try {
+        // Use the existing GCS storage service instance
+        if (!gcsStorageService.isConfigured()) {
+          throw new Error('GCS not configured');
+        }
+        
+        // Access the storage instance from the service
+        const { Storage } = require('@google-cloud/storage');
+        const keyFilePath = process.env.GCP_KEY_FILE || '';
+        const bucketName = process.env.GCP_BUCKET_NAME || '';
+        const path = require('path');
+        const resolvedKeyPath = path.isAbsolute(keyFilePath)
+          ? keyFilePath
+          : path.resolve(process.cwd(), keyFilePath);
+        
+        const storage = new Storage({
+          projectId: process.env.GCP_PROJECT_ID || '',
+          keyFilename: resolvedKeyPath,
+        });
+        
+        const bucket = storage.bucket(bucketName);
+        const file = bucket.file(filePath);
+        
+        // Check if file exists
+        const [exists] = await file.exists();
+        if (!exists) {
+          res.status(404).json({ success: false, error: 'File not found in GCS' });
+          return;
+        }
+        
+        // Get file metadata for content type
+        const [metadata] = await file.getMetadata();
+        const contentType = metadata.contentType || (document as any).mimeType || (document as any).mime_type || 'application/octet-stream';
+        
+        // Set CORS headers
+        const origin = req.headers.origin;
+        if (origin) {
+          res.setHeader('Access-Control-Allow-Origin', origin);
+          res.setHeader('Access-Control-Allow-Credentials', 'true');
+        }
+        res.setHeader('Access-Control-Expose-Headers', 'Content-Type, Content-Disposition');
+        
+        // Set headers for download
+        res.setHeader('Content-Type', contentType);
+        res.setHeader('Content-Disposition', createContentDisposition('attachment', fileName));
+        
+        // Stream file from GCS to response
+        file.createReadStream()
+          .on('error', (streamError: Error) => {
+            const logger = require('../utils/logger').default;
+            logger.error('[Workflow] Failed to stream file from GCS for download', {
+              documentId,
+              filePath,
+              error: streamError.message,
+            });
+            if (!res.headersSent) {
+              res.status(500).json({ 
+                success: false, 
+                error: 'Failed to stream file from storage' 
+              });
+            }
+          })
+          .pipe(res);
+        return;
+      } catch (gcsError) {
+        const logger = require('../utils/logger').default;
+        logger.error('[Workflow] Failed to access GCS file for download', {
+          documentId,
+          filePath,
+          error: gcsError instanceof Error ? gcsError.message : 'Unknown error',
+        });
+        res.status(500).json({ 
+          success: false, 
+          error: 'Failed to access file. Please try again.' 
+        });
+        return;
+      }
+    }
+    
     // Local file handling - check if storageUrl is a local path (starts with /uploads/)
     if (storageUrl && storageUrl.startsWith('/uploads/')) {
       // File is served by express.static middleware, redirect to the storage URL

src/services/ai.service.ts

@@ -115,11 +115,66 @@ class AIService {
       const streamingResp = await generativeModel.generateContent(request);
       const response = streamingResp.response;
       
+      // Log full response structure for debugging if empty
+      if (!response.candidates || response.candidates.length === 0) {
+        logger.error('[AI Service] No candidates in Vertex AI response:', {
+          response: JSON.stringify(response, null, 2),
+          promptLength: prompt.length,
+          model: this.model
+        });
+        throw new Error('Vertex AI returned no candidates. The response may have been blocked by safety filters.');
+      }
+      
+      const candidate = response.candidates[0];
+      
+      // Check for safety ratings or blocked reasons
+      if (candidate.safetyRatings && candidate.safetyRatings.length > 0) {
+        const blockedRatings = candidate.safetyRatings.filter((rating: any) => 
+          rating.probability === 'HIGH' || rating.probability === 'MEDIUM'
+        );
+        if (blockedRatings.length > 0) {
+          logger.warn('[AI Service] Vertex AI safety filters triggered:', {
+            ratings: blockedRatings.map((r: any) => ({
+              category: r.category,
+              probability: r.probability
+            })),
+            finishReason: candidate.finishReason
+          });
+        }
+      }
+      
+      // Check finish reason
+      if (candidate.finishReason && candidate.finishReason !== 'STOP') {
+        logger.warn('[AI Service] Vertex AI finish reason:', {
+          finishReason: candidate.finishReason,
+          safetyRatings: candidate.safetyRatings
+        });
+      }
+      
       // Extract text from response
-      const text = response.candidates?.[0]?.content?.parts?.[0]?.text || '';
+      const text = candidate.content?.parts?.[0]?.text || '';
       
       if (!text) {
-        throw new Error('Empty response from Vertex AI');
+        // Log detailed response structure for debugging
+        logger.error('[AI Service] Empty text in Vertex AI response:', {
+          candidate: JSON.stringify(candidate, null, 2),
+          finishReason: candidate.finishReason,
+          safetyRatings: candidate.safetyRatings,
+          promptLength: prompt.length,
+          promptPreview: prompt.substring(0, 200) + '...',
+          model: this.model
+        });
+        
+        // Provide more helpful error message
+        if (candidate.finishReason === 'SAFETY') {
+          throw new Error('Vertex AI blocked the response due to safety filters. The prompt may contain content that violates safety policies.');
+        } else if (candidate.finishReason === 'MAX_TOKENS') {
+          throw new Error('Vertex AI response was truncated due to token limit.');
+        } else if (candidate.finishReason === 'RECITATION') {
+          throw new Error('Vertex AI blocked the response due to recitation concerns.');
+        } else {
+          throw new Error(`Empty response from Vertex AI. Finish reason: ${candidate.finishReason || 'UNKNOWN'}`);
+        }
       }
 
       return text;

src/services/approval.service.ts

@@ -260,7 +260,7 @@ export class ApprovalService {
                 activityService.log({
                   requestId: level.requestId,
                   type: 'ai_conclusion_generated',
-                  user: { userId: 'system', name: 'System' },
+                  user: { userId: null as any, name: 'System' }, // Use null instead of 'system' for UUID field
                   timestamp: new Date().toISOString(),
                   action: 'AI Conclusion Generated',
                   details: 'AI-powered conclusion remark generated for review by initiator',
@@ -291,7 +291,7 @@ export class ApprovalService {
                 activityService.log({
                   requestId: level.requestId,
                   type: 'summary_generated',
-                  user: { userId: 'system', name: 'System' },
+                  user: { userId: null as any, name: 'System' }, // Use null instead of 'system' for UUID field
                   timestamp: new Date().toISOString(),
                   action: 'Summary Auto-Generated',
                   details: 'Request summary auto-generated after final approval',
@@ -339,15 +339,15 @@ export class ApprovalService {
               targetUserIds.add(p.userId); // Includes spectators
             }
             
-            // Send notification to initiator (with action required)
+            // Send notification to initiator about final approval (triggers email)
             const initiatorId = (wf as any).initiatorId;
             await notificationService.sendToUsers([initiatorId], {
-              title: `Request Approved - Closure Pending`,
-              body: `Your request "${(wf as any).title}" has been fully approved. Please review and finalize the conclusion remark to close the request.`,
+              title: `Request Approved - All Approvals Complete`,
+              body: `Your request "${(wf as any).title}" has been fully approved by all approvers. Please review and finalize the conclusion remark to close the request.`,
               requestNumber: (wf as any).requestNumber,
               requestId: level.requestId,
               url: `/request/${(wf as any).requestNumber}`,
-              type: 'approval_pending_closure',
+              type: 'approval',
               priority: 'HIGH',
               actionRequired: true
             });
@@ -425,23 +425,43 @@ export class ApprovalService {
             );
             
             logger.info(`Approved level ${level.levelNumber}. Activated next level ${nextLevelNumber} for workflow ${level.requestId}`);
+            
+            // Log approval activity
+            activityService.log({
+              requestId: level.requestId,
+              type: 'approval',
+              user: { userId: level.approverId, name: level.approverName },
+              timestamp: new Date().toISOString(),
+              action: 'Approved',
+              details: `Request approved and forwarded to ${(nextLevel as any).approverName || (nextLevel as any).approverEmail} by ${level.approverName || level.approverEmail}`,
+              ipAddress: requestMetadata?.ipAddress || undefined,
+              userAgent: requestMetadata?.userAgent || undefined
+            });
+            
+            // Notify initiator about the approval (triggers email)
+            if (wf) {
+              await notificationService.sendToUsers([(wf as any).initiatorId], {
+                title: `Request Approved - Level ${level.levelNumber}`,
+                body: `Your request "${(wf as any).title}" has been approved by ${level.approverName || level.approverEmail} and forwarded to the next approver.`,
+                requestNumber: (wf as any).requestNumber,
+                requestId: level.requestId,
+                url: `/request/${(wf as any).requestNumber}`,
+                type: 'approval',
+                priority: 'MEDIUM'
+              });
+            }
+            
             // Notify next approver
             if (wf && nextLevel) {
               await notificationService.sendToUsers([ (nextLevel as any).approverId ], {
                 title: `Action required: ${(wf as any).requestNumber}`,
                 body: `${(wf as any).title}`,
                 requestNumber: (wf as any).requestNumber,
-                url: `/request/${(wf as any).requestNumber}`
-              });
-              activityService.log({
                 requestId: level.requestId,
-                type: 'approval',
-                user: { userId: level.approverId, name: level.approverName },
-                timestamp: new Date().toISOString(),
-                action: 'Approved',
-                details: `Request approved and forwarded to ${(nextLevel as any).approverName || (nextLevel as any).approverEmail} by ${level.approverName || level.approverEmail}`,
-                ipAddress: requestMetadata?.ipAddress || undefined,
-                userAgent: requestMetadata?.userAgent || undefined
+                url: `/request/${(wf as any).requestNumber}`,
+                type: 'assignment',
+                priority: 'HIGH',
+                actionRequired: true
               });
             }
           } else {
@@ -528,12 +548,34 @@ export class ApprovalService {
           for (const p of participants as any[]) {
             targetUserIds.add(p.userId);
           }
-          await notificationService.sendToUsers(Array.from(targetUserIds), {
+          
+          // Send notification to initiator with type 'rejection' to trigger email
+          await notificationService.sendToUsers([(wf as any).initiatorId], {
             title: `Rejected: ${(wf as any).requestNumber}`,
             body: `${(wf as any).title}`,
             requestNumber: (wf as any).requestNumber,
-            url: `/request/${(wf as any).requestNumber}`
+            requestId: level.requestId,
+            url: `/request/${(wf as any).requestNumber}`,
+            type: 'rejection',
+            priority: 'HIGH',
+            metadata: {
+              rejectionReason: action.rejectionReason || action.comments || 'No reason provided'
+            }
           });
+          
+          // Send notification to other participants (spectators) for transparency (no email, just in-app)
+          const participantUserIds = Array.from(targetUserIds).filter(id => id !== (wf as any).initiatorId);
+          if (participantUserIds.length > 0) {
+            await notificationService.sendToUsers(participantUserIds, {
+              title: `Rejected: ${(wf as any).requestNumber}`,
+              body: `Request "${(wf as any).title}" has been rejected.`,
+              requestNumber: (wf as any).requestNumber,
+              requestId: level.requestId,
+              url: `/request/${(wf as any).requestNumber}`,
+              type: 'status_change', // Use status_change to avoid triggering emails for participants
+              priority: 'MEDIUM'
+            });
+          }
         }
         
         // Generate AI conclusion remark ASYNCHRONOUSLY for rejected requests (similar to approved)

src/services/email.service.ts

@@ -121,24 +121,42 @@ export class EmailService {
       try {
         const info = await this.transporter!.sendMail(mailOptions);
         
+        if (!info || !info.messageId) {
+          throw new Error('Email sent but no messageId returned');
+        }
+        
         const result: { messageId: string; previewUrl?: string } = {
           messageId: info.messageId
         };
 
         // If using test account, generate preview URL
         if (this.useTestAccount) {
-          const previewUrl = nodemailer.getTestMessageUrl(info);
-          result.previewUrl = previewUrl || undefined;
+          try {
+            const previewUrl = nodemailer.getTestMessageUrl(info);
             
-          // Always log to console for visibility
-          console.log('\n' + '='.repeat(80));
-          console.log(`📧 EMAIL PREVIEW (${options.subject})`);
-          console.log(`To: ${recipients}`);
-          console.log(`Preview URL: ${previewUrl}`);
-          console.log('='.repeat(80) + '\n');
+            if (previewUrl) {
+              result.previewUrl = previewUrl;
               
-          logger.info(`✅ Email sent (TEST MODE) to ${recipients}`);
-          logger.info(`📧 Preview URL: ${previewUrl}`);
+              // Always log to console for visibility
+              console.log('\n' + '='.repeat(80));
+              console.log(`📧 EMAIL PREVIEW (${options.subject})`);
+              console.log(`To: ${recipients}`);
+              console.log(`Preview URL: ${previewUrl}`);
+              console.log(`Message ID: ${info.messageId}`);
+              console.log('='.repeat(80) + '\n');
+              
+              logger.info(`✅ Email sent (TEST MODE) to ${recipients}`);
+              logger.info(`📧 Preview URL: ${previewUrl}`);
+            } else {
+              logger.warn(`⚠️  Email sent but preview URL not available. Message ID: ${info.messageId}`);
+              logger.warn(`💡 This can happen if the email service is rate-limited or the message hasn't been processed yet.`);
+            }
+          } catch (previewError: any) {
+            logger.error(`❌ Failed to generate preview URL:`, previewError);
+            logger.warn(`⚠️  Email was sent successfully (Message ID: ${info.messageId}) but preview URL generation failed.`);
+            logger.warn(`💡 You can try sending the email again to get a new preview URL.`);
+            // Don't throw - email was sent successfully, just preview URL failed
+          }
         } else {
           logger.info(`✅ Email sent to ${recipients}: ${options.subject}`);
         }

src/services/emailNotification.service.ts

@@ -90,7 +90,7 @@ export class EmailNotificationService {
         requestTitle: requestData.title,
         initiatorName: initiatorData.displayName || initiatorData.email,
         firstApproverName: firstApproverData.displayName || firstApproverData.email,
-        requestType: requestData.requestType || 'General',
+        requestType: requestData.templateType || requestData.requestType || 'CUSTOM',
         priority: requestData.priority || 'MEDIUM',
         requestDate: this.formatDate(requestData.createdAt),
         requestTime: this.formatTime(requestData.createdAt),
@@ -157,7 +157,7 @@ export class EmailNotificationService {
           requestId: requestData.requestNumber,
           approverName: approverData.displayName || approverData.email,
           initiatorName: initiatorData.displayName || initiatorData.email,
-          requestType: requestData.requestType || 'General',
+          requestType: requestData.templateType || requestData.requestType || 'CUSTOM',
           requestDescription: requestData.description || '',
           priority: requestData.priority || 'MEDIUM',
           requestDate: this.formatDate(requestData.createdAt),
@@ -188,7 +188,7 @@ export class EmailNotificationService {
           requestId: requestData.requestNumber,
           approverName: approverData.displayName || approverData.email,
           initiatorName: initiatorData.displayName || initiatorData.email,
-          requestType: requestData.requestType || 'General',
+          requestType: requestData.templateType || requestData.requestType || 'CUSTOM',
           requestDescription: requestData.description || '',
           priority: requestData.priority || 'MEDIUM',
           requestDate: this.formatDate(requestData.createdAt),
@@ -243,7 +243,7 @@ export class EmailNotificationService {
         approverName: approverData.displayName || approverData.email,
         approvalDate: this.formatDate(approverData.approvedAt || new Date()),
         approvalTime: this.formatTime(approverData.approvedAt || new Date()),
-        requestType: requestData.requestType || 'General',
+        requestType: requestData.templateType || requestData.requestType || 'CUSTOM',
         approverComments: approverData.comments || undefined,
         isFinalApproval,
         nextApproverName: nextApproverData?.displayName || nextApproverData?.email,
@@ -296,7 +296,7 @@ export class EmailNotificationService {
         approverName: approverData.displayName || approverData.email,
         rejectionDate: this.formatDate(approverData.rejectedAt || new Date()),
         rejectionTime: this.formatTime(approverData.rejectedAt || new Date()),
-        requestType: requestData.requestType || 'General',
+        requestType: requestData.templateType || requestData.requestType || 'CUSTOM',
         rejectionReason,
         viewDetailsLink: getViewDetailsLink(requestData.requestNumber, this.frontendUrl),
         companyName: CompanyInfo.name
@@ -348,12 +348,27 @@ export class EmailNotificationService {
                          : tatInfo.thresholdPercentage >= 50 ? 'medium' 
                          : 'low';
 
+      // Get initiator name - try from requestData first, then fetch if needed
+      let initiatorName = requestData.initiatorName || requestData.initiator?.displayName || 'Initiator';
+      if (initiatorName === 'Initiator' && requestData.initiatorId) {
+        try {
+          const { User } = await import('@models/index');
+          const initiator = await User.findByPk(requestData.initiatorId);
+          if (initiator) {
+            const initiatorJson = initiator.toJSON();
+            initiatorName = initiatorJson.displayName || initiatorJson.email || 'Initiator';
+          }
+        } catch (error) {
+          logger.warn(`Failed to fetch initiator for TAT reminder: ${error}`);
+        }
+      }
+
       const data: TATReminderData = {
         recipientName: approverData.displayName || approverData.email,
         requestId: requestData.requestNumber,
         requestTitle: requestData.title,
         approverName: approverData.displayName || approverData.email,
-        initiatorName: requestData.initiatorName || 'Initiator',
+        initiatorName: initiatorName,
         assignedDate: this.formatDate(tatInfo.assignedDate),
         tatDeadline: this.formatDate(tatInfo.tatDeadline) + ' ' + this.formatTime(tatInfo.tatDeadline),
         timeRemaining: tatInfo.timeRemaining,
@@ -404,12 +419,27 @@ export class EmailNotificationService {
         return;
       }
 
+      // Get initiator name - try from requestData first, then fetch if needed
+      let initiatorName = requestData.initiatorName || requestData.initiator?.displayName || 'Initiator';
+      if (initiatorName === 'Initiator' && requestData.initiatorId) {
+        try {
+          const { User } = await import('@models/index');
+          const initiator = await User.findByPk(requestData.initiatorId);
+          if (initiator) {
+            const initiatorJson = initiator.toJSON();
+            initiatorName = initiatorJson.displayName || initiatorJson.email || 'Initiator';
+          }
+        } catch (error) {
+          logger.warn(`Failed to fetch initiator for TAT breach: ${error}`);
+        }
+      }
+
       const data: TATBreachedData = {
         recipientName: approverData.displayName || approverData.email,
         requestId: requestData.requestNumber,
         requestTitle: requestData.title,
         approverName: approverData.displayName || approverData.email,
-        initiatorName: requestData.initiatorName || 'Initiator',
+        initiatorName: initiatorName,
         priority: requestData.priority || 'MEDIUM',
         assignedDate: this.formatDate(tatInfo.assignedDate),
         tatDeadline: this.formatDate(tatInfo.tatDeadline) + ' ' + this.formatTime(tatInfo.tatDeadline),
@@ -446,6 +476,15 @@ export class EmailNotificationService {
     pauseDuration: string
   ): Promise<void> {
     try {
+      // Validate approver data has email
+      if (!approverData || !approverData.email) {
+        logger.warn(`[Email] Cannot send Workflow Resumed email: approver email missing`, {
+          approverData: approverData ? { userId: approverData.userId, displayName: approverData.displayName } : null,
+          requestNumber: requestData.requestNumber
+        });
+        return;
+      }
+
       const canSend = await shouldSendEmail(
         approverData.userId,
         EmailNotificationType.WORKFLOW_RESUMED
@@ -495,6 +534,75 @@ export class EmailNotificationService {
     }
   }
 
+  /**
+   * Send Workflow Resumed Email to Initiator
+   */
+  async sendWorkflowResumedToInitiator(
+    requestData: any,
+    initiatorData: any,
+    approverData: any,
+    resumedByData: any,
+    pauseDuration: string
+  ): Promise<void> {
+    try {
+      // Validate initiator data has email
+      if (!initiatorData || !initiatorData.email) {
+        logger.warn(`[Email] Cannot send Workflow Resumed email to initiator: email missing`, {
+          initiatorData: initiatorData ? { userId: initiatorData.userId, displayName: initiatorData.displayName } : null,
+          requestNumber: requestData.requestNumber
+        });
+        return;
+      }
+
+      const canSend = await shouldSendEmail(
+        initiatorData.userId,
+        EmailNotificationType.WORKFLOW_RESUMED
+      );
+
+      if (!canSend) {
+        logger.info(`Email skipped (preferences): Workflow Resumed for initiator ${initiatorData.email}`);
+        return;
+      }
+
+      const isAutoResumed = !resumedByData || resumedByData.userId === 'system' || !resumedByData.userId;
+      const resumedByText = isAutoResumed 
+        ? 'automatically' 
+        : `by ${resumedByData.displayName || resumedByData.email || resumedByData.name || 'User'}`;
+
+      const data: WorkflowResumedData = {
+        recipientName: initiatorData.displayName || initiatorData.email,
+        requestId: requestData.requestNumber,
+        requestTitle: requestData.title,
+        resumedByText,
+        resumedDate: this.formatDate(new Date()),
+        resumedTime: this.formatTime(new Date()),
+        pausedDuration: pauseDuration,
+        currentApprover: approverData?.displayName || approverData?.email || 'Current Approver',
+        newTATDeadline: requestData.tatDeadline 
+          ? this.formatDate(requestData.tatDeadline) + ' ' + this.formatTime(requestData.tatDeadline)
+          : 'To be determined',
+        isApprover: false, // This is for initiator
+        viewDetailsLink: getViewDetailsLink(requestData.requestNumber, this.frontendUrl),
+        companyName: CompanyInfo.name
+      };
+
+      const html = getWorkflowResumedEmail(data);
+      const subject = `[${requestData.requestNumber}] Workflow Resumed`;
+
+      const result = await emailService.sendEmail({
+        to: initiatorData.email,
+        subject,
+        html
+      });
+
+      if (result.previewUrl) {
+        logger.info(`📧 Workflow Resumed Email Preview (Initiator): ${result.previewUrl}`);
+      }
+    } catch (error) {
+      logger.error('Failed to send Workflow Resumed email to initiator:', error);
+    }
+  }
+
   /**
    * 8. Send Request Closed Email
    */
@@ -523,11 +631,26 @@ export class EmailNotificationService {
       const duration = closedDate.diff(createdDate, 'day');
       const totalDuration = `${duration} day${duration !== 1 ? 's' : ''}`;
 
+      // Get initiator name - try from requestData first, then fetch if needed
+      let initiatorName = requestData.initiatorName || requestData.initiator?.displayName || 'Initiator';
+      if (initiatorName === 'Initiator' && requestData.initiatorId) {
+        try {
+          const { User } = await import('@models/index');
+          const initiator = await User.findByPk(requestData.initiatorId);
+          if (initiator) {
+            const initiatorJson = initiator.toJSON();
+            initiatorName = initiatorJson.displayName || initiatorJson.email || 'Initiator';
+          }
+        } catch (error) {
+          logger.warn(`Failed to fetch initiator for closed request: ${error}`);
+        }
+      }
+
       const data: RequestClosedData = {
         recipientName: recipientData.displayName || recipientData.email,
         requestId: requestData.requestNumber,
         requestTitle: requestData.title,
-        initiatorName: requestData.initiatorName || 'Initiator',
+        initiatorName: initiatorName,
         createdDate: this.formatDate(requestData.createdAt),
         closedDate: this.formatDate(requestData.closedAt || new Date()),
         closedTime: this.formatTime(requestData.closedAt || new Date()),
@@ -575,6 +698,118 @@ export class EmailNotificationService {
     }
   }
 
+  /**
+   * 9. Send Approver Skipped Email
+   */
+  async sendApproverSkipped(
+    requestData: any,
+    skippedApproverData: any,
+    skippedByData: any,
+    nextApproverData: any,
+    skipReason: string
+  ): Promise<void> {
+    try {
+      const canSend = await shouldSendEmail(
+        skippedApproverData.userId,
+        EmailNotificationType.APPROVER_SKIPPED
+      );
+
+      if (!canSend) {
+        logger.info(`Email skipped (preferences): Approver Skipped for ${skippedApproverData.email}`);
+        return;
+      }
+
+      const data: ApproverSkippedData = {
+        recipientName: skippedApproverData.displayName || skippedApproverData.email,
+        requestId: requestData.requestNumber,
+        requestTitle: requestData.title,
+        skippedApproverName: skippedApproverData.displayName || skippedApproverData.email,
+        skippedByName: skippedByData.displayName || skippedByData.email,
+        skippedDate: this.formatDate(new Date()),
+        skippedTime: this.formatTime(new Date()),
+        nextApproverName: nextApproverData?.displayName || nextApproverData?.email || 'Next Approver',
+        skipReason: skipReason || 'Not provided',
+        viewDetailsLink: getViewDetailsLink(requestData.requestNumber, this.frontendUrl),
+        companyName: CompanyInfo.name
+      };
+
+      const html = getApproverSkippedEmail(data);
+      const subject = `[${requestData.requestNumber}] Approver Skipped`;
+
+      const result = await emailService.sendEmail({
+        to: skippedApproverData.email,
+        subject,
+        html
+      });
+
+      if (result.previewUrl) {
+        logger.info(`📧 Approver Skipped Email Preview: ${result.previewUrl}`);
+      }
+    } catch (error) {
+      logger.error('Failed to send Approver Skipped email:', error);
+    }
+  }
+
+  /**
+   * 10. Send Workflow Paused Email
+   */
+  async sendWorkflowPaused(
+    requestData: any,
+    recipientData: any,
+    pausedByData: any,
+    pauseReason: string,
+    resumeDate: Date | string
+  ): Promise<void> {
+    try {
+      // Validate recipient data has email
+      if (!recipientData || !recipientData.email) {
+        logger.warn(`[Email] Cannot send Workflow Paused email: recipient email missing`, {
+          recipientData: recipientData ? { userId: recipientData.userId, displayName: recipientData.displayName } : null,
+          requestNumber: requestData.requestNumber
+        });
+        return;
+      }
+
+      const canSend = await shouldSendEmail(
+        recipientData.userId,
+        EmailNotificationType.WORKFLOW_PAUSED
+      );
+
+      if (!canSend) {
+        logger.info(`Email skipped (preferences): Workflow Paused for ${recipientData.email}`);
+        return;
+      }
+
+      const data: WorkflowPausedData = {
+        recipientName: recipientData.displayName || recipientData.email,
+        requestId: requestData.requestNumber,
+        requestTitle: requestData.title,
+        pausedByName: pausedByData?.displayName || pausedByData?.email || 'System',
+        pausedDate: this.formatDate(new Date()),
+        pausedTime: this.formatTime(new Date()),
+        resumeDate: this.formatDate(resumeDate),
+        pauseReason: pauseReason || 'Not provided',
+        viewDetailsLink: getViewDetailsLink(requestData.requestNumber, this.frontendUrl),
+        companyName: CompanyInfo.name
+      };
+
+      const html = getWorkflowPausedEmail(data);
+      const subject = `[${requestData.requestNumber}] Workflow Paused`;
+
+      const result = await emailService.sendEmail({
+        to: recipientData.email,
+        subject,
+        html
+      });
+
+      if (result.previewUrl) {
+        logger.info(`📧 Workflow Paused Email Preview: ${result.previewUrl}`);
+      }
+    } catch (error) {
+      logger.error('Failed to send Workflow Paused email:', error);
+    }
+  }
+
   // Add more email methods as needed...
 }
 

src/services/gcsStorage.service.ts

@@ -128,12 +128,15 @@ class GCSStorageService {
       // Ensure bucket exists before uploading
       await this.ensureBucketExists();
       
-      // Generate unique file name
+      // Generate unique file name with original name first for readability
+      // Format: originalName-timestamp-hash.ext (e.g., proposal-1766490022228-qjlojs.pdf)
       const timestamp = Date.now();
       const randomHash = Math.random().toString(36).substring(2, 8);
       const safeName = originalName.replace(/[^a-zA-Z0-9._-]/g, '_');
       const extension = path.extname(originalName);
-      const fileName = `${timestamp}-${randomHash}-${safeName}`;
+      // Extract name without extension, then add timestamp and hash before extension
+      const nameWithoutExt = safeName.substring(0, safeName.length - extension.length);
+      const fileName = `${nameWithoutExt}-${timestamp}-${randomHash}${extension}`;
       
       // Build GCS path: requests/{requestNumber}/{fileType}/{fileName}
       // Example: requests/REQ-2025-12-0001/documents/proposal.pdf
@@ -265,11 +268,15 @@ class GCSStorageService {
     }
 
     try {
-      // Generate unique file name (same format as GCS)
+      // Generate unique file name (same format as GCS) - original name first for readability
+      // Format: originalName-timestamp-hash.ext (e.g., proposal-1766490022228-qjlojs.pdf)
       const timestamp = Date.now();
       const randomHash = Math.random().toString(36).substring(2, 8);
       const safeName = originalName.replace(/[^a-zA-Z0-9._-]/g, '_');
-      const fileName = `${timestamp}-${randomHash}-${safeName}`;
+      const extension = path.extname(originalName);
+      // Extract name without extension, then add timestamp and hash before extension
+      const nameWithoutExt = safeName.substring(0, safeName.length - extension.length);
+      const fileName = `${nameWithoutExt}-${timestamp}-${randomHash}${extension}`;
 
       // Build local path: uploads/requests/{requestNumber}/{fileType}/{fileName}
       // This matches the GCS structure: requests/{requestNumber}/{fileType}/{fileName}

src/services/notification.service.ts

@@ -123,10 +123,12 @@ class NotificationService {
     
     for (const userId of userIds) {
       try {
-        // Fetch user preferences
+        // Fetch user preferences and email data
         const user = await User.findByPk(userId, {
           attributes: [
             'userId',
+            'email',
+            'displayName',
             'emailNotificationsEnabled',
             'pushNotificationsEnabled',
             'inAppNotificationsEnabled'
@@ -266,6 +268,10 @@ class NotificationService {
       'rejection': EmailNotificationType.REQUEST_REJECTED,
       'tat_reminder': EmailNotificationType.TAT_REMINDER,
       'tat_breach': EmailNotificationType.TAT_BREACHED,
+      'threshold1': EmailNotificationType.TAT_REMINDER, // 50% TAT reminder
+      'threshold2': EmailNotificationType.TAT_REMINDER, // 75% TAT reminder
+      'breach': EmailNotificationType.TAT_BREACHED, // 100% TAT breach
+      'tat_breach_initiator': EmailNotificationType.TAT_BREACHED, // Breach notification to initiator
       'workflow_resumed': EmailNotificationType.WORKFLOW_RESUMED,
       'closed': EmailNotificationType.REQUEST_CLOSED,
       // These don't get emails (in-app only)
@@ -275,7 +281,9 @@ class NotificationService {
       'status_change': null,
       'ai_conclusion_generated': null,
       'summary_generated': null,
-      'workflow_paused': null, // Conditional - handled separately
+      'workflow_paused': EmailNotificationType.WORKFLOW_PAUSED,
+      'approver_skipped': EmailNotificationType.APPROVER_SKIPPED,
+      'pause_retrigger_request': EmailNotificationType.WORKFLOW_PAUSED, // Use same template as pause
       'pause_retriggered': null
     };
 
@@ -290,7 +298,11 @@ class NotificationService {
     }
 
     // Check if email should be sent (admin + user preferences)
-    const shouldSend = payload.type === 'rejection' || payload.type === 'tat_breach'
+    // Critical emails: rejection, tat_breach, breach
+    const isCriticalEmail = payload.type === 'rejection' || 
+                            payload.type === 'tat_breach' || 
+                            payload.type === 'breach';
+    const shouldSend = isCriticalEmail
       ? await shouldSendEmailWithOverride(userId, emailType) // Critical emails
       : await shouldSendEmail(userId, emailType); // Regular emails
 
@@ -358,8 +370,17 @@ class NotificationService {
           
           const firstApprover = firstLevel ? await User.findByPk((firstLevel as any).approverId) : null;
           
+          // Get first approver's TAT hours (not total TAT)
+          const firstApproverTatHours = firstLevel ? (firstLevel as any).tatHours : null;
+          
+          // Add first approver's TAT to requestData for the email
+          const requestDataWithFirstTat = {
+            ...requestData,
+            tatHours: firstApproverTatHours || (requestData as any).totalTatHours || 24
+          };
+          
           await emailNotificationService.sendRequestCreated(
-            requestData,
+            requestDataWithFirstTat,
             initiatorData,
             firstApprover ? firstApprover.toJSON() : null
           );
@@ -407,7 +428,7 @@ class NotificationService {
               requestId: payload.requestId,
               status: 'APPROVED'
             },
-            order: [['approvedAt', 'DESC']]
+            order: [['actionDate', 'DESC'], ['levelEndTime', 'DESC']]
           });
 
           const allLevels = await ApprovalLevel.findAll({
@@ -421,9 +442,21 @@ class NotificationService {
           const nextLevel = isFinalApproval ? null : allLevels.find((l: any) => l.status === 'PENDING');
           const nextApprover = nextLevel ? await User.findByPk((nextLevel as any).approverId) : null;
 
+          // Get the approver who just approved from the approved level
+          let approverData = user; // Fallback to user if we can't find the approver
+          if (approvedLevel) {
+            const approverUser = await User.findByPk((approvedLevel as any).approverId);
+            if (approverUser) {
+              approverData = approverUser.toJSON();
+              // Add approval metadata
+              (approverData as any).approvedAt = (approvedLevel as any).actionDate;
+              (approverData as any).comments = (approvedLevel as any).comments;
+            }
+          }
+
           await emailNotificationService.sendApprovalConfirmation(
             requestData,
-            user, // Approver who just approved
+            approverData, // Approver who just approved
             initiatorData,
             isFinalApproval,
             nextApprover ? nextApprover.toJSON() : undefined
@@ -437,12 +470,34 @@ class NotificationService {
             where: { 
               requestId: payload.requestId,
               status: 'REJECTED'
-            }
+            },
+            order: [['actionDate', 'DESC'], ['levelEndTime', 'DESC']]
           });
 
+          // Get the approver who rejected from the rejected level
+          let approverData = user; // Fallback to user if we can't find the approver
+          if (rejectedLevel) {
+            const approverUser = await User.findByPk((rejectedLevel as any).approverId);
+            if (approverUser) {
+              approverData = approverUser.toJSON();
+              // Add rejection metadata
+              (approverData as any).rejectedAt = (rejectedLevel as any).actionDate;
+              (approverData as any).comments = (rejectedLevel as any).comments;
+            } else {
+              // If user not found, use approver info from the level itself
+              approverData = {
+                userId: (rejectedLevel as any).approverId,
+                displayName: (rejectedLevel as any).approverName || 'Unknown Approver',
+                email: (rejectedLevel as any).approverEmail || 'unknown@royalenfield.com',
+                rejectedAt: (rejectedLevel as any).actionDate,
+                comments: (rejectedLevel as any).comments
+              };
+            }
+          }
+
           await emailNotificationService.sendRejectionNotification(
             requestData,
-            user, // Approver who rejected
+            approverData, // Approver who rejected
             initiatorData,
             (rejectedLevel as any)?.comments || payload.metadata?.rejectionReason || 'No reason provided'
           );
@@ -450,38 +505,13 @@ class NotificationService {
         break;
 
       case 'tat_reminder':
+      case 'threshold1':
+      case 'threshold2':
       case 'tat_breach':
+      case 'breach':
+      case 'tat_breach_initiator':
         {
-          // Extract TAT info from metadata or payload
-          const tatInfo = payload.metadata?.tatInfo || {
-            thresholdPercentage: payload.type === 'tat_breach' ? 100 : 75,
-            timeRemaining: payload.metadata?.timeRemaining || 'Unknown',
-            tatDeadline: payload.metadata?.tatDeadline || new Date(),
-            assignedDate: payload.metadata?.assignedDate || requestData.createdAt
-          };
-
-          if (notificationType === 'tat_breach') {
-            await emailNotificationService.sendTATBreached(
-              requestData,
-              user,
-              {
-                timeOverdue: tatInfo.timeOverdue || tatInfo.timeRemaining,
-                tatDeadline: tatInfo.tatDeadline,
-                assignedDate: tatInfo.assignedDate
-              }
-            );
-          } else {
-            await emailNotificationService.sendTATReminder(
-              requestData,
-              user,
-              tatInfo
-            );
-          }
-        }
-        break;
-
-      case 'workflow_resumed':
-        {
+          // Get the approver from the current level (the one who needs to take action)
           const currentLevel = await ApprovalLevel.findOne({
             where: { 
               requestId: payload.requestId,
@@ -490,17 +520,158 @@ class NotificationService {
             order: [['levelNumber', 'ASC']]
           });
 
-          const currentApprover = currentLevel ? await User.findByPk((currentLevel as any).approverId) : null;
+          // Get approver data - prefer from level, fallback to user
+          let approverData = user; // Fallback
+          if (currentLevel) {
+            const approverUser = await User.findByPk((currentLevel as any).approverId);
+            if (approverUser) {
+              approverData = approverUser.toJSON();
+            } else {
+              // If user not found, use approver info from the level itself
+              approverData = {
+                userId: (currentLevel as any).approverId,
+                displayName: (currentLevel as any).approverName || 'Unknown Approver',
+                email: (currentLevel as any).approverEmail || 'unknown@royalenfield.com'
+              };
+            }
+          }
+
+          // Determine threshold percentage based on notification type
+          let thresholdPercentage = 75; // Default
+          if (notificationType === 'threshold1') {
+            thresholdPercentage = 50;
+          } else if (notificationType === 'threshold2') {
+            thresholdPercentage = 75;
+          } else if (notificationType === 'breach' || notificationType === 'tat_breach' || notificationType === 'tat_breach_initiator') {
+            thresholdPercentage = 100;
+          } else if (payload.metadata?.thresholdPercentage) {
+            thresholdPercentage = payload.metadata.thresholdPercentage;
+          }
+
+          // Extract TAT info from metadata or payload
+          const tatInfo = payload.metadata?.tatInfo || {
+            thresholdPercentage: thresholdPercentage,
+            timeRemaining: payload.metadata?.timeRemaining || 'Unknown',
+            tatDeadline: payload.metadata?.tatDeadline || new Date(),
+            assignedDate: payload.metadata?.assignedDate || requestData.createdAt
+          };
+
+          // Update threshold percentage if not in tatInfo
+          if (!payload.metadata?.tatInfo) {
+            tatInfo.thresholdPercentage = thresholdPercentage;
+          }
+
+          // Handle breach notifications (to approver or initiator)
+          if (notificationType === 'breach' || notificationType === 'tat_breach') {
+            // Breach notification to approver
+            if (approverData && approverData.email) {
+              await emailNotificationService.sendTATBreached(
+                requestData,
+                approverData,
+                {
+                  timeOverdue: tatInfo.timeOverdue || tatInfo.timeRemaining || 'Exceeded',
+                  tatDeadline: tatInfo.tatDeadline,
+                  assignedDate: tatInfo.assignedDate
+                }
+              );
+            }
+          } else if (notificationType === 'tat_breach_initiator') {
+            // Breach notification to initiator
+            if (initiatorData && initiatorData.email) {
+              // For initiator, we can use a simpler notification or the same breach template
+              // For now, skip email to initiator on breach (they get in-app notification)
+              // Or we could create a separate initiator breach email template
+              logger.info(`[Email] Breach notification to initiator - in-app only for now`);
+            }
+          } else {
+            // TAT reminder (threshold1, threshold2, or tat_reminder)
+            if (approverData && approverData.email) {
+              await emailNotificationService.sendTATReminder(
+                requestData,
+                approverData,
+                tatInfo
+              );
+            }
+          }
+        }
+        break;
+
+      case 'workflow_resumed':
+        {
+          // Get current level to determine approver
+          const currentLevel = await ApprovalLevel.findOne({
+            where: { 
+              requestId: payload.requestId,
+              status: 'PENDING'
+            },
+            order: [['levelNumber', 'ASC']]
+          });
+
+          // Get approver data from current level
+          let approverData = null;
+          if (currentLevel) {
+            const approverUser = await User.findByPk((currentLevel as any).approverId);
+            if (approverUser) {
+              approverData = approverUser.toJSON();
+            } else {
+              // Use approver info from level
+              approverData = {
+                userId: (currentLevel as any).approverId,
+                displayName: (currentLevel as any).approverName || 'Unknown Approver',
+                email: (currentLevel as any).approverEmail || 'unknown@royalenfield.com'
+              };
+            }
+          }
+
           const resumedBy = payload.metadata?.resumedBy;
           const pauseDuration = payload.metadata?.pauseDuration || 'Unknown';
 
-          await emailNotificationService.sendWorkflowResumed(
-            requestData,
-            currentApprover ? currentApprover.toJSON() : user,
-            initiatorData,
-            resumedBy,
-            pauseDuration
-          );
+          // Convert user to plain object if needed
+          const userData = user.toJSON ? user.toJSON() : user;
+
+          // Determine if the recipient is the approver or initiator
+          const isApprover = approverData && userData.userId === approverData.userId;
+          const isInitiator = userData.userId === initiatorData.userId;
+
+          // Ensure user has email
+          if (!userData.email) {
+            logger.warn(`[Email] Cannot send Workflow Resumed email: user email missing`, {
+              userId: userData.userId,
+              displayName: userData.displayName,
+              requestNumber: requestData.requestNumber
+            });
+            return;
+          }
+
+          // Send appropriate email based on recipient role
+          if (isApprover) {
+            // Recipient is the approver - send approver email
+            await emailNotificationService.sendWorkflowResumed(
+              requestData,
+              userData,
+              initiatorData,
+              resumedBy,
+              pauseDuration
+            );
+          } else if (isInitiator) {
+            // Recipient is the initiator - send initiator email
+            await emailNotificationService.sendWorkflowResumedToInitiator(
+              requestData,
+              userData,
+              approverData,
+              resumedBy,
+              pauseDuration
+            );
+          } else {
+            // Recipient is neither approver nor initiator (spectator) - send initiator-style email
+            await emailNotificationService.sendWorkflowResumedToInitiator(
+              requestData,
+              userData,
+              approverData,
+              resumedBy,
+              pauseDuration
+            );
+          }
         }
         break;
 
@@ -520,6 +691,153 @@ class NotificationService {
         }
         break;
 
+      case 'approver_skipped':
+        {
+          const skippedLevel = await ApprovalLevel.findOne({
+            where: { 
+              requestId: payload.requestId,
+              status: 'SKIPPED'
+            },
+            order: [['levelEndTime', 'DESC'], ['actionDate', 'DESC']]
+          });
+
+          const nextLevel = await ApprovalLevel.findOne({
+            where: { 
+              requestId: payload.requestId,
+              status: 'PENDING'
+            },
+            order: [['levelNumber', 'ASC']]
+          });
+
+          const nextApprover = nextLevel ? await User.findByPk((nextLevel as any).approverId) : null;
+          const skippedBy = payload.metadata?.skippedBy ? await User.findByPk(payload.metadata.skippedBy) : null;
+          const skippedApprover = skippedLevel ? await User.findByPk((skippedLevel as any).approverId) : null;
+
+          if (skippedApprover) {
+            await emailNotificationService.sendApproverSkipped(
+              requestData,
+              skippedApprover.toJSON(),
+              skippedBy ? skippedBy.toJSON() : { userId: null, displayName: 'System', email: 'system' },
+              nextApprover ? nextApprover.toJSON() : null,
+              payload.metadata?.skipReason || (skippedLevel as any)?.skipReason || 'Not provided'
+            );
+          }
+        }
+        break;
+
+      case 'pause_retrigger_request':
+        {
+          // This is when initiator requests approver to resume a paused workflow
+          // Treat it similar to workflow_paused but with different messaging
+          const pausedBy = payload.metadata?.pausedBy ? await User.findByPk(payload.metadata.pausedBy) : null;
+          const resumeDate = payload.metadata?.resumeDate || new Date();
+          
+          // Get recipient data (the approver who paused it)
+          let recipientData = user;
+          if (!recipientData || !recipientData.email) {
+            // Try to get from paused level
+            const pausedLevel = await ApprovalLevel.findOne({
+              where: { 
+                requestId: payload.requestId,
+                isPaused: true
+              },
+              order: [['levelNumber', 'ASC']]
+            });
+            
+            if (pausedLevel) {
+              const approverUser = await User.findByPk((pausedLevel as any).approverId);
+              if (approverUser) {
+                recipientData = approverUser.toJSON();
+              } else {
+                recipientData = {
+                  userId: (pausedLevel as any).approverId,
+                  displayName: (pausedLevel as any).approverName || 'Unknown Approver',
+                  email: (pausedLevel as any).approverEmail || 'unknown@royalenfield.com'
+                };
+              }
+            }
+          }
+
+          // Ensure email exists before sending
+          if (!recipientData || !recipientData.email) {
+            logger.warn(`[Email] Cannot send Pause Retrigger Request email: recipient email missing`, {
+              recipientData: recipientData ? { userId: recipientData.userId, displayName: recipientData.displayName } : null,
+              requestNumber: requestData.requestNumber
+            });
+            return;
+          }
+
+          // Use workflow paused email template but with retrigger context
+          await emailNotificationService.sendWorkflowPaused(
+            requestData,
+            recipientData,
+            pausedBy ? pausedBy.toJSON() : { userId: null, displayName: 'System', email: 'system' },
+            `Initiator has requested to resume this workflow. Please review and resume if appropriate.`,
+            resumeDate
+          );
+        }
+        break;
+
+      case 'workflow_paused':
+        {
+          const pausedBy = payload.metadata?.pausedBy ? await User.findByPk(payload.metadata.pausedBy) : null;
+          const resumeDate = payload.metadata?.resumeDate || new Date();
+
+          // Get recipient data - prefer from user, ensure it has email
+          let recipientData = user;
+          if (!recipientData || !recipientData.email) {
+            // If user object doesn't have email, try to get from current level
+            const currentLevel = await ApprovalLevel.findOne({
+              where: { 
+                requestId: payload.requestId,
+                status: 'PENDING'
+              },
+              order: [['levelNumber', 'ASC']]
+            });
+            
+            if (currentLevel) {
+              const approverUser = await User.findByPk((currentLevel as any).approverId);
+              if (approverUser) {
+                recipientData = approverUser.toJSON();
+              } else {
+                // Use approver info from level
+                recipientData = {
+                  userId: (currentLevel as any).approverId,
+                  displayName: (currentLevel as any).approverName || 'Unknown User',
+                  email: (currentLevel as any).approverEmail || 'unknown@royalenfield.com'
+                };
+              }
+            } else {
+              // If no current level, try to get from initiator
+              const initiatorUser = await User.findByPk(requestData.initiatorId);
+              if (initiatorUser) {
+                recipientData = initiatorUser.toJSON();
+              } else {
+                logger.warn(`[Email] Cannot send Workflow Paused email: no recipient found for request ${payload.requestId}`);
+                return;
+              }
+            }
+          }
+
+          // Ensure email exists before sending
+          if (!recipientData.email) {
+            logger.warn(`[Email] Cannot send Workflow Paused email: recipient email missing`, {
+              recipientData: { userId: recipientData.userId, displayName: recipientData.displayName },
+              requestNumber: requestData.requestNumber
+            });
+            return;
+          }
+
+          await emailNotificationService.sendWorkflowPaused(
+            requestData,
+            recipientData,
+            pausedBy ? pausedBy.toJSON() : { userId: null, displayName: 'System', email: 'system' },
+            payload.metadata?.pauseReason || 'Not provided',
+            resumeDate
+          );
+        }
+        break;
+
       default:
         logger.info(`[Email] No email configured for notification type: ${notificationType}`);
     }

src/services/pause.service.ts

@@ -182,18 +182,23 @@ export class PauseService {
         url: `/request/${requestNumber}`,
         type: 'workflow_paused',
         priority: 'HIGH',
-        actionRequired: false
+        actionRequired: false,
+        metadata: {
+          pauseReason: reason,
+          resumeDate: resumeDate.toISOString(),
+          pausedBy: userId
+        }
       });
       }
 
-      // Notify the user who paused (confirmation)
+      // Notify the user who paused (confirmation) - no email for self-action
       await notificationService.sendToUsers([userId], {
         title: 'Workflow Paused Successfully',
         body: `You have paused request "${title}". It will automatically resume on ${dayjs(resumeDate).format('MMM DD, YYYY')}.`,
         requestId,
         requestNumber,
         url: `/request/${requestNumber}`,
-        type: 'workflow_paused',
+        type: 'status_change', // Use status_change to avoid email for self-action
         priority: 'MEDIUM',
         actionRequired: false
       });
@@ -210,7 +215,12 @@ export class PauseService {
           url: `/request/${requestNumber}`,
           type: 'workflow_paused',
           priority: 'HIGH',
-          actionRequired: false
+          actionRequired: false,
+          metadata: {
+            pauseReason: reason,
+            resumeDate: resumeDate.toISOString(),
+            pausedBy: userId
+          }
         });
       }
 
@@ -448,6 +458,12 @@ export class PauseService {
       const isResumedByInitiator = userId === initiatorId;
       const isResumedByApprover = userId === approverId;
 
+      // Calculate pause duration
+      const pausedAt = (level as any).pausedAt || (workflow as any).pausedAt;
+      const pauseDurationMs = pausedAt ? now.getTime() - new Date(pausedAt).getTime() : 0;
+      const pauseDurationHours = Math.round((pauseDurationMs / (1000 * 60 * 60)) * 100) / 100; // Round to 2 decimal places
+      const pauseDuration = pauseDurationHours > 0 ? `${pauseDurationHours} hours` : 'less than 1 hour';
+
       // Notify initiator only if someone else resumed (or auto-resume)
       // Skip if initiator resumed their own request
       if (!isResumedByInitiator) {
@@ -459,7 +475,11 @@ export class PauseService {
         url: `/request/${requestNumber}`,
         type: 'workflow_resumed',
         priority: 'HIGH',
-        actionRequired: false
+        actionRequired: false,
+        metadata: {
+          resumedBy: userId ? { userId, name: resumeUserName } : null,
+          pauseDuration: pauseDuration
+        }
       });
       }
 
@@ -474,11 +494,15 @@ export class PauseService {
         url: `/request/${requestNumber}`,
         type: 'workflow_resumed',
         priority: 'HIGH',
-        actionRequired: true
+        actionRequired: true,
+        metadata: {
+          resumedBy: userId ? { userId, name: resumeUserName } : null,
+          pauseDuration: pauseDuration
+        }
       });
       }
 
-      // Send confirmation to the user who resumed (if manual resume)
+      // Send confirmation to the user who resumed (if manual resume) - no email for self-action
       if (userId) {
         await notificationService.sendToUsers([userId], {
           title: 'Workflow Resumed Successfully',
@@ -486,7 +510,7 @@ export class PauseService {
           requestId,
           requestNumber,
           url: `/request/${requestNumber}`,
-          type: 'workflow_resumed',
+          type: 'status_change', // Use status_change to avoid email for self-action
           priority: 'MEDIUM',
           actionRequired: isResumedByApprover
         });

src/services/workflow.service.ts

@@ -221,13 +221,31 @@ export class WorkflowService {
         // Update workflow current level
         await workflow.update({ currentLevel: nextLevelNumber });
 
+        // Notify skipped approver (triggers email)
+        await notificationService.sendToUsers([(level as any).approverId], {
+          title: 'Approver Skipped',
+          body: `You have been skipped in request ${(workflow as any).requestNumber}. The workflow has moved to the next approver.`,
+          requestId,
+          requestNumber: (workflow as any).requestNumber,
+          url: `/request/${(workflow as any).requestNumber}`,
+          type: 'approver_skipped',
+          priority: 'MEDIUM',
+          metadata: {
+            skipReason: skipReason,
+            skippedBy: skippedBy
+          }
+        });
+
         // Notify next approver
         await notificationService.sendToUsers([(nextLevel as any).approverId], {
           title: 'Request Escalated',
           body: `Previous approver was skipped. Request ${(workflow as any).requestNumber} is now awaiting your approval.`,
           requestId,
           requestNumber: (workflow as any).requestNumber,
-          url: `/request/${(workflow as any).requestNumber}`
+          url: `/request/${(workflow as any).requestNumber}`,
+          type: 'assignment',
+          priority: 'HIGH',
+          actionRequired: true
         });
       }
 
@@ -3074,8 +3092,16 @@ export class WorkflowService {
       const refreshed = await WorkflowRequest.findByPk(actualRequestId);
       return refreshed;
     } catch (error) {
-      logger.error(`Failed to update workflow ${requestId}:`, error);
-      throw new Error('Failed to update workflow');
+      const errorMessage = error instanceof Error ? error.message : 'Unknown error';
+      const errorStack = error instanceof Error ? error.stack : undefined;
+      logger.error(`Failed to update workflow ${requestId}:`, {
+        error: errorMessage,
+        stack: errorStack,
+        requestId,
+        updateData: JSON.stringify(updateData, null, 2),
+      });
+      // Preserve original error message for better debugging
+      throw new Error(`Failed to update workflow: ${errorMessage}`);
     }
   }