From 573e1b40d20400a490f8ac09329ad9e14c228e2c Mon Sep 17 00:00:00 2001
From: Lukas May <lukas.may@carealytix.com>
Date: Thu, 5 Mar 2026 21:04:39 +0100
Subject: [PATCH] fix: Re-queue approved phases before dispatch to survive
 server restarts

The in-memory phaseQueue (Map) in DefaultPhaseDispatchManager is lost on
server restart. After approving a phase review, dispatchNextPhase() found
nothing in the empty queue, so the next unblocked phase never started.

Now the orchestrator re-queues all approved phases for the initiative from
the DB before attempting to dispatch, making the queue self-healing.
---
 apps/server/execution/orchestrator.ts | 25 +++++++++++++++++++++++++
 1 file changed, 25 insertions(+)

diff --git a/apps/server/execution/orchestrator.ts b/apps/server/execution/orchestrator.ts
index dfa0483..aefce3b 100644
--- a/apps/server/execution/orchestrator.ts
+++ b/apps/server/execution/orchestrator.ts
@@ -234,6 +234,9 @@ export class ExecutionOrchestrator {
       await this.mergePhaseIntoInitiative(phaseId);
       await this.phaseDispatchManager.completePhase(phaseId);
 
+      // Re-queue approved phases (self-healing: survives server restarts that wipe in-memory queue)
+      await this.requeueApprovedPhases(phase.initiativeId);
+
       // Check if this was the last phase — if so, trigger initiative review
       const dispatched = await this.phaseDispatchManager.dispatchNextPhase();
       if (!dispatched.success) {
@@ -305,6 +308,9 @@ export class ExecutionOrchestrator {
     await this.mergePhaseIntoInitiative(phaseId);
     await this.phaseDispatchManager.completePhase(phaseId);
 
+    // Re-queue approved phases (self-healing: survives server restarts that wipe in-memory queue)
+    await this.requeueApprovedPhases(phase.initiativeId);
+
     // Check if this was the last phase — if so, trigger initiative review
     const dispatched = await this.phaseDispatchManager.dispatchNextPhase();
     if (!dispatched.success) {
@@ -395,6 +401,25 @@ export class ExecutionOrchestrator {
     return { taskId: task.id };
   }
 
+  /**
+   * Re-queue approved phases for an initiative into the in-memory dispatch queue.
+   * Self-healing: ensures phases aren't lost if the server restarted since the
+   * initial queueAllPhases() call.
+   */
+  private async requeueApprovedPhases(initiativeId: string): Promise<void> {
+    const phases = await this.phaseRepository.findByInitiativeId(initiativeId);
+    for (const p of phases) {
+      if (p.status === 'approved') {
+        try {
+          await this.phaseDispatchManager.queuePhase(p.id);
+          log.info({ phaseId: p.id }, 're-queued approved phase');
+        } catch {
+          // Already queued or status changed — safe to ignore
+        }
+      }
+    }
+  }
+
   /**
    * Check if all phases for an initiative are completed.
    * If so, set initiative to pending_review and emit event.