fix(runtime): harden process startup and health

src/app/api/health/__tests__/route.test.ts

@@ -0,0 +1,119 @@
+import { beforeEach, describe, expect, it, vi } from "vitest";
+
+interface WorkerStatusFixture {
+  running: boolean;
+  startedAt: string | null;
+  lastHeartbeat: string | null;
+  lastReminderCheck: string | null;
+  lastWithingsSync: string | null;
+  lastInsightsRun: string | null;
+  jobsProcessed: number;
+  errors: number;
+}
+
+const { queryRaw, getWorkerStatus, getGlobalBoss, getSession } = vi.hoisted(
+  () => ({
+    queryRaw: vi.fn(async () => 1),
+    getWorkerStatus: vi.fn((): WorkerStatusFixture => ({
+      running: false,
+      startedAt: null,
+      lastHeartbeat: null,
+      lastReminderCheck: null,
+      lastWithingsSync: null,
+      lastInsightsRun: null,
+      jobsProcessed: 0,
+      errors: 0,
+    })),
+    getGlobalBoss: vi.fn((): object | null => null),
+    getSession: vi.fn(async () => null),
+  }),
+);
+
+vi.mock("@/lib/db", () => ({
+  prisma: { $queryRaw: queryRaw },
+}));
+vi.mock("@/lib/jobs/worker-status", () => ({ getWorkerStatus }));
+vi.mock("@/lib/jobs/boss-instance", () => ({ getGlobalBoss }));
+vi.mock("@/lib/auth/session", () => ({ getSession }));
+vi.mock("@/lib/api-handler", () => ({
+  apiHandler: <T extends (...args: unknown[]) => unknown>(fn: T) => fn,
+}));
+vi.mock("@/lib/logging/context", () => ({ annotate: vi.fn() }));
+
+import { GET } from "../route";
+
+async function health() {
+  const response = await (GET as unknown as () => Promise<Response>)();
+  return { response, body: (await response.json()) as { status: string } };
+}
+
+beforeEach(() => {
+  vi.clearAllMocks();
+  queryRaw.mockResolvedValue(1);
+  getWorkerStatus.mockReturnValue({
+    running: false,
+    startedAt: null,
+    lastHeartbeat: null,
+    lastReminderCheck: null,
+    lastWithingsSync: null,
+    lastInsightsRun: null,
+    jobsProcessed: 0,
+    errors: 0,
+  });
+  getGlobalBoss.mockReturnValue(null);
+  getSession.mockResolvedValue(null);
+});
+
+describe("GET /api/health process topology", () => {
+  it("web mode requires DB and producer readiness, not an in-process worker", async () => {
+    vi.stubEnv("HEALTHLOG_PROCESS_TYPE", "web");
+    getGlobalBoss.mockReturnValue({});
+
+    const { response, body } = await health();
+
+    expect(response.status).toBe(200);
+    expect(body).toEqual({ status: "ok" });
+  });
+
+  it("worker mode requires DB and worker readiness, not web producer readiness", async () => {
+    vi.stubEnv("HEALTHLOG_PROCESS_TYPE", "worker");
+    getWorkerStatus.mockReturnValue({
+      running: true,
+      startedAt: "2026-07-20T00:00:00.000Z",
+      lastHeartbeat: "2026-07-20T00:00:00.000Z",
+      lastReminderCheck: null,
+      lastWithingsSync: null,
+      lastInsightsRun: null,
+      jobsProcessed: 0,
+      errors: 0,
+    });
+
+    const { response, body } = await health();
+
+    expect(response.status).toBe(200);
+    expect(body).toEqual({ status: "ok" });
+  });
+
+  it("all mode requires both producer and worker readiness", async () => {
+    vi.stubEnv("HEALTHLOG_PROCESS_TYPE", "all");
+    getWorkerStatus.mockReturnValue({
+      running: true,
+      startedAt: "2026-07-20T00:00:00.000Z",
+      lastHeartbeat: "2026-07-20T00:00:00.000Z",
+      lastReminderCheck: null,
+      lastWithingsSync: null,
+      lastInsightsRun: null,
+      jobsProcessed: 0,
+      errors: 0,
+    });
+
+    const missingProducer = await health();
+    expect(missingProducer.response.status).toBe(503);
+    expect(missingProducer.body).toEqual({ status: "degraded" });
+
+    getGlobalBoss.mockReturnValue({});
+    const ready = await health();
+    expect(ready.response.status).toBe(200);
+    expect(ready.body).toEqual({ status: "ok" });
+  });
+});

src/app/api/health/route.ts

@@ -1,5 +1,7 @@
 import { prisma } from "@/lib/db";
 import { getWorkerStatus } from "@/lib/jobs/worker-status";
+import { getGlobalBoss } from "@/lib/jobs/boss-instance";
+import { shouldRunWeb, shouldRunWorker } from "@/lib/process-type";
 import { getSession } from "@/lib/auth/session";
 import { NextResponse } from "next/server";
 import { apiHandler } from "@/lib/api-handler";
@@ -19,7 +21,13 @@ export const GET = apiHandler(async () => {
   }
 
   const worker = getWorkerStatus();
-  const status = dbOk && worker.running ? "ok" : "degraded";
+  const producerReady = getGlobalBoss() !== null;
+  const status =
+    dbOk &&
+    (!shouldRunWeb() || producerReady) &&
+    (!shouldRunWorker() || worker.running)
+      ? "ok"
+      : "degraded";
   const statusCode = status === "ok" ? 200 : 503;
 
   const cacheHeaders = {