Unstick analysis running when the worker is dead.

A container rebuild left Emmaforo status=running with no process, so
PCB start kept 409. Heal on GET now matches placement/PCB: complete if
report.json exists, otherwise error.

backend/services/projects.py

@@ -308,46 +308,68 @@ def mark_stale_running(
 def heal_if_pipeline_finished(
     storage: StorageBackend, user_id: str, project_id: str,
 ) -> ProjectMeta | None:
-    """If meta says queued/running but events already ended with
-    ``pipeline_complete``, flip status to ``complete``.
+    """Unstick analysis ``queued``/``running`` when the worker is gone.
 
-    Covers zombies where the worker wrote the terminal event (and often
-    the report) then died before the meta transition — e.g. container
-    rebuild mid-shutdown. Returns updated meta, or ``None`` if no heal.
+    - Last event ``pipeline_complete`` → ``complete``
+    - Dead worker + ``report.json`` → ``complete``
+    - Dead worker otherwise → ``error`` (so PCB/placement can start)
     """
     meta = get_project(storage, user_id, project_id)
     if meta is None or meta.status not in (STATUS_RUNNING, STATUS_QUEUED):
         return None
 
-    events_prefix = f"{_project_prefix(user_id, project_id)}/events/"
+    prefix = _project_prefix(user_id, project_id)
+    events_prefix = f"{prefix}/events/"
+    last = None
     try:
-        keys = storage.list_prefix(events_prefix)
+        event_keys = sorted(
+            k for k in storage.list_prefix(events_prefix)
+            if k.endswith(".json") and "/events/" in k
+        )
+        if event_keys:
+            last = storage.read_json(event_keys[-1])
     except Exception:
-        return None
-    event_keys = sorted(
-        k for k in keys if k.endswith(".json") and "/events/" in k
-    )
-    if not event_keys:
-        return None
+        last = None
+
+    if (last or {}).get("event") == "pipeline_complete":
+        summary = (last.get("data") or {}).get("summary")
+        try:
+            return transition_status(
+                storage, user_id, project_id,
+                from_status={STATUS_RUNNING, STATUS_QUEUED},
+                to_status=STATUS_COMPLETE,
+                summary=summary if isinstance(summary, dict) else meta.summary,
+                cancel_requested=False,
+                pipeline_state=None,
+            )
+        except StatusConflict:
+            return None
+
+    from backend.services import job_runner
+
+    exec_name = meta.execution_name or f"local/projects/{project_id}"
     try:
-        last = storage.read_json(event_keys[-1])
+        state = job_runner.get_execution_state(exec_name)
     except Exception:
-        return None
-    if (last or {}).get("event") != "pipeline_complete":
+        state = "unknown"
+    if state in ("pending", "running"):
         return None
 
-    summary = (last.get("data") or {}).get("summary")
-    try:
-        return transition_status(
-            storage, user_id, project_id,
-            from_status={STATUS_RUNNING, STATUS_QUEUED},
-            to_status=STATUS_COMPLETE,
-            summary=summary if isinstance(summary, dict) else meta.summary,
-            cancel_requested=False,
-            pipeline_state=None,
-        )
-    except StatusConflict:
-        return None
+    if storage.exists(f"{prefix}/report.json"):
+        try:
+            return transition_status(
+                storage, user_id, project_id,
+                from_status={STATUS_RUNNING, STATUS_QUEUED},
+                to_status=STATUS_COMPLETE,
+                cancel_requested=False,
+                pipeline_state=None,
+            )
+        except StatusConflict:
+            return None
+    return mark_stale_running(
+        storage, user_id, project_id,
+        f"Analysis worker terminated ({state})",
+    )
 
 
 def heal_if_placement_stuck(

tests/test_pcb_review.py

@@ -170,7 +170,27 @@ def test_pcb_busy_helpers():
     assert draft.status in analysis
 
 
-def test_pcb_start_requires_board(tmp_path: Path):
+def test_heal_dead_analysis_worker_unblocks_pcb(tmp_path: Path, monkeypatch):
+    from backend.services import job_runner, projects as proj_svc
+    from backend.services.storage import LocalStorageBackend
+
+    storage = LocalStorageBackend(tmp_path)
+    meta = proj_svc.create_project(storage, "usr_jwt", "board")
+    proj_svc.update_project(
+        storage, "usr_jwt", meta.id,
+        status=STATUS_RUNNING,
+        has_pcb=True,
+        has_bom=True,
+        has_netlist=True,
+        pcb_status="draft",
+    )
+    monkeypatch.setattr(job_runner, "get_execution_state", lambda _n: "failed")
+    healed = proj_svc.heal_if_pipeline_finished(storage, "usr_jwt", meta.id)
+    assert healed is not None
+    assert healed.status == "error"
+    from backend.services.pcb_pipeline import analysis_busy
+
+    assert not analysis_busy(healed)
     from fastapi.testclient import TestClient
     from backend.main import app
     from backend.services.storage import LocalStorageBackend