robustness

orchestrator/src/client/components/ReadyPanel.tsx

@@ -215,8 +215,8 @@ export const ReadyPanel: React.FC<ReadyPanelProps> = ({
       setIsRegenerating(true);
       await api.generateJobPdf(job.id);
       toast.success("PDF regenerated");
-      setMode("ready");
       await onJobUpdated();
+      setMode("ready");
     } catch (error) {
       const message = error instanceof Error ? error.message : "Failed to regenerate PDF";
       toast.error(message);
@@ -282,7 +282,7 @@ export const ReadyPanel: React.FC<ReadyPanelProps> = ({
           <Button asChild variant="outline" className="h-9 w-full gap-1 px-2 text-xs">
             <a
               href={pdfHref}
-              download={`${personName.replace(/\s+/g, '_')}_${safeFilenamePart(job.employer)}.pdf`}
+              download={`${safeFilenamePart(personName)}_${safeFilenamePart(job.employer)}.pdf`}
             >
               <Download className="h-3.5 w-3.5 shrink-0" />
               <span className="truncate">Download PDF</span>

orchestrator/src/server/api/routes/manual-jobs.ts

@@ -4,7 +4,7 @@ import { z } from 'zod';
 import * as jobsRepo from '../../repositories/jobs.js';
 import { inferManualJobDetails } from '../../services/manualJob.js';
 import { scoreJobSuitability } from '../../services/scorer.js';
-import { loadResumeProfile } from '../../services/resumeProjects.js';
+import { getProfile } from '../../services/profile.js';
 import type { ApiResponse, ManualJobInferenceResponse } from '../../../shared/types.js';
 
 export const manualJobsRouter = Router();
@@ -98,7 +98,7 @@ manualJobsRouter.post('/import', async (req: Request, res: Response) => {
     // Score asynchronously so the import returns immediately.
     (async () => {
       try {
-        const rawProfile = await loadResumeProfile();
+        const rawProfile = await getProfile();
         if (!rawProfile || typeof rawProfile !== 'object' || Array.isArray(rawProfile)) {
           throw new Error('Invalid resume profile format');
         }

orchestrator/src/server/api/routes/profile.ts

@@ -1,5 +1,6 @@
 import { Router, Request, Response } from 'express';
-import { extractProjectsFromProfile, loadResumeProfile } from '../../services/resumeProjects.js';
+import { extractProjectsFromProfile } from '../../services/resumeProjects.js';
+import { getProfile } from '../../services/profile.js';
 
 export const profileRouter = Router();
 
@@ -8,7 +9,7 @@ export const profileRouter = Router();
  */
 profileRouter.get('/projects', async (req: Request, res: Response) => {
   try {
-    const profile = await loadResumeProfile();
+    const profile = await getProfile();
     const { catalog } = extractProjectsFromProfile(profile);
     res.json({ success: true, data: catalog });
   } catch (error) {
@@ -22,7 +23,7 @@ profileRouter.get('/projects', async (req: Request, res: Response) => {
  */
 profileRouter.get('/', async (req: Request, res: Response) => {
   try {
-    const profile = await loadResumeProfile();
+    const profile = await getProfile();
     res.json({ success: true, data: profile });
   } catch (error) {
     const message = error instanceof Error ? error.message : 'Unknown error';

orchestrator/src/server/api/routes/settings.ts

@@ -3,10 +3,10 @@ import { z } from 'zod';
 import * as settingsRepo from '../../repositories/settings.js';
 import {
   extractProjectsFromProfile,
-  loadResumeProfile,
   normalizeResumeProjectsSettings,
   resolveResumeProjectsSettings,
 } from '../../services/resumeProjects.js';
+import { getProfile } from '../../services/profile.js';
 
 export const settingsRouter = Router();
 
@@ -37,7 +37,7 @@ settingsRouter.get('/', async (_req: Request, res: Response) => {
     const defaultJobCompleteWebhookUrl = process.env.JOB_COMPLETE_WEBHOOK_URL || '';
     const jobCompleteWebhookUrl = overrideJobCompleteWebhookUrl || defaultJobCompleteWebhookUrl;
 
-    const profile = await loadResumeProfile();
+    const profile = await getProfile();
     const { catalog } = extractProjectsFromProfile(profile);
     const overrideResumeProjectsRaw = await settingsRepo.getSetting('resumeProjects');
     const resumeProjectsData = resolveResumeProjectsSettings({ catalog, overrideRaw: overrideResumeProjectsRaw });
@@ -216,7 +216,7 @@ settingsRouter.patch('/', async (req: Request, res: Response) => {
       if (resumeProjects === null) {
         await settingsRepo.setSetting('resumeProjects', null);
       } else {
-        const rawProfile = await loadResumeProfile();
+        const rawProfile = await getProfile();
 
         if (rawProfile === null || typeof rawProfile !== 'object' || Array.isArray(rawProfile)) {
           throw new Error('Invalid resume profile format: expected a non-null object');
@@ -301,7 +301,7 @@ settingsRouter.patch('/', async (req: Request, res: Response) => {
     const defaultJobCompleteWebhookUrl = process.env.JOB_COMPLETE_WEBHOOK_URL || '';
     const jobCompleteWebhookUrl = overrideJobCompleteWebhookUrl || defaultJobCompleteWebhookUrl;
 
-    const profile = await loadResumeProfile();
+    const profile = await getProfile();
     const { catalog } = extractProjectsFromProfile(profile);
     const overrideResumeProjectsRaw = await settingsRepo.getSetting('resumeProjects');
     const resumeProjectsData = resolveResumeProjectsSettings({ catalog, overrideRaw: overrideResumeProjectsRaw });

orchestrator/src/server/services/openrouter.ts

@@ -87,7 +87,12 @@ export async function callOpenRouter<T>(
             });
 
             if (!response.ok) {
-                throw new Error(`OpenRouter API error: ${response.status}`);
+                // Throw error with status to allow specific retries
+                const errorBody = await response.text().catch(() => 'No error body');
+                const err = new Error(`OpenRouter API error: ${response.status}`);
+                (err as any).status = response.status;
+                (err as any).body = errorBody;
+                throw err;
             }
 
             const data = await response.json();
@@ -104,10 +109,22 @@ export async function callOpenRouter<T>(
 
         } catch (error) {
             const message = error instanceof Error ? error.message : String(error);
+            const status = (error as any).status;
 
-            // Only retry on parsing errors
+            // Retry on:
-            if (attempt < maxRetries && message.includes('parse')) {
+            // 1. Parsing errors (AI returned malformed JSON)
-                console.warn(`⚠️ [${jobId ?? 'unknown'}] Attempt ${attempt + 1} failed: ${message}`);
+            // 2. Rate limits (429)
+            // 3. Server errors (5xx)
+            // 4. Timeouts/Network issues
+            const shouldRetry = 
+                message.includes('parse') || 
+                status === 429 || 
+                (status >= 500 && status <= 599) ||
+                message.toLowerCase().includes('timeout') ||
+                message.toLowerCase().includes('fetch failed');
+
+            if (attempt < maxRetries && shouldRetry) {
+                console.warn(`⚠️ [${jobId ?? 'unknown'}] Attempt ${attempt + 1} failed (${status ?? 'no-status'}): ${message}. Retrying...`);
                 continue;
             }
 
@@ -129,9 +146,12 @@ export function parseJsonContent<T>(content: string, jobId?: string): T {
     candidate = candidate.replace(/```(?:json|JSON)?\s*/g, '').replace(/```/g, '').trim();
 
     // Try to extract JSON object if there's surrounding text
-    const jsonMatch = candidate.match(/\{[\s\S]*\}/);
+    // Use non-greedy match and find the outermost braces
-    if (jsonMatch) {
+    const firstBrace = candidate.indexOf('{');
-        candidate = jsonMatch[0];
+    const lastBrace = candidate.lastIndexOf('}');
+    
+    if (firstBrace !== -1 && lastBrace !== -1 && lastBrace > firstBrace) {
+        candidate = candidate.substring(firstBrace, lastBrace + 1);
     }
 
     try {

orchestrator/src/server/services/pdf.ts

@@ -69,7 +69,7 @@ export async function generatePdf(
     if (baseResume.sections?.skills?.items && Array.isArray(baseResume.sections.skills.items)) {
       baseResume.sections.skills.items = baseResume.sections.skills.items.map((skill: any, index: number) => ({
         ...skill,
-        id: skill.id || `skill-${Date.now()}-${index}`,
+        id: skill.id || `skill-${index}`,
         visible: skill.visible ?? true,
         // Zod schema requires string, default to empty string if missing
         description: skill.description ?? '',
@@ -112,7 +112,7 @@ export async function generatePdf(
           const existing = existingSkills.find((s: any) => s.name === newSkill.name);
 
           return {
-            id: newSkill.id || existing?.id || `skill-${Date.now()}-${index}`,
+            id: newSkill.id || existing?.id || `skill-${index}`,
             visible: newSkill.visible !== undefined ? newSkill.visible : (existing?.visible ?? true),
             name: newSkill.name || existing?.name || '',
             description: newSkill.description !== undefined ? newSkill.description : (existing?.description || ''),

orchestrator/src/server/services/profile.ts

@@ -3,7 +3,7 @@ import { join, dirname } from 'path';
 import { fileURLToPath } from 'url';
 
 const __dirname = dirname(fileURLToPath(import.meta.url));
-const DEFAULT_PROFILE_PATH = process.env.RESUME_PROFILE_PATH || join(__dirname, '../../../../resume-generator/base.json');
+export const DEFAULT_PROFILE_PATH = process.env.RESUME_PROFILE_PATH || join(__dirname, '../../../../resume-generator/base.json');
 
 let cachedProfile: any = null;
 let cachedProfilePath: string | null = null;

orchestrator/src/server/services/resumeProjects.ts

@@ -4,23 +4,12 @@ import { fileURLToPath } from 'url';
 
 import type { ResumeProjectCatalogItem, ResumeProjectsSettings } from '../../shared/types.js';
 
-import { getProfile } from './profile.js';
+import { getProfile, DEFAULT_PROFILE_PATH } from './profile.js';
 
 const __dirname = dirname(fileURLToPath(import.meta.url));
 
-export const DEFAULT_RESUME_PROFILE_PATH =
-  process.env.RESUME_PROFILE_PATH || join(__dirname, '../../../../resume-generator/base.json');
-
 type ResumeProjectSelectionItem = ResumeProjectCatalogItem & { summaryText: string };
 
-export async function loadResumeProfile(profilePath: string = DEFAULT_RESUME_PROFILE_PATH): Promise<unknown> {
-  if (profilePath === DEFAULT_RESUME_PROFILE_PATH) {
-    return getProfile(profilePath);
-  }
-  const content = await readFile(profilePath, 'utf-8');
-  return JSON.parse(content) as unknown;
-}
-
 export function extractProjectsFromProfile(profile: unknown): {
   catalog: ResumeProjectCatalogItem[];
   selectionItems: ResumeProjectSelectionItem[];