fix(sync): harden incremental observability and periodic reconciliation

User rows have a FK constraint to CwMember (User_cwMemberId_fkey). Syncing
Users first caused all 140 User upserts to fail since the CwMember table was
empty. This cascade failure then caused all Opportunity upserts to fail because
Opportunity.primarySalesRepId is FK-constrained to User.cwIdentifier.

Fix: reorder steps so CW Members syncs first, then Users.

.github/workflows/deploy.yaml

@@ -231,9 +231,10 @@ jobs:
         run: bun install --frozen-lockfile
 
       - name: Rebuild native modules
-        run: npm rebuild
+        run: npm rebuild --ignore-scripts
         env:
           HUSKY: "0"
+          HUSKY_SKIP_INSTALL: "1"
 
       - name: Build macOS distributables
         run: bun run make:macos
@@ -272,9 +273,10 @@ jobs:
         run: bun install --frozen-lockfile
 
       - name: Rebuild native modules
-        run: npm rebuild
+        run: npm rebuild --ignore-scripts
         env:
           HUSKY: "0"
+          HUSKY_SKIP_INSTALL: "1"
 
       - name: Build Windows distributables
         run: bun run make -- --platform win32

api/Dockerfile

@@ -90,6 +90,9 @@ COPY --from=build /app/dalpuri/generated/ ./dalpuri/generated/
 # Copy production node_modules (Prisma adapter needs native bindings)
 COPY --from=deps /app/node_modules/ ./node_modules/
 
+# Ensure pdfmake Roboto fonts are present at runtime for PDF generation.
+COPY --from=build /app/api/node_modules/pdfmake/build/fonts/ ./node_modules/pdfmake/build/fonts/
+
 ENV NODE_ENV=production
 
 # ---- Stage 4: API server runtime image ----

api/kubernetes/worker-deployment.yaml

@@ -20,6 +20,11 @@ spec:
           env:
             - name: MANAGER_SOCKET_URL
               value: "http://optima-api.optima.svc.cluster.local:8671"
+            - name: API_DATABASE_URL
+              valueFrom:
+                secretKeyRef:
+                  name: api-env-secret
+                  key: DATABASE_URL
           envFrom:
             - secretRef:
                 name: api-env-secret

api/src/modules/pdf-utils/generateQuote.ts

@@ -1,5 +1,5 @@
 import PdfPrinter from "pdfmake/src/Printer";
-import { readFileSync } from "node:fs";
+import { existsSync, readFileSync } from "node:fs";
 import { join } from "node:path";
 
 export interface QuoteLineItem {
@@ -110,7 +110,26 @@ const COMPANY = {
 
 const DEFAULT_LOGO_PATH = join(process.cwd(), "logo.png");
 
-const fontDir = join(process.cwd(), "node_modules/pdfmake/build/fonts/Roboto");
+function resolveRobotoFontDir(): string {
+  const candidates = [
+    join(process.cwd(), "node_modules/pdfmake/build/fonts/Roboto"),
+    join(import.meta.dir, "../../../node_modules/pdfmake/build/fonts/Roboto"),
+    join("/app/node_modules/pdfmake/build/fonts/Roboto"),
+    join("/app/api/node_modules/pdfmake/build/fonts/Roboto"),
+  ];
+
+  for (const dir of candidates) {
+    if (existsSync(join(dir, "Roboto-Medium.ttf"))) {
+      return dir;
+    }
+  }
+
+  throw new Error(
+    `[pdf] Could not locate pdfmake Roboto fonts. Checked: ${candidates.join(", ")}`
+  );
+}
+
+const fontDir = resolveRobotoFontDir();
 const fonts = {
   Roboto: {
     normal: join(fontDir, "Roboto-Regular.ttf"),

api/src/modules/workers/coms.ts

@@ -1,6 +1,7 @@
 import { Server } from "socket.io";
 import { events, EventTypes } from "../globalEvents";
 import { WorkerQueue } from "./queues";
+import { reserveWorkerId } from "../../workert";
 
 function emitGlobalEvent<K extends keyof EventTypes>(
   name: K,

api/src/modules/workers/dalpuri-sync.ts

@@ -1,5 +1,6 @@
 import { Socket } from "socket.io-client";
 import { executeFullDalpuriSync, executeForcedIncrementalDalpuriSync } from "dalpuri";
+import { prisma } from "../../constants";
 
 /**
  * Execute a full sync from Dalpuri (ConnectWise) to the API database.
@@ -14,5 +15,53 @@ export async function executeFullSync(_workerSocket: Socket): Promise<void> {
  * Called every 5 seconds via PgBoss from the API process interval.
  */
 export async function executeIncrementalSync(): Promise<void> {
-  return executeForcedIncrementalDalpuriSync();
+  let jobRunId: string | undefined;
+
+  try {
+    const run = await prisma.syncJobRun.create({
+      data: {
+        jobType: "INCREMENTAL_SYNC",
+        status: "RUNNING",
+        triggeredBy: "worker",
+        startedAt: new Date(),
+      },
+      select: { id: true },
+    });
+    jobRunId = run.id;
+  } catch (err) {
+    // Sync should still run even if tracking insert fails.
+    console.error("[sync] Failed to create incremental SyncJobRun", err);
+  }
+
+  try {
+    await executeForcedIncrementalDalpuriSync({ jobRunId });
+
+    if (jobRunId) {
+      await prisma.syncJobRun.update({
+        where: { id: jobRunId },
+        data: {
+          status: "COMPLETED",
+          completedAt: new Date(),
+        },
+      });
+    }
+  } catch (err) {
+    if (jobRunId) {
+      const errorSummary = err instanceof Error ? err.message : String(err);
+      await prisma.syncJobRun
+        .update({
+          where: { id: jobRunId },
+          data: {
+            status: "FAILED",
+            completedAt: new Date(),
+            errorSummary: errorSummary.slice(0, 2000),
+          },
+        })
+        .catch(() => {
+          // Best-effort update only.
+        });
+    }
+
+    throw err;
+  }
 }

api/src/modules/workers/incremental-sync.ts

@@ -6,5 +6,17 @@ import { WorkerQueue } from "./queues";
  * Called on an interval from the main API process so it survives worker restarts.
  */
 export async function enqueueIncrementalSync(): Promise<void> {
-  await getBoss().send(WorkerQueue.DALPURI_INCREMENTAL_SYNC, {});
+  const jobId = await getBoss().send(
+    WorkerQueue.DALPURI_INCREMENTAL_SYNC,
+    {
+      enqueuedAt: new Date().toISOString(),
+    },
+    {
+      singletonKey: "dalpuri-incremental-sync",
+    }
+  );
+
+  if (!jobId) {
+    console.debug("[interval] DALPURI_INCREMENTAL_SYNC already pending or active");
+  }
 }

api/src/modules/workers/jobFactory.ts

@@ -32,6 +32,8 @@ export async function createWorkerJob<T>(
   queueType: WorkerQueue,
   workFn: (workerSocket: Socket) => Promise<T>,
 ): Promise<T> {
+  const managerUrl = process.env.MANAGER_SOCKET_URL ?? "http://localhost:8671";
+
   return new Promise((resolve, reject) => {
     // Request a worker ID and namespace from the manager
     socket.emit(
@@ -53,7 +55,7 @@ export async function createWorkerJob<T>(
         }
 
         // Connect to the worker-specific namespace
-        const workerSocket = io(`http://localhost:8671/worker-${workerId}`, {
+        const workerSocket = io(`${managerUrl}/worker-${workerId}`, {
           reconnection: false,
         });
 

api/src/workert.ts

@@ -163,6 +163,7 @@ if (import.meta.main) {
   // Register job handler for DALPURI_FULL_SYNC
   const { enqueueDalpuriFullSync } = await import("./modules/workers/sync-manager");
   const { executeIncrementalSync } = await import("./modules/workers/dalpuri-sync");
+  const { enqueueIncrementalSync } = await import("./modules/workers/incremental-sync");
   await boss.work(WorkerQueue.DALPURI_FULL_SYNC, async () => {
     const socket = await ensureManagerSocketReady();
     await enqueueDalpuriFullSync(socket);
@@ -170,10 +171,37 @@ if (import.meta.main) {
   console.log("[worker] Registered DALPURI_FULL_SYNC job handler");
 
   await boss.work(WorkerQueue.DALPURI_INCREMENTAL_SYNC, async () => {
-    await executeIncrementalSync();
+    const startedAt = Date.now();
+    console.log("[worker] DALPURI_INCREMENTAL_SYNC started");
+    try {
+      await executeIncrementalSync();
+      console.log(
+        `[worker] DALPURI_INCREMENTAL_SYNC completed in ${Date.now() - startedAt}ms`
+      );
+    } catch (err) {
+      console.error(
+        `[worker] DALPURI_INCREMENTAL_SYNC failed in ${Date.now() - startedAt}ms`,
+        err
+      );
+      throw err;
+    }
   });
   console.log("[worker] Registered DALPURI_INCREMENTAL_SYNC job handler");
 
+  const enqueueIncrementalWithLogging = () => {
+    enqueueIncrementalSync().catch((err) => {
+      console.error(
+        `[worker] interval enqueueIncrementalSync failed: ${err?.message ?? err}`
+      );
+    });
+  };
+
+  // Keep a worker-local 5s scheduler so incremental sync continues even when
+  // API interval scheduling is unavailable.
+  enqueueIncrementalWithLogging();
+  setInterval(enqueueIncrementalWithLogging, 5_000);
+  console.log("[worker] Started 5-second incremental enqueue interval");
+
   // Register job handler for REFRESH_SALES_METRICS
   const { executeSalesMetricsRefresh } = await import("./modules/workers/sales-metrics");
   await boss.work(WorkerQueue.REFRESH_SALES_METRICS, async (jobs) => {

dalpuri/src/sync.ts

@@ -75,6 +75,43 @@ type DeleteResult = {
 
 let incrementalDeleteStepIndex = 0;
 
+const CRITICAL_INCREMENTAL_RECONCILE_TABLES = new Set([
+  "Companies",
+  "Company Addresses",
+  "Contacts",
+]);
+
+const criticalFullSyncIntervalMinutes = Math.max(
+  1,
+  Number.parseInt(
+    process.env.DALPURI_CRITICAL_FULL_SYNC_INTERVAL_MINUTES ?? "60",
+    10
+  ) || 60
+);
+
+const CRITICAL_FULL_SYNC_INTERVAL_MS =
+  criticalFullSyncIntervalMinutes * 60 * 1000;
+
+const lastCriticalFullSyncByStep = new Map<string, number>();
+
+const shouldForceCriticalFullSync = (
+  step: Step,
+  forceIncremental: boolean
+): boolean => {
+  if (!forceIncremental) return false;
+  if (!CRITICAL_INCREMENTAL_RECONCILE_TABLES.has(step.name)) return false;
+
+  const now = Date.now();
+  const last = lastCriticalFullSyncByStep.get(step.name) ?? 0;
+
+  if (now - last < CRITICAL_FULL_SYNC_INTERVAL_MS) {
+    return false;
+  }
+
+  lastCriticalFullSyncByStep.set(step.name, now);
+  return true;
+};
+
 const parseEnvFile = (path: string): Record<string, string> => {
   const envData = readFileSync(path, "utf8");
   const out: Record<string, string> = {};
@@ -107,6 +144,20 @@ const resolveApiDatabaseUrl = (): string => {
   if (process.env.OPTIMA_API_DATABASE_URL)
     return process.env.OPTIMA_API_DATABASE_URL;
 
+  // Worker/runtime fallback:
+  // In Kubernetes we often provide CW via CW_DATABASE_URL and API Postgres via
+  // DATABASE_URL. Only use DATABASE_URL as API when we can safely infer that.
+  if (process.env.CW_DATABASE_URL && process.env.DATABASE_URL) {
+    return process.env.DATABASE_URL;
+  }
+
+  if (
+    process.env.DATABASE_URL &&
+    /^(postgres|postgresql):\/\//i.test(process.env.DATABASE_URL)
+  ) {
+    return process.env.DATABASE_URL;
+  }
+
   const candidates = [
     resolve(import.meta.dir, "../../api/.env"),
     resolve(process.cwd(), "../api/.env"),
@@ -1351,6 +1402,15 @@ export const executeFullDalpuriSync = async (options?: {
   const isTimedOut = () => Date.now() - syncStartTime > timeoutMs;
 
   const steps: Step[] = [
+    {
+      name: "CW Members",
+      sourceModel: "member",
+      targetModel: "cwMember",
+      translation: cwMemberTranslation as unknown as AnyTranslation,
+      uniqueField: "cwMemberId",
+      sourceIdField: "memberRecId",
+      sourceUpdatedField: "lastUpdatedUtc",
+    },
     {
       name: "Users",
       sourceModel: "member",
@@ -1365,15 +1425,6 @@ export const executeFullDalpuriSync = async (options?: {
         },
       },
     },
-    {
-      name: "CW Members",
-      sourceModel: "member",
-      targetModel: "cwMember",
-      translation: cwMemberTranslation as unknown as AnyTranslation,
-      uniqueField: "cwMemberId",
-      sourceIdField: "memberRecId",
-      sourceUpdatedField: "lastUpdatedUtc",
-    },
     {
       name: "Companies",
       sourceModel: "company",
@@ -1757,19 +1808,35 @@ export const executeFullDalpuriSync = async (options?: {
         step,
         forceIncremental
       );
+      const forceCriticalFullSync = shouldForceCriticalFullSync(
+        step,
+        forceIncremental
+      );
+      const effectiveDecision = forceCriticalFullSync
+        ? ({ mode: "full", differences: decision.differences } as SmartSyncDecision)
+        : decision;
+
+      if (forceCriticalFullSync) {
+        console.log(
+          `  [smart-sync][forced-full] ${step.name}: forcing periodic full reconciliation every ${criticalFullSyncIntervalMinutes}m`
+        );
+      }
+
       const sourceIdsFilter =
-        decision.mode === "incremental" ? decision.sourceIds : undefined;
+        effectiveDecision.mode === "incremental"
+          ? effectiveDecision.sourceIds
+          : undefined;
       console.log(
         `  [smart-sync]${forceIncremental ? "[forced]" : ""} mode=${
-          decision.mode
+          effectiveDecision.mode
         }${
-          decision.mode === "incremental"
+          effectiveDecision.mode === "incremental"
-            ? ` (${decision.sourceIds.length} ids)`
+            ? ` (${effectiveDecision.sourceIds.length} ids)`
             : ""
         }`
       );
       if (logAllDifferences) {
-        logAllSmartSyncDifferences(step, decision.differences);
+        logAllSmartSyncDifferences(step, effectiveDecision.differences);
       }
       const result = await syncStep(
         cwPrisma,
@@ -1791,7 +1858,7 @@ export const executeFullDalpuriSync = async (options?: {
 
       await writeStepLog(
         step.name,
-        decision.mode,
+        effectiveDecision.mode,
         result,
         { deleted: 0, failed: 0 },
         Date.now() - stepStart