Stop the resume melt-down on leaked broker agent names

packages/factory-sdk/src/orchestrator/factory.test.ts

@@ -204,6 +204,21 @@ class SpawnFailingFleetClient extends FakeFleetClient {
   }
 }
 
+// Mimics the broker rejecting a resume because it never released the agent's
+// name on exit (relay#1116-family): http 500 "agent '<name>' already exists".
+class ResumeNameCollisionFleetClient extends FakeFleetClient {
+  override async resume(input: Parameters<FakeFleetClient['resume']>[0]): Promise<SpawnResult> {
+    this.resumes.push(input)
+    const name = input.name ?? input.sessionRef
+    throw Object.assign(new Error(`agent '${name}' already exists`), {
+      code: 'http_500',
+      status: 500,
+      retryable: true,
+      data: { error: `agent '${name}' already exists`, name, success: false },
+    })
+  }
+}
+
 class ManualClock {
   value = 0
 
@@ -3092,6 +3107,25 @@ describe('FactoryLoop', () => {
     expect(factory.status().inFlight).toEqual([])
   })
 
+  it('does not loop when resume hits a leaked broker name ("already exists")', async () => {
+    const mount = new FakeMountClient({ [issuePath(80)]: issueFile(80) })
+    const fleet = new ResumeNameCollisionFleetClient()
+    fleet.setSessionRef('ar-80-review', 'session-review-80')
+    const factory = createFactory(config(), { mount, fleet, triage: new StaticTriage() })
+    const decision = await factory.triageIssue(parseLinearIssue(issuePath(80), issueFile(80)))
+
+    await factory.dispatch(decision)
+    fleet.emitAgentExit('ar-80-review', 'crash')
+    await flush()
+    // A second exit event must NOT trigger another resume attempt.
+    fleet.emitAgentExit('ar-80-review', 'crash')
+    await flush()
+
+    expect(fleet.resumes).toHaveLength(1) // resumed once, collided, then short-circuited
+    expect(factory.status().counters.resumeNameCollisions).toBe(1)
+    expect(factory.status().counters.errors ?? 0).toBe(0) // not surfaced as a hard error
+  })
+
   it('does not complete on an implementer exit when only a draft PR exists', async () => {
     const issue = realIssueFile(256, ready, { title: 'Real implementer draft PR exit' })
     const mount = new FakeMountClient({ [issuePath(256)]: issue })

packages/factory-sdk/src/orchestrator/factory.ts

@@ -1603,6 +1603,24 @@ export class FactoryLoop implements Factory {
         try {
           await resume
           this.#resumedExitKeys.add(resumeKey)
+        } catch (error) {
+          if (isAgentAlreadyExistsError(error)) {
+            // The broker never released this agent's name on exit
+            // (relay#1116-family), so re-registering collides with the stuck
+            // name. The error is marked retryable but isn't — retrying just
+            // re-collides forever. Treat it as terminal for this name: record
+            // the resume key so subsequent exit events short-circuit, count it,
+            // and warn once instead of spamming a 500 stack trace. The external
+            // reaper / a broker restart reclaims the leaked name.
+            this.#resumedExitKeys.add(resumeKey)
+            this.#increment('resumeNameCollisions')
+            this.#logger.warn?.('[factory] resume skipped: broker still holds agent name (relay#1116); not retrying', {
+              issue: record.issue.key,
+              name,
+            })
+          } else {
+            throw error
+          }
         } finally {
           this.#resumeInFlight.delete(resumeKey)
         }
@@ -2912,6 +2930,17 @@ const labelName = (value: unknown): string | undefined => {
 const isCompletionReason = (reason?: string): boolean =>
   reason === 'issue-done' || reason === 'done' || reason === 'completed'
 
+// The broker rejects re-registering a name it never released on exit
+// (relay#1116-family) with a 500 "agent '<name>' already exists". Detect it from
+// the structured payload or the message so resume can treat it as terminal
+// rather than retrying the (falsely) "retryable" error forever.
+const isAgentAlreadyExistsError = (error: unknown): boolean => {
+  const record = asRecord(error)
+  const data = asRecord(record?.data)
+  const message = stringValue(data?.error) ?? (error instanceof Error ? error.message : '')
+  return /already exists/iu.test(message)
+}
+
 const defaultRestartPolicy = (spec: AgentSpec): AgentSpec['restartPolicy'] | undefined =>
   spec.role === 'implementer' ? { maxRestarts: 3, strategy: 'resume' } as AgentSpec['restartPolicy'] : spec.restartPolicy