[KDM-TEST-FIX-417] Fix multi-agent council timeouts and fallback

src/__tests__/analyze-dashboard-events.test.tsx

@@ -185,7 +185,7 @@ describe('Phase 13: Live NDJSON Streaming UI Components', () => {
       ({ role, name, status, message, expectedIcon, expectedRoleIcon }) => {
         const { unmount } = render(
           <AgentCard role={role} name={name} status={status} message={message} />,
-          { stdout: mockStdout as any }
+          { stdout: mockStdout as any, interactive: true }
         );
 
         const output = mockStdout.frames.join('\n');
@@ -202,6 +202,7 @@ describe('Phase 13: Live NDJSON Streaming UI Components', () => {
     it('returns null when no active tool is executing', () => {
       const { unmount } = render(<ActiveToolPanel tool={null} />, {
         stdout: mockStdout as any,
+        interactive: false,
       });
 
       const output = mockStdout.frames.join('\n');
@@ -212,6 +213,7 @@ describe('Phase 13: Live NDJSON Streaming UI Components', () => {
     it('displays idle message when showIdle is enabled and tool is null', () => {
       const { unmount } = render(<ActiveToolPanel tool={null} showIdle={true} />, {
         stdout: mockStdout as any,
+        interactive: true,
       });
 
       const output = mockStdout.frames.join('\n');
@@ -230,7 +232,7 @@ describe('Phase 13: Live NDJSON Streaming UI Components', () => {
             status: 'running',
           }}
         />,
-        { stdout: mockStdout as any }
+        { stdout: mockStdout as any, interactive: true }
       );
 
       const output = mockStdout.frames.join('\n');
@@ -252,7 +254,7 @@ describe('Phase 13: Live NDJSON Streaming UI Components', () => {
             status: 'completed',
           }}
         />,
-        { stdout: mockStdout as any }
+        { stdout: mockStdout as any, interactive: true }
       );
 
       const output = mockStdout.frames.join('\n');
@@ -268,7 +270,7 @@ describe('Phase 13: Live NDJSON Streaming UI Components', () => {
     it('renders structured consensus with root cause, confidence badge, findings, and fix command', () => {
       const { unmount } = render(
         <ConsensusDiagnosisView consensus={mockConsensus} />,
-        { stdout: mockStdout as any }
+        { stdout: mockStdout as any, interactive: true }
       );
 
       const output = mockStdout.frames.join('\n');
@@ -290,7 +292,7 @@ describe('Phase 13: Live NDJSON Streaming UI Components', () => {
       const detailsText = 'Root Cause (HIGH confidence):\n  Node pressure\nRecommended Remediation:\n  Scale up node pool';
       const { unmount } = render(
         <ConsensusDiagnosisView details={detailsText} />,
-        { stdout: mockStdout as any }
+        { stdout: mockStdout as any, interactive: true }
       );
 
       const output = mockStdout.frames.join('\n');

src/__tests__/cli-flags.test.ts

@@ -4,6 +4,7 @@ import { runAnalysis } from '../analysis/analysis';
 import { registerAnalyzeCommand } from '../commands/analyze';
 import { registerConfigCommand } from '../commands/config';
 import * as pythonBridge from '../agent/python-bridge';
+import * as probesModule from '../analysis/probes';
 import { clearConfig, getConfig, setMultiAgentConfig } from '../config/store';
 import { logger } from '../utils/logger';
 import type { ConsensusDiagnosis } from '../agent/types';
@@ -77,6 +78,11 @@ describe('Phase 23 - Feature Flags, Rollout Modes & Legacy Fallback (Issue #294)
     delete process.env.KDM_MULTI_AGENT;
 
     vi.mocked(pythonBridge.runAgentCouncilProcess).mockResolvedValue(MOCK_CONSENSUS);
+    vi.spyOn(probesModule, 'checkCouncilDependencies').mockResolvedValue({
+      pythonAvailable: true,
+      ollamaAvailable: true,
+      canRunCouncil: true,
+    });
   });
 
   afterEach(() => {

src/__tests__/e2e-system.test.ts

@@ -291,6 +291,11 @@ describe('Phase 24: Final System Architecture Integration & E2E Validation', ()
       } as any);
 
       vi.spyOn(pythonBridge, 'runAgentCouncilProcess').mockResolvedValue(CANONICAL_CONSENSUS);
+      vi.spyOn(probesModule, 'checkCouncilDependencies').mockResolvedValue({
+        pythonAvailable: true,
+        ollamaAvailable: true,
+        canRunCouncil: true,
+      });
 
       const logSpy = vi.spyOn(console, 'log').mockImplementation(() => {});
 

src/__tests__/safety-prompt.test.ts

@@ -91,6 +91,7 @@ async function setupPromptHarness(
     {
       stdout: stdout as any,
       stdin: stdin as any,
+      interactive: true,
     }
   );
 
@@ -119,6 +120,7 @@ describe('SafetyPrompt Component & Interactive Safety Gate', () => {
       {
         stdout: mockStdout as any,
         stdin: mockStdin as any,
+        interactive: true,
       }
     );
 
@@ -152,6 +154,7 @@ describe('SafetyPrompt Component & Interactive Safety Gate', () => {
       {
         stdout: mockStdout as any,
         stdin: mockStdin as any,
+        interactive: true,
       }
     );
 
@@ -241,6 +244,7 @@ describe('SafetyPrompt Component & Interactive Safety Gate', () => {
     const promise = promptSafetyConfirmation(SAMPLE_PROPOSAL, {
       stdin: mockStdin as any,
       stdout: mockStdout as any,
+      interactive: true,
     });
 
     await waitForFrame(mockStdout, 'Apply this remediation to the cluster?');
@@ -254,6 +258,7 @@ describe('SafetyPrompt Component & Interactive Safety Gate', () => {
     const promise = promptSafetyConfirmation(SAMPLE_PROPOSAL, {
       stdin: mockStdin as any,
       stdout: mockStdout as any,
+      interactive: true,
     });
 
     await waitForFrame(mockStdout, 'Apply this remediation to the cluster?');

src/agent/python-bridge.ts

@@ -17,7 +17,7 @@ import { fileURLToPath } from 'node:url';
 import { parseNDJSONLine } from './event-schema';
 import type { ConsensusDiagnosis, AgentProgressEvent, NDJSONEvent } from './types';
 
-const DEFAULT_TIMEOUT_MS = 45_000;
+export const DEFAULT_TIMEOUT_MS = 120_000;
 const SIGKILL_GRACE_PERIOD_MS = 1_500;
 const DEFAULT_MODEL = 'llama3.1';
 const DEFAULT_BASE_URL = 'http://localhost:11434';
@@ -38,7 +38,7 @@ export interface CouncilBridgeOptions {
   model?: string;
   /** Base URL for Ollama API (default: 'http://localhost:11434'). */
   baseUrl?: string;
-  /** Maximum execution duration in milliseconds before watchdog triggers SIGTERM/SIGKILL (default: 45000). */
+  /** Maximum execution duration in milliseconds before watchdog triggers SIGTERM/SIGKILL. */
   timeoutMs?: number;
   /** Callback invoked on parsed NDJSON streaming events. */
   onEvent?: (event: NDJSONEvent) => void;
@@ -50,6 +50,16 @@ export interface CouncilBridgeOptions {
   spawnFn?: typeof spawn;
 }
 
+/** Resolves a valid per-call, environment, or default council timeout. */
+export function resolveCouncilTimeoutMs(timeoutMs?: number): number {
+  if (Number.isSafeInteger(timeoutMs) && timeoutMs! > 0) return timeoutMs!;
+
+  const fromEnvironment = Number(process.env.KDM_COUNCIL_TIMEOUT_MS);
+  if (Number.isSafeInteger(fromEnvironment) && fromEnvironment > 0) return fromEnvironment;
+
+  return DEFAULT_TIMEOUT_MS;
+}
+
 /**
  * Execution parameters for the Python agent council (backward-compatibility alias).
  */
@@ -368,7 +378,7 @@ export async function runAgentCouncilProcess(
 ): Promise<ConsensusDiagnosis> {
   const scriptPath = getCouncilScriptPath();
   const spawnImpl = options.spawnFn || spawn;
-  const timeoutMs = options.timeoutMs ?? DEFAULT_TIMEOUT_MS;
+  const timeoutMs = resolveCouncilTimeoutMs(options.timeoutMs);
 
   const payload = JSON.stringify({
     failureText: options.failureText,

src/analysis/__tests__/analysis-baseline.test.ts

@@ -12,7 +12,8 @@
 import { describe, it, expect, vi, beforeEach, afterEach } from 'vitest';
 import { runAnalysis, explainSingleResult, resolveBackend } from '../analysis';
 import { clearConfig, setAIConfig } from '../../config/store';
-import { isPythonAgentAvailable, runPythonAgentCouncil } from '../../agent/python-bridge';
+import { isPythonAgentAvailable, runAgentCouncilProcess, runPythonAgentCouncil } from '../../agent/python-bridge';
+import * as probesModule from '../probes';
 import {
   registry,
   PodAnalyzer,
@@ -83,6 +84,7 @@ vi.mock('../../ai/factory', () => ({
 }));
 
 vi.mock('../../agent/python-bridge', () => ({
+  runAgentCouncilProcess: vi.fn(),
   runPythonAgentCouncil: vi.fn(),
   isPythonAgentAvailable: vi.fn(async () => false),
 }));
@@ -108,6 +110,11 @@ let originalMultiAgentEnv: string | undefined;
 
 describe('Baseline Pipeline Regression Tests', () => {
   beforeEach(() => {
+    vi.spyOn(probesModule, 'checkCouncilDependencies').mockResolvedValue({
+      pythonAvailable: true,
+      ollamaAvailable: true,
+      canRunCouncil: true,
+    });
     clearConfig();
     registry.clear();
     registry.register(PodAnalyzer);
@@ -299,21 +306,31 @@ describe('Baseline Pipeline Regression Tests', () => {
 
     // Test 2: With env var flag set, pipeline still works (falls through to legacy)
     process.env.KDM_MULTI_AGENT = 'true';
-    mockGetCompletion.mockResolvedValue(OOM_KILLED_LLM_RESPONSE);
+    vi.mocked(runAgentCouncilProcess).mockResolvedValue({
+      confidence: 'high',
+      rootCause: 'council diagnosis',
+      bestSolution: { actionTitle: 'council fix', steps: [] },
+      findings: [],
+    } as any);
 
     const multiAgentResult = await runAnalysis({
       filters: ['Pod'],
       explain: true,
       backend: 'openai',
       noCache: true,
     });
-    // Should still produce valid results since multi-agent falls through to legacy
+    // Multi-agent mode uses council output instead of the legacy single-prompt response.
     expect(multiAgentResult.status).toBe('ProblemDetected');
-    expect(multiAgentResult.results[0].details).toBe(OOM_KILLED_LLM_RESPONSE);
+    expect(multiAgentResult.results[0].details).toContain('council diagnosis');
 
     // Test 3: With options.multiAgent flag set
     delete process.env.KDM_MULTI_AGENT;
-    mockGetCompletion.mockResolvedValue(OOM_KILLED_LLM_RESPONSE);
+    vi.mocked(runAgentCouncilProcess).mockResolvedValue({
+      confidence: 'high',
+      rootCause: 'council diagnosis',
+      bestSolution: { actionTitle: 'council fix', steps: [] },
+      findings: [],
+    } as any);
 
     const optionsFlagResult = await runAnalysis({
       filters: ['Pod'],
@@ -323,6 +340,6 @@ describe('Baseline Pipeline Regression Tests', () => {
       multiAgent: true,
     });
     expect(optionsFlagResult.status).toBe('ProblemDetected');
-    expect(optionsFlagResult.results[0].details).toBe(OOM_KILLED_LLM_RESPONSE);
+    expect(optionsFlagResult.results[0].details).toContain('council diagnosis');
   });
 });

src/analysis/analysis.ts

@@ -177,6 +177,7 @@ export interface ExplainSingleParams {
   noCache: boolean;
   customHeaders?: Record<string, string>;
   baseUrl?: string;
+  timeoutMs?: number;
   onAgentProgress?: (event: AgentProgressEvent) => void;
   onEvent?: (event: NDJSONEvent) => void;
 }
@@ -238,6 +239,7 @@ async function tryRunAgentCouncil(
       },
       model: params.model || model,
       baseUrl: params.baseUrl || baseUrl,
+      timeoutMs: params.timeoutMs,
       onProgress: params.onAgentProgress,
       onEvent: params.onEvent,
     });
@@ -451,6 +453,7 @@ async function explainResults(results: AnalyzerResult[], options: AnalysisOption
       shouldAnonymize,
       noCache,
       customHeaders: options.customHeaders,
+      timeoutMs: options.councilTimeoutMs,
     });
   }
 }
@@ -573,7 +576,7 @@ async function executeCouncilForResults(
   results: AnalyzerResult[],
   options: AnalysisOptions,
 ): Promise<void> {
-  const primaryResult = results[0];
+  const primaryResult = results.find((result) => result.errors.length > 0) || results[0];
   const failureText = results
     .flatMap((r) => r.errors.map((e) => e.text))
     .join('\n') || (options.targetResource ? `Workload ${options.targetResource} failure` : options.labelSelector ? `Workload matching selector ${options.labelSelector} failure` : 'Cluster workload failure');
@@ -588,37 +591,94 @@ async function executeCouncilForResults(
   };
 
   try {
+    const baseUrl = resolveOllamaBaseUrl();
+    const dependencies = await checkCouncilDependencies(baseUrl);
+    if (!dependencies.canRunCouncil) {
+      throw new Error(dependencies.degradationReason || 'Council dependencies are unavailable');
+    }
+
     const runner = runAgentCouncilProcess || runPythonAgentCouncil;
     const consensus = await runner({
       failureText,
       context: targetContext,
       model: options.model,
-      baseUrl: getAIConfig().providers.find((provider) => provider.name.toLowerCase() === 'ollama')?.baseUrl || resolveOllamaBaseUrl(),
+      baseUrl,
+      timeoutMs: options.councilTimeoutMs,
     });
 
-    if (consensus) {
-      if (primaryResult) {
-        (primaryResult as any).consensus = consensus;
-        primaryResult.details = formatConsensusExplanation(consensus);
-        primaryResult.fallbackStep = 'council';
-      } else {
-        results.push({
-          kind: targetContext.kind,
-          name: targetContext.name,
-          namespace: targetContext.namespace || 'default',
-          errors: [{ text: failureText }],
-          details: formatConsensusExplanation(consensus),
-          consensus,
-          fallbackStep: 'council',
-        } as any);
-      }
-      return;
+    if (primaryResult) {
+      (primaryResult as any).consensus = consensus;
+      primaryResult.details = formatConsensusExplanation(consensus);
+      primaryResult.fallbackStep = 'council';
+    } else {
+      results.push({
+        kind: targetContext.kind,
+        name: targetContext.name,
+        namespace: targetContext.namespace || 'default',
+        errors: [{ text: failureText }],
+        details: formatConsensusExplanation(consensus),
+        consensus,
+        fallbackStep: 'council',
+      } as any);
     }
   } catch (err) {
-    logger.warn(`Multi-agent council bridge failed: ${(err as Error).message}. Falling back to legacy pipeline.`);
+    const degradationReason = (err as Error).message;
+    logger.warn(`Multi-agent council bridge failed: ${degradationReason}. Falling back to diagnostics.`);
+    await applyCouncilFallbacks(results, options, degradationReason);
   }
+}
 
-  await explainResults(results, options);
+/** Fills result details through the rule, cloud, or raw-summary degradation ladder. */
+async function applyCouncilFallbacks(
+  results: AnalyzerResult[],
+  options: AnalysisOptions,
+  degradationReason: string,
+): Promise<void> {
+  const backend = resolveBackend(options);
+  for (const result of results) {
+    if (result.errors.length > 0) {
+      await applyCouncilFallbackForResult(result, options, backend, degradationReason);
+    }
+  }
+}
+
+function createCouncilFallbackContext(
+  result: AnalyzerResult,
+  options: AnalysisOptions,
+  backend: string,
+  degradationReason: string,
+): { context: FallbackContext; mapping: { original: string; placeholder: string }[] } {
+  const failureText = result.errors.map((error) => error.text).join('\n');
+  const { promptText, mapping } = preparePromptMapping(failureText, options.anonymize);
+  const prompt = buildPrompt({
+    failureText: promptText,
+    language: options.language ?? DEFAULT_LANGUAGE,
+    analyzerName: result.kind,
+  });
+  return {
+    context: {
+      result,
+      backend,
+      failureText: promptText,
+      prompt,
+      degradationReason,
+      customHeaders: options.customHeaders,
+    },
+    mapping,
+  };
+}
+
+async function applyCouncilFallbackForResult(
+  result: AnalyzerResult,
+  options: AnalysisOptions,
+  backend: string,
+  degradationReason: string,
+): Promise<void> {
+  const { context, mapping } = createCouncilFallbackContext(result, options, backend, degradationReason);
+  if (!applyRuleEngineFallback(context) && !(await applyLegacyAiFallback(context))) {
+    applyRawSummaryFallback(context);
+  }
+  result.details = applyAnonymization(result.details || '', mapping, options.anonymize);
 }
 
 /**