Preserve overlay across macOS flaps and mpv playlist changes

- keep visible overlays alive during transient macOS tracker loss
- reuse the running mpv overlay path on playlist navigation
- update regression coverage and changelog fragments

backlog/tasks/task-323 - Fix-macOS-overlay-hiding-while-mpv-remains-active.md

@@ -0,0 +1,60 @@
+---
+id: TASK-323
+title: Fix macOS overlay hiding while mpv remains active
+status: Done
+assignee:
+  - '@codex'
+created_date: '2026-05-03 07:41'
+updated_date: '2026-05-03 07:48'
+labels:
+  - bug
+  - macos
+  - overlay
+dependencies: []
+references:
+  - src/core/services/overlay-visibility.ts
+  - src/window-trackers/macos-tracker.ts
+priority: high
+---
+
+## Description
+
+<!-- SECTION:DESCRIPTION:BEGIN -->
+macOS visible overlay can hide/reload during normal playback even while mpv, or the overlay over mpv, remains the active viewing surface. The fix should preserve overlay visibility and subtitle continuity during transient macOS focus/tracker flaps, while still hiding the overlay when the tracked mpv window is genuinely unavailable or another app is brought forward.
+<!-- SECTION:DESCRIPTION:END -->
+
+## Acceptance Criteria
+<!-- AC:BEGIN -->
+- [x] #1 When the macOS tracker has recent valid mpv geometry, transient focus/helper misses do not hide the visible overlay or force a reload.
+- [x] #2 The overlay still hides when the tracked mpv window is genuinely lost beyond the existing tracking grace behavior.
+- [x] #3 A regression test covers the macOS active-playback case where mpv/overlay focus is preserved despite a transient non-tracking state.
+- [x] #4 Relevant docs or task notes are updated if behavior or verification guidance changes.
+<!-- AC:END -->
+
+## Implementation Plan
+
+<!-- SECTION:PLAN:BEGIN -->
+1. Add a failing regression in `src/core/services/overlay-visibility.test.ts`: on macOS, after the overlay is visible/tracked, a transient tracker state with `isTracking() === false` but non-null `getGeometry()` keeps the overlay visible, updates bounds, and does not call `hide()` or loading OSD.
+2. Implement the minimal macOS preserve path in `src/core/services/overlay-visibility.ts`, mirroring the existing Windows transient non-minimized branch but without Windows z-order binding.
+3. Preserve existing startup/lost-window behavior: `windowTracker: null` and `isTracking() === false` with `getGeometry() === null` still hide and show the first loading OSD.
+4. Run focused tests for `src/core/services/overlay-visibility.test.ts`; then typecheck or the repo runtime verification lane if the focused patch passes.
+5. Update TASK-323 notes/acceptance criteria with verification results.
+<!-- SECTION:PLAN:END -->
+
+## Implementation Notes
+
+<!-- SECTION:NOTES:BEGIN -->
+Added a macOS overlay visibility regression for transient tracker loss with retained geometry. The test failed first because the old path marked tracker-not-ready and hid the overlay. Implemented a scoped preserve path in `src/core/services/overlay-visibility.ts`: macOS now keeps the visible overlay alive only when the tracker still has retained geometry; true loss with null geometry still hides and emits the existing loading OSD behavior. Added changelog fragment `changes/323-macos-overlay-tracker-flaps.md`.
+
+Verification: `bun test src/core/services/overlay-visibility.test.ts` passed after the fix; `bun test src/window-trackers/macos-tracker.test.ts src/core/services/overlay-visibility.test.ts` passed; `bun run typecheck` passed; `bun run test:env` passed; isolated `bun test src/core/services/subsync.test.ts` passed; `bun run build` passed; `bun run test:smoke:dist` passed; `bun run changelog:lint` passed. `bun run test:fast` failed twice in an unrelated broad-suite interaction where `src/renderer/handlers/keyboard.ts` tried to use missing `window.electronAPI` while `src/core/services/subsync.test.ts` was running, followed by Bun node:test nested-test cascade errors.
+<!-- SECTION:NOTES:END -->
+
+## Final Summary
+
+<!-- SECTION:FINAL_SUMMARY:BEGIN -->
+Fixed the macOS visible-overlay hide/reload path during normal playback by preserving the overlay when the tracker briefly reports non-tracking but still has retained mpv geometry. The overlay visibility service now treats that macOS state like a transient tracker flap: it keeps bounds/layer/order refreshed and leaves the overlay click-through instead of hiding or showing the loading OSD. True macOS loss remains unchanged: no tracker or null geometry still hides the overlay and uses the existing loading behavior.
+
+Added regression coverage in `src/core/services/overlay-visibility.test.ts` for the active-playback case and added changelog fragment `changes/323-macos-overlay-tracker-flaps.md`.
+
+Verification passed: focused overlay tests, macOS tracker + overlay tests, typecheck, `test:env`, isolated `subsync.test.ts`, build, dist smoke, and changelog lint. Full `test:fast` remains blocked by an unrelated broad-suite interaction where renderer keyboard state fires without `window.electronAPI` during `subsync.test.ts`, then Bun reports node:test cascade errors.
+<!-- SECTION:FINAL_SUMMARY:END -->

backlog/tasks/task-324 - Fix-mpv-playlist-changes-re-running-app-warmups.md

@@ -0,0 +1,63 @@
+---
+id: TASK-324
+title: Fix mpv playlist changes re-running app warmups
+status: Done
+assignee: []
+created_date: '2026-05-03 07:48'
+updated_date: '2026-05-03 07:52'
+labels:
+  - bug
+  - mpv
+  - overlay
+dependencies: []
+references:
+  - launcher/
+  - src/core/services/mpv.ts
+  - src/main/runtime/
+priority: medium
+---
+
+## Description
+
+<!-- SECTION:DESCRIPTION:BEGIN -->
+When moving to the next or previous mpv playlist entry, SubMiner should reconnect the existing app/runtime to mpv instead of treating the new video like a fresh app startup. Re-running startup warmups or creating another app session after the first video can interfere with overlay behavior.
+<!-- SECTION:DESCRIPTION:END -->
+
+## Acceptance Criteria
+<!-- AC:BEGIN -->
+- [x] #1 Changing to next or previous mpv playlist item reuses the existing app/runtime instead of launching a new app session.
+- [x] #2 Startup warmups are not repeated for playlist item changes after the first app startup.
+- [x] #3 Overlay behavior remains available after playlist navigation.
+- [x] #4 Regression test covers the playlist-change/reconnect path.
+<!-- AC:END -->
+
+## Implementation Plan
+
+<!-- SECTION:PLAN:BEGIN -->
+1. Reproduce the plugin auto-start regression with a failing Lua start-gate test.
+2. Update mpv plugin auto-start handling so playlist/file changes with an already-running overlay reuse the existing app path and do not re-arm pause-until-ready warmup.
+3. Add changelog fragment and run plugin/launcher verification.
+<!-- SECTION:PLAN:END -->
+
+## Implementation Notes
+
+<!-- SECTION:NOTES:BEGIN -->
+RED: `lua scripts/test-plugin-start-gate.lua` failed after changing the duplicate pause-until-ready auto-start expectations; it showed the loading gate was armed twice while overlay was already running.
+
+GREEN: `plugin/subminer/process.lua` now disarms any old ready gate and only reasserts visible overlay state when auto-start fires while `state.overlay_running` is already true.
+<!-- SECTION:NOTES:END -->
+
+## Final Summary
+
+<!-- SECTION:FINAL_SUMMARY:BEGIN -->
+Summary:
+- Updated the mpv Lua plugin auto-start reuse path so a file/playlist load with an already-running overlay no longer re-arms the pause-until-ready tokenization gate.
+- Kept the existing app/control command reuse behavior: subsequent auto-starts reassert visible/hidden overlay state without issuing another `--start` subprocess.
+- Added a changelog fragment for the mpv playlist overlay reuse fix.
+
+Tests:
+- `lua scripts/test-plugin-start-gate.lua` (red before fix, green after)
+- `bun run test:plugin:src`
+- `bun run changelog:lint`
+- `bun run test:launcher:env:src`
+<!-- SECTION:FINAL_SUMMARY:END -->

changes/323-macos-overlay-tracker-flaps.md

@@ -0,0 +1,4 @@
+type: fixed
+area: overlay
+
+- Kept the macOS visible overlay alive during transient mpv tracker flaps when the last tracked video geometry is still available.

changes/324-mpv-playlist-overlay-reuse.md

@@ -0,0 +1,4 @@
+type: fixed
+area: mpv
+
+- mpv: Playlist navigation now reuses the running SubMiner overlay without repeating the pause-until-ready warmup gate.

plugin/subminer/process.lua

@@ -299,16 +299,7 @@ function M.create(ctx)
 			if overrides.auto_start_trigger == true then
 				subminer_log("debug", "process", "Auto-start ignored because overlay is already running")
 				local socket_path = overrides.socket_path or opts.socket_path
-				local should_pause_until_ready = (
+				disarm_auto_play_ready_gate()
-					resolve_visible_overlay_startup()
-					and resolve_pause_until_ready()
-					and has_matching_mpv_ipc_socket(socket_path)
-				)
-				if should_pause_until_ready then
-					arm_auto_play_ready_gate()
-				else
-					disarm_auto_play_ready_gate()
-				end
 				local visibility_action = resolve_visible_overlay_startup()
 						and "show-visible-overlay"
 					or "hide-visible-overlay"

scripts/test-plugin-start-gate.lua

@@ -906,23 +906,23 @@ do
 	)
 	assert_true(
 		count_control_calls(recorded.async_calls, "--show-visible-overlay") == 4,
-		"duplicate pause-until-ready auto-start should re-assert visible overlay on both start and ready events"
+		"duplicate pause-until-ready auto-start should re-assert visible overlay on initial start, ready, and later file load"
 	)
 	assert_true(
-		count_osd_message(recorded.osd, "SubMiner: Loading subtitle tokenization...") == 2,
+		count_osd_message(recorded.osd, "SubMiner: Loading subtitle tokenization...") == 1,
-		"duplicate pause-until-ready auto-start should arm tokenization loading gate for each file"
+		"duplicate pause-until-ready auto-start should not repeat tokenization loading gate after overlay is running"
 	)
 	assert_true(
-		count_osd_message(recorded.osd, "SubMiner: Subtitle tokenization ready") == 2,
+		count_osd_message(recorded.osd, "SubMiner: Subtitle tokenization ready") == 1,
-		"duplicate pause-until-ready auto-start should release tokenization gate for each file"
+		"duplicate pause-until-ready auto-start should not wait for a second readiness signal after overlay is running"
 	)
 	assert_true(
-		count_property_set(recorded.property_sets, "pause", true) == 2,
+		count_property_set(recorded.property_sets, "pause", true) == 1,
-		"duplicate pause-until-ready auto-start should force pause for each file"
+		"duplicate pause-until-ready auto-start should not force pause after overlay is running"
 	)
 	assert_true(
-		count_property_set(recorded.property_sets, "pause", false) == 2,
+		count_property_set(recorded.property_sets, "pause", false) == 1,
-		"duplicate pause-until-ready auto-start should resume playback for each file"
+		"duplicate pause-until-ready auto-start should not resume a gate that was never rearmed"
 	)
 end
 

src/core/services/overlay-visibility.test.ts

@@ -1192,6 +1192,65 @@ test('macOS keeps visible overlay hidden while tracker is not initialized yet',
   assert.ok(!calls.includes('update-bounds'));
 });
 
+test('macOS preserves visible overlay during transient tracker loss with retained geometry', () => {
+  const { window, calls } = createMainWindowRecorder();
+  const osdMessages: string[] = [];
+  let trackerWarning = false;
+  let tracking = true;
+  const tracker: WindowTrackerStub = {
+    isTracking: () => tracking,
+    getGeometry: () => ({ x: 0, y: 0, width: 1280, height: 720 }),
+    isTargetWindowFocused: () => true,
+  };
+
+  const run = () =>
+    updateVisibleOverlayVisibility({
+      visibleOverlayVisible: true,
+      mainWindow: window as never,
+      windowTracker: tracker as never,
+      trackerNotReadyWarningShown: trackerWarning,
+      setTrackerNotReadyWarningShown: (shown: boolean) => {
+        trackerWarning = shown;
+      },
+      updateVisibleOverlayBounds: () => {
+        calls.push('update-bounds');
+      },
+      ensureOverlayWindowLevel: () => {
+        calls.push('ensure-level');
+      },
+      syncPrimaryOverlayWindowLayer: () => {
+        calls.push('sync-layer');
+      },
+      enforceOverlayLayerOrder: () => {
+        calls.push('enforce-order');
+      },
+      syncOverlayShortcuts: () => {
+        calls.push('sync-shortcuts');
+      },
+      isMacOSPlatform: true,
+      showOverlayLoadingOsd: (message: string) => {
+        osdMessages.push(message);
+      },
+    } as never);
+
+  run();
+  calls.length = 0;
+  tracking = false;
+
+  run();
+
+  assert.equal(trackerWarning, false);
+  assert.deepEqual(osdMessages, []);
+  assert.ok(calls.includes('update-bounds'));
+  assert.ok(calls.includes('sync-layer'));
+  assert.ok(calls.includes('mouse-ignore:true:forward'));
+  assert.ok(calls.includes('ensure-level'));
+  assert.ok(calls.includes('enforce-order'));
+  assert.ok(calls.includes('sync-shortcuts'));
+  assert.ok(!calls.includes('hide'));
+  assert.ok(!calls.includes('show'));
+});
+
 test('macOS suppresses immediate repeat loading OSD after tracker recovery until cooldown expires', () => {
   const { window } = createMainWindowRecorder();
   const osdMessages: string[] = [];

src/core/services/overlay-visibility.ts

@@ -260,11 +260,16 @@ export function updateVisibleOverlayVisibility(args: {
     return;
   }
 
+  const hasRetainedTrackedGeometry = args.windowTracker.getGeometry() !== null;
+  const shouldPreserveTransientTrackedOverlay =
+    (args.isMacOSPlatform && hasRetainedTrackedGeometry) ||
+    (args.isWindowsPlatform &&
+      typeof args.windowTracker.isTargetWindowMinimized === 'function' &&
+      !args.windowTracker.isTargetWindowMinimized());
+
   if (
-    args.isWindowsPlatform &&
+    shouldPreserveTransientTrackedOverlay &&
-    typeof args.windowTracker.isTargetWindowMinimized === 'function' &&
+    (mainWindow.isVisible() || hasRetainedTrackedGeometry)
-    !args.windowTracker.isTargetWindowMinimized() &&
-    (mainWindow.isVisible() || args.windowTracker.getGeometry() !== null)
   ) {
     args.setTrackerNotReadyWarningShown(false);
     const geometry = args.windowTracker.getGeometry();
@@ -273,6 +278,9 @@ export function updateVisibleOverlayVisibility(args: {
     }
     args.syncPrimaryOverlayWindowLayer('visible');
     showPassiveVisibleOverlay();
+    if (!args.forceMousePassthrough && !args.isWindowsPlatform) {
+      args.enforceOverlayLayerOrder();
+    }
     args.syncOverlayShortcuts();
     return;
   }