fix(effort): per-role floor for --effort resolution + developer→xhigh

resolve_agent_effort returned '' for all agents in prod because empty
ORCH_AGENT_EFFORT_*= env vars clobber pydantic class-defaults, leaving no
non-empty floor to fall back to -> --effort never reached the Claude CLI.

Add a level-4 per-role floor in resolve_agent_effort (src/agents/launcher.py):
_agent_effort_floor reads the declared class-default of agent_effort_<agent>
(model_fields[...].default), which a present-but-empty env cannot override.
Floor applies only when levels 1-3 are empty and BEFORE validation, so a typo
(non-empty) still drops to '' (never-break ORCH-41) and explicit env/override
still wins (priority preserved). config.py: agent_effort_developer high->xhigh
(single source of truth; floor follows automatically).

Refs: ORCH-081

Co-Authored-By: Claude Opus 4.7 <noreply@anthropic.com>

src/agents/launcher.py

@@ -158,12 +158,50 @@ def resolve_agent_model(agent: str, project_id: str = None) -> str:
     return ""
 
 
+def _agent_effort_floor(agent: str) -> str:
+    """ORCH-081 (ORCH-52h): per-role non-empty floor for --effort resolution.
+
+    Returns the DECLARED class-default of the ``agent_effort_<agent>`` field on
+    Settings (e.g. developer -> ``xhigh``, tester/deployer -> ``medium``, the rest
+    -> ``high``). This is the value pydantic WOULD have used were it not clobbered
+    by a spurious empty env var (``ORCH_AGENT_EFFORT_<ROLE>=``): the class-default
+    is fixed in the class body and a present-but-empty env value cannot override it,
+    so it is a robust floor even when the host ``.env`` zeroes every effort var.
+
+    config.py is the single source of truth: upgrading developer to ``xhigh`` there
+    automatically raises the floor here — no second map to keep in sync (ADR-001).
+
+    Unknown agent (a name outside the 6 roles) has no ``agent_effort_<agent>``
+    field; we degrade to the class-default of ``agent_effort_default`` (``high``),
+    a safe non-empty floor. Never raises.
+    """
+    fields = type(settings).model_fields
+    for key in (f"agent_effort_{agent}", "agent_effort_default"):
+        field = fields.get(key)
+        if field is not None and field.default:
+            return field.default
+    return ""
+
+
 def resolve_agent_effort(agent: str, project_id: str = None) -> str:
     """ORCH-41: resolve the --effort level for an agent (optionally per-project).
 
-    Same priority as resolve_agent_model. The resolved value is validated against
-    VALID_EFFORTS; an invalid value is logged and dropped (returns "") so a typo
-    in env/projects_json can never pass a bad flag to the CLI.
+    Same priority as resolve_agent_model, with one extra level below the global
+    default (ORCH-081 / ADR-001):
+      1. project-override (projects_json.agent_efforts[agent])
+      2. per-agent env    (settings.agent_effort_<agent>)
+      3. global default   (settings.agent_effort_default)
+      4. per-role FLOOR   (class-default of agent_effort_<agent>) — NEW
+
+    The floor only kicks in when levels 1-3 are all empty (the prod bug: a present
+    but empty ``ORCH_AGENT_EFFORT_*=`` clobbers every default to ''), guaranteeing
+    a non-empty target effort for the 6 known roles regardless of host .env state.
+
+    The floor is applied BEFORE validation and ONLY to an empty resolve, so it
+    never masks a typo: an explicit invalid value (e.g. ``turbo``) is non-empty,
+    skips the floor, and is logged + dropped to "" exactly as in ORCH-41 (the
+    resolved value is validated against VALID_EFFORTS; an invalid value can never
+    pass a bad flag to the CLI). Never raises.
     """
     value = _resolve_agent_attr(
         agent, project_id,
@@ -171,6 +209,11 @@ def resolve_agent_effort(agent: str, project_id: str = None) -> str:
         env_attr_prefix="agent_effort_",
         default_attr="agent_effort_default",
     )
+    if not value:
+        # Levels 1-3 all empty (typically a prod .env with empty ORCH_AGENT_EFFORT_*):
+        # fall through to the per-role floor (class-default). Applied before
+        # validation but only here, so a typo (non-empty) never reaches this branch.
+        value = _agent_effort_floor(agent)
     if value and value not in VALID_EFFORTS:
         logger.warning(
             f"Invalid effort '{value}' for agent '{agent}' "

src/config.py

@@ -97,13 +97,15 @@ class Settings(BaseSettings):
     agent_model_deployer: str = ""
 
     # ORCH-41: per-agent effort / reasoning level: low|medium|high|xhigh|max.
-    # Empty -> agent_effort_default. Same resolution order as model. Default split:
-    # thinking agents (analyst/architect/developer/reviewer) -> high; mechanical
-    # agents (tester/deployer) -> medium.
+    # Empty -> agent_effort_default. Same resolution order as model. Default split
+    # (ORCH-081/ORCH-52h): thinking agents (analyst/architect/reviewer) -> high;
+    # developer -> xhigh (coding/agentic role, Opus 4.8 canon); mechanical agents
+    # (tester/deployer) -> medium. These class-defaults are ALSO the per-role floor
+    # used by resolve_agent_effort when the env is empty (single source of truth).
     agent_effort_default: str = "high"
     agent_effort_analyst: str = "high"
     agent_effort_architect: str = "high"
-    agent_effort_developer: str = "high"
+    agent_effort_developer: str = "xhigh"
     agent_effort_reviewer: str = "high"
     agent_effort_tester: str = "medium"
     agent_effort_deployer: str = "medium"