refactor(onboard): derive progress labels from FSM metadata

src/lib/onboard.ts

@@ -429,6 +429,7 @@ const { handlePoliciesState }: typeof import("./onboard/machine/handlers/policie
 const { handlePreflightState }: typeof import("./onboard/machine/handlers/preflight") = require("./onboard/machine/handlers/preflight");
 const { handleProviderInferenceState }: typeof import("./onboard/machine/handlers/provider-inference") = require("./onboard/machine/handlers/provider-inference");
 const { handleSandboxState }: typeof import("./onboard/machine/handlers/sandbox") = require("./onboard/machine/handlers/sandbox");
+const { getOnboardProgressStep }: typeof import("./onboard/machine/progress") = require("./onboard/machine/progress");
 const policies: typeof import("./policy") = require("./policy");
 const tiers: typeof import("./policy/tiers") = require("./policy/tiers");
 const { ensureUsageNoticeConsent } = require("./onboard/usage-notice");
@@ -6334,28 +6335,18 @@ const recordRepairEvent = onboardRuntimeBoundary.recordRepairEvent.bind(onboardR
 const recordPostVerifyStarted = onboardRuntimeBoundary.recordPostVerifyStarted.bind(onboardRuntimeBoundary);
 const recordSessionComplete = onboardRuntimeBoundary.recordSessionComplete.bind(onboardRuntimeBoundary);
 
-const ONBOARD_STEP_INDEX: Record<string, { number: number; title: string }> = {
-  preflight: { number: 1, title: "Preflight checks" },
-  gateway: { number: 2, title: "Starting OpenShell gateway" },
-  provider_selection: { number: 3, title: "Configuring inference (NIM)" },
-  inference: { number: 4, title: "Setting up inference provider" },
-  messaging: { number: 5, title: "Messaging channels" },
-  sandbox: { number: 6, title: "Creating sandbox" },
-  openclaw: { number: 7, title: "Setting up agent inside sandbox" },
-  policies: { number: 8, title: "Policy presets" },
-};
-
 function skippedStepMessage(
   stepName: string,
   detail?: string | null,
   reason: "resume" | "reuse" = "resume",
 ): void {
-  let stepInfo = ONBOARD_STEP_INDEX[stepName];
-  if (stepInfo && stepName === "openclaw") {
-    stepInfo = { ...stepInfo, title: `Setting up ${agentProductName()} inside sandbox` };
-  }
+  const progressStep = getOnboardProgressStep(stepName);
+  const stepInfo =
+    progressStep && stepName === "openclaw"
+      ? { ...progressStep, title: `Setting up ${agentProductName()} inside sandbox` }
+      : progressStep;
   if (stepInfo) {
-    step(stepInfo.number, 8, stepInfo.title);
+    step(stepInfo.number, stepInfo.total, stepInfo.title);
   }
   const prefix = reason === "reuse" ? "[reuse]" : "[resume]";
   console.log(`  ${prefix} Skipping ${stepName}${detail ? ` (${detail})` : ""}`);

src/lib/onboard/machine/definition.ts

@@ -45,7 +45,6 @@ export const ONBOARD_MACHINE_STATE_DEFINITIONS = [
     state: "agent_setup",
     terminal: false,
     stepName: "agent_setup",
-    progress: { number: 7, total: 8, title: "Setting up agent inside sandbox" },
   },
   {
     state: "openclaw",

src/lib/onboard/machine/progress.test.ts

@@ -0,0 +1,38 @@
+// SPDX-FileCopyrightText: Copyright (c) 2026 NVIDIA CORPORATION & AFFILIATES. All rights reserved.
+// SPDX-License-Identifier: Apache-2.0
+
+import { describe, expect, it } from "vitest";
+
+import { ONBOARD_MACHINE_STATE_DEFINITIONS } from "./definition";
+import { getOnboardProgressStep, ONBOARD_PROGRESS_STEPS } from "./progress";
+
+describe("onboard progress metadata", () => {
+  it("derives state-backed progress labels from machine definitions", () => {
+    for (const definition of ONBOARD_MACHINE_STATE_DEFINITIONS) {
+      if (!("progress" in definition)) continue;
+      expect(ONBOARD_PROGRESS_STEPS[definition.stepName]).toEqual(definition.progress);
+    }
+  });
+
+  it("preserves the existing eight-step onboarding labels", () => {
+    expect(ONBOARD_PROGRESS_STEPS).toEqual({
+      preflight: { number: 1, total: 8, title: "Preflight checks" },
+      gateway: { number: 2, total: 8, title: "Starting OpenShell gateway" },
+      provider_selection: { number: 3, total: 8, title: "Configuring inference (NIM)" },
+      inference: { number: 4, total: 8, title: "Setting up inference provider" },
+      messaging: { number: 5, total: 8, title: "Messaging channels" },
+      sandbox: { number: 6, total: 8, title: "Creating sandbox" },
+      openclaw: { number: 7, total: 8, title: "Setting up agent inside sandbox" },
+      policies: { number: 8, total: 8, title: "Policy presets" },
+    });
+  });
+
+  it("looks up known labels and ignores unknown steps", () => {
+    expect(getOnboardProgressStep("gateway")).toEqual({
+      number: 2,
+      total: 8,
+      title: "Starting OpenShell gateway",
+    });
+    expect(getOnboardProgressStep("not-a-step")).toBeNull();
+  });
+});

src/lib/onboard/machine/progress.ts

@@ -0,0 +1,42 @@
+// SPDX-FileCopyrightText: Copyright (c) 2026 NVIDIA CORPORATION & AFFILIATES. All rights reserved.
+// SPDX-License-Identifier: Apache-2.0
+
+import {
+  ONBOARD_MACHINE_STATE_DEFINITIONS,
+  type OnboardMachineStateWithProgressDefinition,
+} from "./definition";
+
+export interface OnboardProgressStep {
+  number: number;
+  total: number;
+  title: string;
+}
+
+export type OnboardMachineProgressStepName =
+  OnboardMachineStateWithProgressDefinition["stepName"];
+
+export type OnboardProgressStepName = OnboardMachineProgressStepName | "messaging";
+
+// Messaging is still emitted inside the sandbox flow rather than represented as
+// a session/FSM state. Keep this legacy pseudo-step here only while the progress
+// API preserves that visible label; remove it when messaging becomes a real
+// FSM-backed onboarding step or the legacy pseudo-step lookup goes away.
+const EXTRA_PROGRESS_STEPS = [
+  {
+    stepName: "messaging",
+    progress: { number: 5, total: 8, title: "Messaging channels" },
+  },
+] as const;
+
+export const ONBOARD_PROGRESS_STEPS = Object.fromEntries([
+  ...ONBOARD_MACHINE_STATE_DEFINITIONS.flatMap((definition) =>
+    "progress" in definition ? [[definition.stepName, definition.progress]] : [],
+  ),
+  ...EXTRA_PROGRESS_STEPS.map((definition) => [definition.stepName, definition.progress]),
+]) as Readonly<Record<OnboardProgressStepName, OnboardProgressStep>>;
+
+export function getOnboardProgressStep(stepName: string): OnboardProgressStep | null {
+  return Object.prototype.hasOwnProperty.call(ONBOARD_PROGRESS_STEPS, stepName)
+    ? ONBOARD_PROGRESS_STEPS[stepName as OnboardProgressStepName]
+    : null;
+}