Enhance error handling and logging in early-settings and worker-utils

- Added silent debugging for settings file loading failures in early-settings.ts.
- Improved error logging in worker-utils.ts for health check and worker startup failures, including detailed error information and context.

src/shared/early-settings.ts

@@ -1,6 +1,7 @@
 import { join } from 'path';
 import { homedir } from 'os';
 import { existsSync, readFileSync } from 'fs';
+import { silentDebug } from '../utils/silent-debug.js';
 
 const SETTINGS_PATH = join(homedir(), '.claude-mem', 'settings.json');
 
@@ -23,8 +24,8 @@ export function loadEarlySetting(key: keyof EarlySettings, defaultValue: string)
       const fileValue = data.env?.[key];
       if (fileValue !== undefined) return fileValue;
     }
-  } catch {
-    // Fail silently - fall through to env var
+  } catch (error) {
+    silentDebug('Failed to load settings file', { error, settingsPath: SETTINGS_PATH, key });
   }
 
   return process.env[key] || defaultValue;

src/shared/worker-utils.ts

@@ -3,6 +3,7 @@ import { existsSync } from "fs";
 import { homedir } from "os";
 import { spawnSync } from "child_process";
 import { SettingsDefaultsManager } from "../services/worker/settings/SettingsDefaultsManager.js";
+import { logger } from "../utils/logger.js";
 
 // CRITICAL: Always use marketplace directory for PM2/ecosystem
 // This ensures cross-platform compatibility and avoids cache directory confusion
@@ -34,7 +35,11 @@ async function isWorkerHealthy(): Promise<boolean> {
       signal: AbortSignal.timeout(HEALTH_CHECK_TIMEOUT_MS)
     });
     return response.ok;
-  } catch {
+  } catch (error) {
+    logger.debug('SYSTEM', 'Worker health check failed', {
+      error: error instanceof Error ? error.message : String(error),
+      errorType: error?.constructor?.name
+    });
     return false;
   }
 }
@@ -102,7 +107,12 @@ async function startWorker(): Promise<boolean> {
 
     return false;
   } catch (error) {
-    // Failed to start worker
+    logger.error('SYSTEM', 'Failed to start worker', {
+      platform: process.platform,
+      workerScript: path.join(MARKETPLACE_ROOT, 'plugin', 'scripts', 'worker-service.cjs'),
+      error: error instanceof Error ? error.message : String(error),
+      marketplaceRoot: MARKETPLACE_ROOT
+    });
     return false;
   }
 }