demo: real synthetic headshots — fetch pool + serve route + UI wire

Three layers shipped:

1. SCRIPT — scripts/staffing/fetch_face_pool.py
   Pulls N synthetic StyleGAN faces from thispersondoesnotexist.com
   into data/headshots/face_NNNN.jpg, writes manifest.jsonl. Idempotent:
   re-running skips existing files. Optional gender tagging via deepface
   (currently unavailable on this box; the script handles ImportError
   gracefully and tags everything as untagged). Fetched 198 faces with
   concurrency=3 in ~67s.

2. SERVER — /headshots/:key route in mcp-server/index.ts
   Loads manifest at first hit, caches in globalThis._faces. Hashes the
   key with djb2-style mixing → pool index → returns the JPG. Same
   key always gets the same face (deterministic). Accepts
   ?g=man|woman&e=caucasian|black|hispanic|south_asian|east_asian|middle_eastern
   to bias pool selection — the gender/ethnicity buckets fall back to
   the full pool when no tagged matches exist. Cache-Control:
   86400 immutable so faces ride the browser cache after first hit.
   /headshots/__reload re-reads the manifest without restart.

3. UI — search.html + console.html worker cards
   Re-added overlay <img> on top of the monogram .av circle. img.src
   = /headshots/<encoded-key>?g=<hint>&e=<hint>. img.onerror removes
   the failed image so the monogram stays visible if the face pool
   isn't fetched / CDN is blocked. .av now has overflow:hidden +
   position:relative to clip the img to a perfect circle.

Forced-confident name resolution (J: "we're CREATING the profile,
created as though you truly have the information Xavier is more
likely Hispanic and he's a male"):

   genderFor(name)        — looks up MALE_NAMES + FEMALE_NAMES,
                            falls back to a deterministic hash split
                            so unknown names spread ~50/50. Sets now
                            include cross-cultural names: Alejandro/
                            Andres/Mateo/Santiago/Joaquin/Cesar/Hugo/
                            Felipe/Gerardo/Salvador/Ramon (Hispanic),
                            Raj/Anil/Vikram/Krishna/Pradeep (South
                            Asian), Wei/Yi/Hiroshi/Akira/Hyun (East
                            Asian), Demetrius/Kareem/DaQuan/Khalil
                            (Black), Omar/Khalid/Hassan/Ahmed/Bilal
                            (Middle Eastern). FEMALE_NAMES extended
                            in parallel.

   guessEthnicityFromFirstName(name)
                          — confident default of 'caucasian' for any
                            name not in the cultural buckets so every
                            worker resolves to a category the face
                            pool can be biased toward. Order: ME → Black
                            → Hispanic → South Asian → East Asian →
                            Caucasian (matters where names overlap,
                            e.g. Aisha appears in ME + Black, biases
                            toward ME for visual fit).

   Both helpers also ported into console.html so the triage backfills
   and try-it-yourself rendering get the same hint stack.

Privacy note in the script + route comments: the synthetic data uses
the worker's name as the seed; production should hash worker_id (not
name) to avoid leaking PII to a third-party CDN. The fetch URL itself
is referenced once per pool build, not per-worker.

.gitignore — added data/headshots/face_*.jpg (~100MB for 198 faces;
the manifest + script are tracked). Re-running the script on a fresh
checkout rebuilds the pool from scratch.

Verified end-to-end via playwright on devop.live/lakehouse:
   forklift query → 10 worker cards
   10/10 with face images (real synthetic headshots, not monograms)
   0/10 broken
   Alejandro G. Nelson  → ?g=man&e=hispanic
   Patricia K. Garcia    → ?g=woman&e=caucasian
   Each name → unique face, deterministic across loads.
   Console triage backfills get the same treatment.

mcp-server/console.html

@@ -55,7 +55,8 @@ details .body{padding-top:10px;font-size:12px;color:#8b949e}
 .accent-r{border-left:3px solid #f85149}
 
 .worker{display:flex;align-items:center;gap:10px;padding:8px 10px;background:#161b22;border-radius:6px;margin-bottom:4px;font-size:12px;border-left:3px solid #30363d}
-.worker .av{width:32px;height:32px;border-radius:50%;background:#0d1117;border:1px solid #21262d;display:flex;align-items:center;justify-content:center;font-weight:600;color:#c9d1d9;font-size:11px;flex-shrink:0;letter-spacing:0.5px}
+.worker .av{width:32px;height:32px;border-radius:50%;background:#0d1117;border:1px solid #21262d;display:flex;align-items:center;justify-content:center;font-weight:600;color:#c9d1d9;font-size:11px;flex-shrink:0;letter-spacing:0.5px;overflow:hidden;position:relative}
+.worker .av img{position:absolute;inset:0;width:100%;height:100%;object-fit:cover;display:block}
 .worker[data-role-band="warehouse"]{border-left-color:#58a6ff}
 .worker[data-role-band="production"]{border-left-color:#d29922}
 .worker[data-role-band="trades"]{border-left-color:#bc8cff}
@@ -232,13 +233,70 @@ function roleBand(role){
 // the left edge + uppercase role pill in the detail line. Used by
 // every chapter that renders worker rows. `name` and `role` drive the
 // classification; `detail` is the full text after the pill.
+// Quick first-name → gender hint for face-pool selection. Same lookup
+// idea as the dashboard; if the name is unknown, the server falls back
+// to the full pool. Trimmed table — covers the most common names that
+// appear in the synthetic worker data.
+var FEMALE_NAMES = new Set(['Mary','Patricia','Jennifer','Linda','Elizabeth','Barbara','Susan','Jessica','Sarah','Karen','Lisa','Nancy','Betty','Sandra','Margaret','Ashley','Kimberly','Emily','Donna','Michelle','Carol','Amanda','Melissa','Deborah','Stephanie','Dorothy','Rebecca','Sharon','Laura','Cynthia','Amy','Kathleen','Angela','Shirley','Brenda','Emma','Anna','Pamela','Nicole','Samantha','Katherine','Christine','Helen','Debra','Rachel','Carolyn','Janet','Maria','Catherine','Heather','Diane','Olivia','Julie','Joyce','Victoria','Ruth','Virginia','Lauren','Kelly','Christina','Joan','Evelyn','Judith','Andrea','Hannah','Megan','Cheryl','Jacqueline','Martha','Madison','Teresa','Gloria','Sara','Janice','Ann','Kathryn','Abigail','Sophia','Frances','Jean','Alice','Judy','Isabella','Julia','Grace','Amber','Denise','Danielle','Marilyn','Beverly','Charlotte','Natalie','Theresa','Diana','Brittany','Kayla','Alexis','Lori','Marie','Carmen','Aisha','Rosa','Mia','Audrey','Erin','Tina','Vanessa','Tara','Wendy','Tanya','Maya','Crystal','Yvonne','Kara','Shannon','Brianna','Faith','Caroline','Carla','Tracey','Tracy','Rita','Dawn','Tiffany','Stacy','Stacey','Gina','Bonnie','Tammy','Joanne','Jamie','Tonya','Alyssa','Ariana','Elena','Ellie','Erica','Erika','Felicia','Holly','Jenna','Jenny','Krista','Kristen','Kristin','Krystal','Lana','Leah','Lucy','Mallory','Melinda','Meredith','Misty','Monica','Naomi','Paige','Paula','Renee','Rhonda','Robin','Roxanne','Selena','Sierra','Skylar','Sonia','Stella','Tamara','Veronica','Vivian','Whitney','Yolanda','Zoe']);
+var MALE_NAMES = new Set(['James','Robert','John','Michael','David','William','Richard','Joseph','Thomas','Charles','Christopher','Daniel','Matthew','Anthony','Mark','Donald','Steven','Paul','Andrew','Joshua','Kenneth','Kevin','Brian','George','Edward','Ronald','Timothy','Jason','Jeffrey','Ryan','Jacob','Gary','Nicholas','Eric','Jonathan','Stephen','Larry','Justin','Scott','Brandon','Benjamin','Samuel','Gregory','Frank','Alexander','Raymond','Patrick','Jack','Dennis','Jerry','Tyler','Aaron','Jose','Adam','Henry','Nathan','Douglas','Zachary','Peter','Kyle','Walter','Ethan','Jeremy','Harold','Keith','Christian','Roger','Noah','Gerald','Carl','Terry','Sean','Austin','Arthur','Lawrence','Jesse','Dylan','Bryan','Joe','Jordan','Billy','Bruce','Albert','Willie','Gabriel','Logan','Alan','Juan','Wayne','Roy','Ralph','Randy','Eugene','Vincent','Russell','Elijah','Louis','Bobby','Philip','Johnny','Marcus','Antonio','Carlos','Diego','Hector','Jorge','Julio','Manuel','Miguel','Pedro','Raul','Ricardo','Roberto','Sergio','Victor','Jamal','Xavier','DeShawn','Dwayne','Jermaine','Malik','Tyrone','Devon','Andre','Brent','Calvin','Casey','Cody','Cole','Cory','Dale','Damon','Darius','Darrell','Dean','Derek','Drew','Earl','Eddie','Floyd','Glenn','Greg','Howard','Ivan','Jared','Jay','Jeff','Joel','Lance','Lee','Leonard','Lloyd','Mario','Martin','Mason','Maurice','Max','Mitchell','Morgan','Nick','Norman','Oliver','Owen','Pete','Quincy','Rafael','Reggie','Rex','Ricky','Russ','Shane','Shaun','Stanley','Steve','Theodore','Todd','Travis','Trevor','Troy','Wade','Warren','Wesley']);
+function guessGenderFromFirstName(n){
+  if(!n) return null;
+  var clean=n.replace(/[^A-Za-z]/g,'');
+  if(!clean) return null;
+  var c=clean[0].toUpperCase()+clean.slice(1).toLowerCase();
+  if(FEMALE_NAMES.has(c)) return 'woman';
+  if(MALE_NAMES.has(c)) return 'man';
+  return null;
+}
+function genderFor(name){
+  var g = guessGenderFromFirstName(name);
+  if(g) return g;
+  if(!name) return 'man';
+  var s=String(name); var h=0;
+  for(var i=0;i<s.length;i++) h=(h*31+s.charCodeAt(i))|0;
+  return (Math.abs(h)&1)?'man':'woman';
+}
+// Confident first-name → ethnicity. Synthetic data — we own the call.
+var NAMES_SOUTH_ASIAN_C=new Set(['Raj','Anil','Rohan','Vikram','Arjun','Sanjay','Ravi','Krishna','Pradeep','Sunil','Amit','Deepak','Ashok','Manoj','Rahul','Vijay','Suresh','Naveen','Anand','Nikhil','Aditya','Karan','Rajesh','Priya','Anjali','Neha','Kavya','Pooja','Divya','Meera','Lakshmi','Rani','Asha','Saanvi','Aanya','Aaradhya','Shreya','Riya','Tanvi','Ishita','Aarav','Ishaan','Shivani']);
+var NAMES_EAST_ASIAN_C=new Set(['Wei','Mei','Yi','Jin','Chen','Lin','Liu','Wang','Zhang','Yang','Wu','Zhao','Sun','Hiroshi','Yuki','Akira','Kenji','Sakura','Aiko','Haruto','Sora','Hyun','Eun','Yoon','Kai','Long','Hong','Xiu','Lan','Hua','Hao','Tao','Bao','Cheng','Feng','Jian','Dong','Bin','Min','Lei','Hui','Yu','Xin','Ying','Zhen','Yuan','Yan']);
+var NAMES_HISPANIC_C=new Set(['Carmen','Carlos','Maria','Diego','Hector','Jorge','Julio','Manuel','Miguel','Pedro','Raul','Ricardo','Roberto','Sergio','Antonio','Esperanza','Luz','Sofia','Lucia','Isabella','Camila','Valentina','Mariana','Elena','Rosa','Catalina','Esteban','Fernando','Eduardo','Javier','Alejandro','Andres','Mateo','Santiago','Sebastian','Emilio','Tomas','Cristina','Daniela','Gabriela','Ximena','Adriana','Beatriz','Pilar','Mercedes','Xavier','Marisol','Guadalupe','Lupita','Inez','Itzel','Yesenia','Joaquin','Ignacio','Rafael','Salvador','Cesar','Arturo','Armando','Hugo','Marco','Alejandra','Felipe','Gerardo','Jaime','Leonardo','Luis','Pablo','Ramon']);
+var NAMES_BLACK_C=new Set(['DeShawn','Jamal','Aisha','Latoya','Tyrone','Malik','Imani','Keisha','Tariq','Lakisha','Kenya','Tamika','Andre','Marcus','Demetrius','Jermaine','Reggie','Tyrese','Darius','Trevon','Kareem','Damon','Jalen','Jaylen','Dwayne','DaQuan','Aaliyah','Kiara','Janelle','Jasmine','Tanisha','Maurice','Tyrell','Kwame','Khalil','Terrell','Cedric','Nia','Zuri','Jada','Ebony','Dominique']);
+var NAMES_MIDDLE_EASTERN_C=new Set(['Layla','Omar','Khalid','Fatima','Yasmin','Hassan','Hussein','Ahmed','Mohamed','Mohammed','Ali','Karim','Yusuf','Yara','Nadia','Zainab','Rania','Samira','Mariam','Salma','Ibrahim','Mahmoud','Saif','Anwar','Bilal','Faisal','Hamza','Imran','Sami','Wael','Zaid','Amira','Iman','Lina','Mona','Noor','Rana','Soha','Zara']);
+function guessEthnicityFromFirstName(n){
+  if(!n) return 'caucasian';
+  var clean=n.replace(/[^A-Za-z]/g,''); if(!clean) return 'caucasian';
+  var c=clean[0].toUpperCase()+clean.slice(1).toLowerCase();
+  if(NAMES_MIDDLE_EASTERN_C.has(c)) return 'middle_eastern';
+  if(NAMES_BLACK_C.has(c)) return 'black';
+  if(NAMES_HISPANIC_C.has(c)) return 'hispanic';
+  if(NAMES_SOUTH_ASIAN_C.has(c)) return 'south_asian';
+  if(NAMES_EAST_ASIAN_C.has(c)) return 'east_asian';
+  return 'caucasian';
+}
+
 function workerRow(name, role, detail, opts){
   opts = opts || {};
   var band = roleBand(role||'');
   var w = el('div','worker');
   if(band.band) w.dataset.roleBand = band.band;
   var initials = (name||'?').split(' ').map(function(s){return (s[0]||'').toUpperCase()}).join('').substring(0,2);
-  w.appendChild(el('div','av',initials));
+  var av = el('div','av',initials);
+  // Real synthetic headshot via /headshots/<key>; deterministic so
+  // same worker always gets the same face. Falls back to monogram if
+  // pool isn't fetched yet.
+  var faceKey = (opts.face_key) || name || '';
+  var firstName = (name||'').split(/\s+/)[0]||'';
+  var gHint = genderFor(firstName);
+  var eHint = guessEthnicityFromFirstName(firstName);
+  if(faceKey){
+    var img=document.createElement('img');
+    img.alt='';
+    img.loading='lazy';
+    img.src = P + '/headshots/' + encodeURIComponent(faceKey) + '?g='+gHint+'&e='+eHint;
+    img.onerror=function(){ this.remove(); };
+    av.appendChild(img);
+  }
+  w.appendChild(av);
   var info = el('div','info');
   var nm = el('div','nm', name||'?');
   if(opts.endorsed){