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Actually we have much less code in os-autoinst-distri-openqa, lets see what we need from the new code

The program is started with x11_start_program("firefox http://localhost", 60, { valid => 1 } ); so it has a dedicated one minute timeout.

The error message says # Test died: no candidate needle with tag(s) 'displaymanager, displaymanager-password-prompt, generic-desktop, screenlock, gnome-screenlock-password' matched which implies it is looking for a locked screen for some reason, which makes sense as the test runs ensure_unlocked_desktop before.
On the first glance the function looks the same for both distributions.

In conclusion this might have been some serious hiccup, since the newer runs work fine

It looks now to me like the send_key 'esc' in Line 60 didn't reach the SUT, so this would qualify as a lost key problem

There should be no "lost keys" on x86_64 unless it's wayland or virtio or system bogged down by services on the SUT itself.

As a simple suggestion one could trigger some more jobs, e.g. 100, and check fail rate – if it fails at all.

We had the issue 1 time the last 100 runs in production, it did not appear again after this ticket was created

Started 100 times on pinky

It failed very often on pinky with this exact behaviour

The issue seems to be that the session got locked (I guess due to low performance extending the time between the instructions) but we have no needle with the password prompt for this product.

I will create a needle and try this on pinky

https://openqa.opensuse.org/tests/965208#step/worker/4 shows that worker failed which should fixed at first because it blocks it's following test modules.

http://f40.suse.de/tests/4149 failed for clone_job:

if we compare this vars.json: https://openqa.opensuse.org/tests/965331/file/vars.json
with the one of your instance: http://f40.suse.de/tests/4147/file/vars.json
a lot of settings are missing

open a ticket:
https://progress.opensuse.org/issues/53606

@okurz yes, I need also to corret NEEDLE_DIR as well:

openqa-clone-job --from http://f40.suse.de 4158 PRODUCTDIR=/var/lib/openqa/cache/f40.suse.de/tests/openqa --skip-deps NEEDLES_DIR=/var/lib/openqa/cache/f40.suse.de/tests/openqa/products/openqa/needles

https://openqa.opensuse.org/tests/975393 doesn't show any issue.

need to check https://openqa.opensuse.org/tests/975438#next_previous

and it fails at moduel "worker" for matching needle gnome-desktop at wait_for_desktop: http://f40.suse.de/tests/4181#live

this is quite strange, check if this is really a timeout issue.

it seems that unlock desktop doesn't work...

to check on O3:
https://openqa.opensuse.org/tests/overview?build=%3ATW.2357_zluo-verification_poo44441&distri=openqa&version=Tumbleweed

https://openqa.opensuse.org/tests/975610/file/autoinst-log.txt shows sometimes gnome-desktop-20190509 is not matched. this is very strange.
compare with http://f40.suse.de/tests/4199/file/autoinst-log.txt, there is just fine without any issue to go further with x11_start_program.

http://f40.suse.de/tests/4290#next_previous shows no issue for 100 test run.

I see also something changes from okurz in openqa tests. And needle gnome-desktop matches without any issue for current build.

https://openqa.opensuse.org/tests/977793#next_previous shows that from TW.2356 to TW.2371 no failure. Reject it for now.