diff --git a/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/core/dispatch/DispatchEngineImpl.java b/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/core/dispatch/DispatchEngineImpl.java
index 1cf884d8..ba7d98cf 100644
--- a/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/core/dispatch/DispatchEngineImpl.java
+++ b/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/core/dispatch/DispatchEngineImpl.java
@@ -362,6 +362,23 @@ public class DispatchEngineImpl implements DispatchEngine {
         Long orderId = context.getOrderId();
         Long assigneeId = context.getRecommendedAssigneeId();
 
+        // 兜底校验：调度策略基于 Redis 的设备状态判空闲，可能与 MySQL 的 ops_order 实际活跃态不一致
+        // （例如设备 Redis 状态被某次 COMPLETED 清回 IDLE 但历史 CONFIRMED/DISPATCHED 单仍残留）。
+        // 若分配路径会真正推送工单给设备（DIRECT_DISPATCH / PUSH_AND_ENQUEUE），
+        // 此处再查一次 MySQL，非空闲时强制降级到 ENQUEUE_ONLY，避免同一设备并行多单的状态错乱。
+        if (assigneeId != null
+                && (decision.getPath() == DispatchPath.DIRECT_DISPATCH
+                        || decision.getPath() == DispatchPath.PUSH_AND_ENQUEUE)) {
+            List<OpsOrderDO> activeOrders = orderMapper.selectActiveByAssignee(assigneeId, orderId);
+            if (!activeOrders.isEmpty()) {
+                OpsOrderDO head = activeOrders.get(0);
+                log.warn("调度决策为 {} 但执行人仍挂活跃工单，降级为仅入队: orderId={}, assigneeId={}, activeCount={}, sampleOrderId={}, sampleStatus={}",
+                        decision.getPath(), orderId, assigneeId,
+                        activeOrders.size(), head.getId(), head.getStatus());
+                return executeEnqueueOnly(context, assigneeId);
+            }
+        }
+
         switch (decision.getPath()) {
             case DIRECT_DISPATCH:
                 return executeDirectDispatch(context, assigneeId);
diff --git a/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/dal/mysql/queue/OpsOrderQueueMapper.java b/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/dal/mysql/queue/OpsOrderQueueMapper.java
index f6ed6f62..a25c207d 100644
--- a/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/dal/mysql/queue/OpsOrderQueueMapper.java
+++ b/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/dal/mysql/queue/OpsOrderQueueMapper.java
@@ -54,7 +54,7 @@ public interface OpsOrderQueueMapper extends BaseMapperX<OpsOrderQueueDO> {
     }
 
     /**
-     * 根据用户ID查询队列列表
+     * 根据用户ID查询队列列表（含历史 REMOVED 记录，通常用于审计/统计）
      */
     default List<OpsOrderQueueDO> selectListByUserId(Long userId) {
         return selectList(new LambdaQueryWrapperX<OpsOrderQueueDO>()
@@ -62,6 +62,19 @@ public interface OpsOrderQueueMapper extends BaseMapperX<OpsOrderQueueDO> {
                 .orderByDesc(OpsOrderQueueDO::getEnqueueTime));
     }
 
+    /**
+     * 根据用户ID查询活跃队列列表（仅 WAITING/PROCESSING/PAUSED，排除 REMOVED/已终态）
+     * <p>
+     * 同步到 Redis、计算队列长度、查询当前任务等场景应走此方法，避免
+     * 将历史 REMOVED 记录同步到 Redis 造成 ZSet / Hash 膨胀。
+     */
+    default List<OpsOrderQueueDO> selectActiveListByUserId(Long userId) {
+        return selectList(new LambdaQueryWrapperX<OpsOrderQueueDO>()
+                .eq(OpsOrderQueueDO::getUserId, userId)
+                .in(OpsOrderQueueDO::getQueueStatus, "WAITING", "PROCESSING", "PAUSED")
+                .orderByDesc(OpsOrderQueueDO::getEnqueueTime));
+    }
+
     /**
      * 根据用户ID和状态查询队列列表
      * 用于强制从 MySQL 读取最新数据
diff --git a/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/service/queue/OrderQueueServiceEnhanced.java b/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/service/queue/OrderQueueServiceEnhanced.java
index aeb3fc2b..ef723a69 100644
--- a/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/service/queue/OrderQueueServiceEnhanced.java
+++ b/viewsh-module-ops/viewsh-module-ops-biz/src/main/java/com/viewsh/module/ops/service/queue/OrderQueueServiceEnhanced.java
@@ -467,7 +467,8 @@ public class OrderQueueServiceEnhanced implements OrderQueueService {
         }
 
         // 2. Redis 未命中，从 MySQL 获取并同步到 Redis
-        List<OpsOrderQueueDO> mysqlList = orderQueueMapper.selectListByUserId(userId);
+        // 只同步活跃态（WAITING/PROCESSING/PAUSED），排除 REMOVED 历史记录，避免 Redis 膨胀
+        List<OpsOrderQueueDO> mysqlList = orderQueueMapper.selectActiveListByUserId(userId);
         if (mysqlList != null && !mysqlList.isEmpty()) {
             // 同步到 Redis
             List<OrderQueueDTO> dtoList = convertToDTO(mysqlList);
@@ -764,7 +765,8 @@ public class OrderQueueServiceEnhanced implements OrderQueueService {
     }
 
     private void syncUserQueueToRedis(Long userId, List<OrderQueueDTO> rebuiltWaitingTasks) {
-        List<OpsOrderQueueDO> queues = orderQueueMapper.selectListByUserId(userId);
+        // 只同步活跃态（WAITING/PROCESSING/PAUSED），避免把历史 REMOVED 记录回写 Redis ZSet/Hash
+        List<OpsOrderQueueDO> queues = orderQueueMapper.selectActiveListByUserId(userId);
         if (queues == null || queues.isEmpty()) {
             redisQueueService.clearQueue(userId);
             return;