diff --git a/vr180_matting/checkpoint_manager.py b/vr180_matting/checkpoint_manager.py
index 3272d89..b16fdd0 100644
--- a/vr180_matting/checkpoint_manager.py
+++ b/vr180_matting/checkpoint_manager.py
@@ -140,12 +140,25 @@ class CheckpointManager:
     def get_completed_chunk_files(self) -> List[Path]:
         """Get list of all completed chunk files in order"""
         chunk_files = []
+        missing_chunks = []
+        
         for i in range(self.status['total_chunks']):
             chunk_file = self.get_chunk_file(i)
             if chunk_file:
                 chunk_files.append(chunk_file)
             else:
-                break  # Stop at first missing chunk
+                # Check if chunk is marked as completed but file is missing
+                if self.is_chunk_completed(i):
+                    missing_chunks.append(i)
+                    print(f"⚠️  Chunk {i} marked complete but file missing!")
+                else:
+                    break  # Stop at first unprocessed chunk
+        
+        if missing_chunks:
+            print(f"❌ Missing checkpoint files for chunks: {missing_chunks}")
+            print(f"   This may happen if files were deleted during streaming merge")
+            print(f"   These chunks may need to be reprocessed")
+        
         return chunk_files
     
     def mark_processing_complete(self):
diff --git a/vr180_matting/video_processor.py b/vr180_matting/video_processor.py
index 3ee8957..94759cd 100644
--- a/vr180_matting/video_processor.py
+++ b/vr180_matting/video_processor.py
@@ -453,20 +453,17 @@ class VideoProcessor:
                 chunk_data.close()
                 del chunk_data, frames_array
                 
-                # Delete chunk file to free disk space
-                try:
-                    chunk_file.unlink()
-                    print(f"   🗑️  Deleted {chunk_file.name}")
-                except Exception as e:
-                    print(f"   ⚠️  Could not delete {chunk_file.name}: {e}")
+                # Don't delete checkpoint files - they're needed for potential resume
+                # The checkpoint system manages cleanup separately
+                print(f"   📋 Keeping checkpoint file: {chunk_file.name}")
                 
                 # Aggressive cleanup and memory monitoring after each chunk
                 self._aggressive_memory_cleanup(f"After streaming merge chunk {i}")
                 
                 # Memory safety check
                 memory_info = self._get_process_memory_info()
-                if memory_info['rss_gb'] > 35:  # Warning if approaching 46GB limit
-                    print(f"⚠️  High memory usage: {memory_info['rss_gb']:.1f}GB - forcing cleanup")
+                if memory_info['total_process_gb'] > 35:  # Warning if approaching 46GB limit
+                    print(f"⚠️  High memory usage: {memory_info['total_process_gb']:.1f}GB - forcing cleanup")
                     gc.collect()
                     import torch
                     if torch.cuda.is_available():
@@ -882,6 +879,13 @@ class VideoProcessor:
                 # Use streaming merge to avoid memory accumulation (fixes OOM)
                 print("\n🎬 Using streaming merge (no memory accumulation)...")
                 
+                # For resume scenarios, make sure we have all chunk files
+                if resume_info['can_resume']:
+                    checkpoint_chunk_files = checkpoint_mgr.get_completed_chunk_files()
+                    if len(checkpoint_chunk_files) != len(chunk_files):
+                        print(f"⚠️  Using {len(checkpoint_chunk_files)} checkpoint files instead of {len(chunk_files)} temp files")
+                        chunk_files = checkpoint_chunk_files
+                
                 # Determine audio source for final video
                 audio_source = None
                 if self.config.output.preserve_audio and Path(self.config.input.video_path).exists():