Gary,
I've investigated the problem, but I don't have a solution.
I can tell you what's
not happening. When a command process starts, it announces itself by sending a message to all listening processes. This is handled by a OS X framework called the Distributed Notification Center.
In a nutshell, the command says "hey, I'm starting, if anyone wants to monitor my progress you can do so." The monitor process listens for that message, connects with the command, and displays its progress.
On your system, the message sent by the command doesn't always get to the monitor. I filtered your log records down to just those between the monitor process and the commands. Most of the time it works the way it should, like this:
2012-02-21 06:37:47.325 - Monitor process started (pid=190)
2012-02-21 06:47:03.827 Command requested monitoring (pid=403)
2012-02-21 06:47:03.829 Monitor received request for monitoring (pid=190)
2012-02-21 06:50:23.423 Command requested monitoring (pid=406)
2012-02-21 06:50:23.426 Monitor received request for monitoring (pid=190)
2012-02-21 09:21:11.037 Command requested monitoring (pid=1031)
2012-02-21 09:21:11.041 Monitor received request for monitoring (pid=190)
The command announces itself, the monitor receives that announcement within milliseconds, and starts monitoring it.
But for some reason, the announcement sometimes gets lost. This if from the same diagnostic report you sent:
2012-02-23 00:14:54.776 - Monitor process started (pid=195)
2012-02-23 00:15:23.959 Command requested monitoring (pid=235)
2012-02-23 00:16:14.360 Command requested monitoring (pid=242)
2012-02-23 00:16:33.947 Command requested monitoring (pid=235)
Here the commands announce themselves again and again, but the monitor process never receives any announcements. This agrees with the behavior you describe; you start an action, but the monitor window never appears.
I don't see anything unusual about your configuration, nor can I explain why it works sometimes and not others. The only thing I can think of would be to look in the system.log console log to see if there are any messages related to the QRecallMonitor process around the time that the notification wasn't delivered.
I'll report my findings to Apple, but I don't have a fix for this at this time.