release-and-ci

name	release-and-ci
description	PR-to-production pipeline — failed CI checks (Build, Unit Tests Complete, Quality, PWA Smoke Test, Conventional Commit), bundle-size (size-limit) failures, PR title rules, release-please version bumps, stuck "chore(main): release" PRs, Vercel deploy/skip logic, production rollback, "Production smoke failed" issues, editing .github/workflows/*.

Release and CI

When to use

• A PR check is red and you need to diagnose or reproduce it locally.
• Shipping a change: PR title, merge, release, deploy questions.
• Releases stopped flowing, a version bump is wrong, or production needs a rollback.
• Adding or editing anything under .github/workflows/ or the Vercel config.

Mental model

1. Everything squash-merges to main. The PR title (validated by .github/workflows/pr-title.yml as a conventional commit, lowercase subject) becomes the main commit, the CHANGELOG line, and the version-bump signal. fix/perf → patch, feat → minor, !/breaking footer → major. Types refactor/chore/test/docs/style are hidden from the CHANGELOG and bump nothing (release-please-config.json).
2. On every main push, .github/workflows/release.yml runs release-please, which maintains a chore(main): release gridfinity-layout-tool x.y.z PR and auto-approves + auto-merges it (GitHub App token, 6 merge retries). No human touches releases. CHANGELOG.md, .release-please-manifest.json, and the version in package.json are machine-owned — never hand-edit; the manifest and package.json version must move in lockstep.
3. Vercel deploys every merge to main that touches SPA paths (the list in scripts/vercel-ignore.sh: src/, public/, index.html, package.json, pnpm-lock.yaml, vite.config.ts, tsconfig*, api/) — deploys are not tied to releases. vercel.json is deliberately NOT on that list: a headers/CSP/rewrites-only change needs a manual Vercel deploy or a ride-along SPA change.
4. Two smoke layers, one spec (e2e/smoke/pwa-smoke.spec.ts via playwright.smoke.config.ts): smoke-preview.yml polls the GitHub deployments API for the Vercel preview URL on PRs; smoke-postpromote.yml smokes https://gridfinitylayouttool.com after each production deploy and on failure runs vercel rollback and files a priority: critical issue.
5. CI is stricter on main than on PRs: PRs run 6 sharded test jobs (3 generators, 3 core); main runs the full suite with coverage thresholds plus the fail-closed OSV scan and PostHog source-map upload. A PR can merge green and still break main.
6. Every CI job carries if: !startsWith(github.head_ref, 'release-please--'). Any new required workflow MUST copy this guard, or the release PR waits forever on a check that never runs and all releases silently stall. Branch protection requires the aggregate Unit Tests Complete (test-gate job in ci.yml), not shard names — change shard counts freely, never rename that job.

The workflow files themselves (ci.yml, release.yml, smoke-*.yml, vite.config.ts) carry incident-history comments — read them before editing; they explain traps this file only indexes.

Recipe: diagnose a failed PR check

1. gh pr checks <pr-number> — identify the failing context.
2. Conventional Commit → the PR title is wrong (bad type or uppercase subject). Edit the title on GitHub; it re-validates on edit, no push needed. Allowed types are listed in pr-title.yml.
3. Quality → the red step is only an aggregator; every real check runs with continue-on-error. Run gh run view <run-id> --log-failed and find the earlier step with the failure annotation. A "skipped" check counts as failure and means pnpm install died (usually lockfile drift under --frozen-lockfile). For what each check enforces and its legitimate unblock, see the quality-gates skill.
4. Unit Tests (shard) / Unit Tests Complete → reproduce locally:

   pnpm run build:en-locale
   pnpm vitest run --project=generators        # generators shard
   pnpm vitest run --project=unit --project=dom  # core shard
   

   build:en-locale is mandatory first — en.json is generated and gitignored. CI runs vitest with -u, so snapshot mismatches can NEVER fail CI; rule them out. See the testing skill for the project layout.
5. Build at "Check bundle size" → bundle-budget recipe below.
6. PWA Smoke Test timeout ("Timed out waiting for Vercel preview") → check the Vercel dashboard for a failed preview build; if the PR is infra-only and should skip, confirm its paths are absent from scripts/vercel-ignore.sh. For real test failures, download the trace artifact, or run locally:

   PLAYWRIGHT_TEST_BASE_URL=<preview-url> pnpm exec playwright test --config=playwright.smoke.config.ts
   

Recipe: fix a bundle-size failure

1. Reproduce: pnpm run build && pnpm run size:check.
2. Budgets live in the size-limit array in package.json: Main bundle 190 kB gzip, Eager initial JS 260 kB (main + react-vendor + state + core-foundation), Total JS 2000 kB.
3. Open bundle-analysis.html (repo root, emitted by the build) to see what grew.
4. Preferred fix: keep the weight out of eager chunks — dynamic-import it, or check the advancedChunks rules in vite.config.ts (~lines 246–290) still route it to a lazy chunk. Raising a limit in package.json is a last resort and needs justification in the PR.
5. If you rename/add a chunk in vite.config.ts, update the matching size-limit path glob in package.json in the same PR — the globs match chunk file names and drift silently otherwise.

Recipe: ship end-to-end

1. Branch off main (protected; PRs only). Pre-commit (.husky/pre-commit) does NOT run tests — run pnpm run test:run and pnpm run quality yourself before pushing.
2. Title the PR as a conventional commit, lowercase subject, scope = the touched slice (recent scopes: baseplate, bin-designer, generation, scan, design-system, deps, ci, api, shared). This exact string ships in the CHANGELOG.
3. Wait for checks (smoke-preview adds ~5 min for the Vercel preview), squash-merge.
4. If SPA paths changed, production deploys immediately; post-promote smoke guards it. release.yml then updates/merges the release PR unattended. Users see the new version (version.json / __APP_VERSION__, emitted by scripts/vite-plugin-version.ts) after the release-merge deploy.
5. Verify production: curl -s https://gridfinitylayouttool.com/version.json — gitSha should match the deployed commit (the file is no-store by vercel.json design).

Recipe: unstick a stalled release

Symptom: a chore(main): release gridfinity-layout-tool x.y.z PR sits open; no versions ship.

1. gh pr list --search "chore(main): release" to find it; check the latest release.yml run: gh run list --workflow=release.yml, then gh run view <id> --log-failed.
2. Two usual causes: expired/rotated GitHub App credentials (APP_ID / APP_PRIVATE_KEY secrets — the 6-attempt merge loop errors out), or a newly added required check missing the release-please-- skip guard so it never runs on the release branch.
3. Unblock now by merging the release PR manually (squash); fix the root cause after.

Recipe: roll back production

1. If post-promote smoke failed, rollback already ran — look for a "Production smoke failed: " issue and verify the alias in the Vercel dashboard first.
2. Manual: Vercel dashboard → Deployments → previous good deploy → Instant Rollback, or npx vercel rollback --token $VERCEL_TOKEN --scope $VERCEL_ORG_ID --yes (mirrors smoke-postpromote.yml).
3. Rollback only moves the alias. Users' installed service workers keep the bad precache until a NEW deploy's SW passes the client-side smoke gate (src/shared/pwa/smokeGate.ts). Always fix forward with a new merge to main.
4. Verify with curl -s https://gridfinitylayouttool.com/version.json.

PWA/deploy invariants (do not "simplify" these)

Setting	Where	Why it must stay
registerType: 'prompt', skipWaiting: false, clientsClaim: false	vite.config.ts VitePWA	smokeGate.ts activates the waiting SW (SKIP_WAITING), then smokes the new bundle in a hidden iframe served by the now-active SW; on failure the caller unregisters + purges the precache. autoUpdate would skip the gate and ship broken bundles straight into users' service workers
globIgnores: wwwMigration-*, smokeBoot-*, version.json	vite.config.ts workbox	Precaching one-shot chunks caused SW install failures on hash mismatch — the old SW stays in control and no fix can ever reach users
/sw.js must-revalidate, /version.json no-store	vercel.json headers	The smoke gate fetches version.json to detect fresh deploys; caching it strands users on stale versions
No extraHTTPHeaders bypass token	playwright.smoke.config.ts	Playwright sends extra headers to every origin (fonts.gstatic.com etc.), breaking CORS preflights; the spec sets a same-origin cookie via query string instead
No actions/checkout in pr-title.yml / labeler.yml	those workflows	They use pull_request_target (secrets in base-branch context); checking out PR code there is a documented pwn-request vector

Traps

Symptom	Cause	Fix
Main CI red right after a green PR merged	Coverage thresholds and fail-closed OSV run only on main	Coverage step → add tests; OSV → bump/override the vulnerable dep. Not snapshots (CI passes -u)
Deploy didn't happen after merging a config change	scripts/vercel-ignore.sh skipped it (vercel.json / docs / CI paths excluded)	Manual deploy from Vercel dashboard, or ride along with an SPA change
pnpm install can't resolve a version visible on npm	minimumReleaseAge: 10080 in pnpm-workspace.yaml (7-day supply-chain cooldown)	Wait, pin the previous version, or add to minimumReleaseAgeExclude with justification per SECURITY.md
CHANGELOG entry / version bump missing for a merged PR	PR title used a hidden type (chore/refactor/etc.)	Titles are baked in at squash; land a follow-up correctly-typed commit if a bump is needed
Green "PWA Smoke Test" but no preview was actually tested	Vercel legitimately ignored the build (docs/CI-only PR) or Dependabot PR (no bypass secret)	Expected; the job passes with a warning by design
Unminified production stack traces in PostHog lag a deploy	Source-map upload runs only on main pushes (POSTHOG_API_KEY / POSTHOG_PROJECT_ID)	Check that step in the main-branch CI run
Fresh clone: bare pnpm vitest fails with lazy-load errors	en.json is generated and gitignored	pnpm run build:en-locale first

For share/collab runtime env vars on Vercel, see the share-api-collab skill. For pre-commit gate internals and unblocks, see quality-gates.