fix: shrink npm tarball by excluding sharp and pruning standalone

[NiveditJain]

Summary

The published npm package was 20.3 MB packed / 56.4 MB unpacked / 1761 files, dominated by .next/standalone/ (55.9 MB). This shrinks it to ~4.1 MB packed / ~19.2 MB unpacked / ~1342 files — a ~5x reduction in packed size — with zero runtime behavior change.

Motivated by a user report of ETARGET: No matching version found for failproofai@0.0.6-beta.3 seen ~49 s after publish completed; investigation traced the root cause to oversized artifacts (34 MB of @img/sharp native binaries + over-traced project files) bundled into .next/standalone/ by Next.js NFT.

Changes

• next.config.ts: add outputFileTracingExcludes for node_modules/@img/** and node_modules/sharp/**. Image optimization is already disabled globally (images.unoptimized: true), so the 34 MB of sharp binaries NFT was tracing in as an optional dep is dead weight.
• scripts/prune-standalone.mjs (new): post-build pass that
  1. removes @img/sharp belt-and-suspenders in case NFT still catches them on some Turbopack version,
  2. strips .md/.map/test dirs/changelogs from bundled node_modules/,
  3. deletes over-traced project artifacts (docs/, src/, scripts/, dist/, bin/, examples/, agent configs, root markdown, build/lint/test configs, bun.lock) from the standalone root that NFT pulls in but the runtime never reads.
• package.json: append && node scripts/prune-standalone.mjs to the build script.
• CHANGELOG.md: entry under ## Unreleased → ### Fixes.

Test plan

• bun run build — clean build, prune logs 1632 files / 20.32 MB -> 1270 files / 17.82 MB (saved 362 files / 2.50 MB)
• node .next/standalone/server.js — dashboard boots: / → 307 → /policies, /policies returns 200 with 23.6 KB HTML, /projects returns 200
• bun run test:run — 965/965 unit tests pass across 52 files
• bun run test:e2e — 207/207 e2e tests pass across 6 files
• Docker clean-install smoke test per CLAUDE.md — failproofai --version returns 0.0.6-beta.4, failproofai p -i -c /tmp/test-policy.mjs validates the custom hook
• npm pack --dry-run — package size 4.1 MB, unpacked 19.2 MB, 1342 files

🤖 Generated with Claude Code

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ℹ️ Review info

⚙️ Run configuration

Configuration used: defaults

Review profile: CHILL

Plan: Pro

Run ID: d552e055-867e-4207-92c4-776aa5444ac6

📥 Commits

Reviewing files that changed from the base of the PR and between cb3e5e3 and 46b1aec.

📒 Files selected for processing (4)

• CHANGELOG.md
• next.config.ts
• package.json
• scripts/prune-standalone.mjs

✨ Finishing Touches

🧪 Generate unit tests (beta)

• Create PR with unit tests
• Commit unit tests in branch luv-136

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