fix: reduce dashboard JS bundle from 1.7MB to 170KB (#792)

packages/cli/__tests__/commands/dashboard.test.ts

@@ -89,45 +89,83 @@ describe("findRunningDashboardPid", () => {
   });
 });
 
-describe("findProcessWebDir", () => {
-  it("extracts cwd from lsof output", async () => {
-    const webDir = join(tmpDir, "web");
-    mkdirSync(webDir, { recursive: true });
-    writeFileSync(join(webDir, "package.json"), "{}");
+describe("isInstalledUnderNodeModules", () => {
+  it("returns true for a Unix node_modules path segment", async () => {
+    const { isInstalledUnderNodeModules } = await import("../../src/lib/dashboard-rebuild.js");
 
-    // Simulate lsof -p <pid> -Fn output
-    mockExecSilent.mockResolvedValue(
-      `p12345\nfcwd\nn${webDir}\nftxt\nn/usr/bin/node`,
-    );
+    expect(isInstalledUnderNodeModules("/usr/local/lib/node_modules/@composio/ao-web")).toBe(true);
+  });
 
-    const { findProcessWebDir } = await import("../../src/lib/dashboard-rebuild.js");
+  it("returns true for a Windows node_modules path segment", async () => {
+    const { isInstalledUnderNodeModules } = await import("../../src/lib/dashboard-rebuild.js");
 
-    const result = await findProcessWebDir("12345");
-    expect(result).toBe(webDir);
+    expect(isInstalledUnderNodeModules("C:\\Users\\me\\node_modules\\@composio\\ao-web")).toBe(true);
   });
 
-  it("returns null when cwd has no package.json", async () => {
-    const webDir = join(tmpDir, "web");
+  it("returns false for source paths containing node_modules as plain text", async () => {
+    const { isInstalledUnderNodeModules } = await import("../../src/lib/dashboard-rebuild.js");
+
+    expect(
+      isInstalledUnderNodeModules("/home/user/node_modules_backup/agent-orchestrator/packages/web"),
+    ).toBe(false);
+  });
+});
+
+describe("assertDashboardRebuildSupported", () => {
+  it("passes for a source checkout", async () => {
+    const { assertDashboardRebuildSupported } = await import("../../src/lib/dashboard-rebuild.js");
+
+    expect(() =>
+      assertDashboardRebuildSupported("/home/user/agent-orchestrator/packages/web"),
+    ).not.toThrow();
+  });
+
+  it("throws for an npm-installed package path", async () => {
+    const { assertDashboardRebuildSupported } = await import("../../src/lib/dashboard-rebuild.js");
+
+    expect(() =>
+      assertDashboardRebuildSupported("/usr/local/lib/node_modules/@composio/ao-web"),
+    ).toThrow("Dashboard rebuild is only available from a source checkout");
+  });
+});
+
+describe("rebuildDashboardProductionArtifacts", () => {
+  it("cleans .next and runs pnpm build on success", async () => {
+    const webDir = join(tmpDir, "packages", "web");
     mkdirSync(webDir, { recursive: true });
-    // No package.json
+    mkdirSync(join(webDir, ".next"), { recursive: true });
 
-    mockExecSilent.mockResolvedValue(
-      `p12345\nfcwd\nn${webDir}\nftxt\nn/usr/bin/node`,
-    );
+    mockExec.mockResolvedValue({ stdout: "", stderr: "" });
 
-    const { findProcessWebDir } = await import("../../src/lib/dashboard-rebuild.js");
+    const { rebuildDashboardProductionArtifacts } = await import("../../src/lib/dashboard-rebuild.js");
 
-    const result = await findProcessWebDir("12345");
-    expect(result).toBeNull();
+    await rebuildDashboardProductionArtifacts(webDir);
+
+    // .next should be cleaned
+    expect(existsSync(join(webDir, ".next"))).toBe(false);
+    // pnpm build should be called from workspace root (../../ relative to webDir)
+    expect(mockExec).toHaveBeenCalledWith("pnpm", ["build"], { cwd: tmpDir });
   });
 
-  it("returns null when lsof fails", async () => {
-    mockExecSilent.mockResolvedValue(null);
+  it("throws when pnpm build fails", async () => {
+    const webDir = join(tmpDir, "packages", "web");
+    mkdirSync(webDir, { recursive: true });
+
+    mockExec.mockRejectedValue(new Error("build failed"));
+
+    const { rebuildDashboardProductionArtifacts } = await import("../../src/lib/dashboard-rebuild.js");
+
+    await expect(rebuildDashboardProductionArtifacts(webDir)).rejects.toThrow(
+      "Failed to rebuild dashboard production artifacts",
+    );
+  });
 
-    const { findProcessWebDir } = await import("../../src/lib/dashboard-rebuild.js");
+  it("throws when called from an npm-installed path", async () => {
+    const { rebuildDashboardProductionArtifacts } = await import("../../src/lib/dashboard-rebuild.js");
 
-    const result = await findProcessWebDir("12345");
-    expect(result).toBeNull();
+    await expect(
+      rebuildDashboardProductionArtifacts("/usr/local/lib/node_modules/@composio/ao-web"),
+    ).rejects.toThrow("Dashboard rebuild is only available from a source checkout");
   });
 });
 

packages/cli/__tests__/commands/start.test.ts

@@ -113,9 +113,8 @@ vi.mock("../../src/lib/web-dir.js", () => ({
 }));
 
 vi.mock("../../src/lib/dashboard-rebuild.js", () => ({
-  cleanNextCache: vi.fn(),
   findRunningDashboardPid: vi.fn().mockResolvedValue(null),
-  findProcessWebDir: vi.fn().mockResolvedValue(null),
+  rebuildDashboardProductionArtifacts: vi.fn().mockResolvedValue(undefined),
   waitForPortFree: vi.fn(),
 }));
 

packages/cli/__tests__/lib/preflight.test.ts

@@ -18,6 +18,11 @@ vi.mock("node:fs", () => ({
   existsSync: mockExistsSync,
 }));
 
+vi.mock("../../src/lib/dashboard-rebuild.js", () => ({
+  isInstalledUnderNodeModules: (path: string) =>
+    path.includes("/node_modules/") || path.includes("\\node_modules\\"),
+}));
+
 import { preflight } from "../../src/lib/preflight.js";
 
 beforeEach(() => {
@@ -58,9 +63,12 @@ describe("preflight.checkBuilt", () => {
     // /web/node_modules/@composio/ao-core     — miss
     // /node_modules/@composio/ao-core         — hit
     // /node_modules/@composio/ao-core/dist/index.js — exists
+    // /web/.next/BUILD_ID and /web/dist-server/start-all.js — exist
     mockExistsSync
       .mockReturnValueOnce(false)
       .mockReturnValueOnce(true)
+      .mockReturnValueOnce(true)
+      .mockReturnValueOnce(true)
       .mockReturnValueOnce(true);
     await expect(preflight.checkBuilt("/web")).resolves.toBeUndefined();
   });
@@ -88,6 +96,38 @@ describe("preflight.checkBuilt", () => {
       "Packages not built",
     );
   });
+
+  it("throws when web production artifacts are missing", async () => {
+    // findPackageUp finds ao-core, dist/index.js exists, but .next/BUILD_ID missing
+    mockExistsSync
+      .mockReturnValueOnce(true)
+      .mockReturnValueOnce(true)
+      .mockReturnValueOnce(false);
+    await expect(preflight.checkBuilt("/web")).rejects.toThrow(
+      "Packages not built",
+    );
+  });
+
+  it("throws npm hint when web artifacts missing in global install", async () => {
+    // ao-core found at first check, dist exists, but .next/BUILD_ID missing
+    mockExistsSync
+      .mockReturnValueOnce(true)
+      .mockReturnValueOnce(true)
+      .mockReturnValueOnce(false);
+    await expect(
+      preflight.checkBuilt("/usr/local/lib/node_modules/@composio/ao-web"),
+    ).rejects.toThrow("npm install -g @composio/ao@latest");
+  });
+
+  it("throws npm hint when ao-core dist is missing in global install", async () => {
+    // ao-core found, but dist/index.js missing
+    mockExistsSync
+      .mockReturnValueOnce(true)
+      .mockReturnValueOnce(false);
+    await expect(
+      preflight.checkBuilt("/usr/local/lib/node_modules/@composio/ao-web"),
+    ).rejects.toThrow("npm install -g @composio/ao@latest");
+  });
 });
 
 describe("preflight.checkTmux", () => {

packages/cli/src/commands/dashboard.ts

@@ -1,11 +1,16 @@
 import { spawn } from "node:child_process";
-import { existsSync } from "node:fs";
 import { resolve } from "node:path";
 import chalk from "chalk";
 import type { Command } from "commander";
 import { loadConfig } from "@composio/ao-core";
 import { findWebDir, buildDashboardEnv, waitForPortAndOpen } from "../lib/web-dir.js";
-import { cleanNextCache, findRunningDashboardPid, findProcessWebDir, waitForPortFree } from "../lib/dashboard-rebuild.js";
+import {
+  findRunningDashboardPid,
+  isInstalledUnderNodeModules,
+  rebuildDashboardProductionArtifacts,
+  waitForPortFree,
+} from "../lib/dashboard-rebuild.js";
+import { preflight } from "../lib/preflight.js";
 
 export function registerDashboard(program: Command): void {
   program
@@ -14,6 +19,7 @@ export function registerDashboard(program: Command): void {
     .option("-p, --port <port>", "Port to listen on")
     .option("--no-open", "Don't open browser automatically")
     .option("--rebuild", "Clean stale build artifacts and rebuild before starting")
+    /* c8 ignore start -- process-spawning startup code, tested via integration/onboarding */
     .action(async (opts: { port?: string; open?: boolean; rebuild?: boolean }) => {
       const config = loadConfig();
       const port = opts.port ? parseInt(opts.port, 10) : (config.port ?? 3000);
@@ -28,11 +34,9 @@ export function registerDashboard(program: Command): void {
       if (opts.rebuild) {
         // Check if a dashboard is already running on this port.
         const runningPid = await findRunningDashboardPid(port);
-        const runningWebDir = runningPid ? await findProcessWebDir(runningPid) : null;
-        const targetWebDir = runningWebDir ?? localWebDir;
 
         if (runningPid) {
-          // Kill the running server, clean .next, then start fresh below.
+          // Stop the running server before rebuilding or restarting below.
           console.log(
             chalk.dim(`Stopping dashboard (PID ${runningPid}) on port ${port}...`),
           );
@@ -45,8 +49,10 @@ export function registerDashboard(program: Command): void {
           await waitForPortFree(port, 5000);
         }
 
-        await cleanNextCache(targetWebDir);
+        await rebuildDashboardProductionArtifacts(localWebDir);
         // Fall through to start the dashboard on this port.
+      } else {
+        await preflight.checkBuilt(localWebDir);
       }
 
       const webDir = localWebDir;
@@ -60,21 +66,12 @@ export function registerDashboard(program: Command): void {
         config.directTerminalPort,
       );
 
-      // In dev mode (monorepo), use `pnpm run dev` which starts Next.js AND
-      // the terminal WebSocket servers via concurrently. Without the WS servers,
-      // the live terminal in the dashboard won't work.
-      const isDevMode = existsSync(resolve(webDir, "server"));
-      const child = isDevMode
-        ? spawn("pnpm", ["run", "dev"], {
-            cwd: webDir,
-            stdio: ["inherit", "inherit", "pipe"],
-            env,
-          })
-        : spawn("npx", ["next", "dev", "-p", String(port)], {
-            cwd: webDir,
-            stdio: ["inherit", "inherit", "pipe"],
-            env,
-          });
+      const startScript = resolve(webDir, "dist-server", "start-all.js");
+      const child = spawn("node", [startScript], {
+        cwd: webDir,
+        stdio: ["inherit", "inherit", "pipe"],
+        env,
+      });
 
       const stderrChunks: string[] = [];
 
@@ -108,10 +105,13 @@ export function registerDashboard(program: Command): void {
         if (code !== 0 && code !== null && !opts.rebuild) {
           const stderr = stderrChunks.join("");
           if (looksLikeStaleBuild(stderr)) {
+            const recoveryCommand = isInstalledUnderNodeModules(webDir)
+              ? "npm install -g @composio/ao@latest"
+              : "ao dashboard --rebuild";
             console.error(
               chalk.yellow(
                 "\nThis looks like a stale build cache issue. Try:\n\n" +
-                  `  ${chalk.cyan("ao dashboard --rebuild")}\n`,
+                  `  ${chalk.cyan(recoveryCommand)}\n`,
               ),
             );
           }
@@ -120,6 +120,7 @@ export function registerDashboard(program: Command): void {
         process.exit(code ?? 0);
       });
     });
+    /* c8 ignore stop */
 }
 
 /**