build: add bundle-size analysis tooling + baseline report + 500 kB gate

[adm01-debug]

Summary

Adds bundle-size analysis tooling, a baseline report, an optimization plan, and a CI-ready 500 kB gzip gate.

Why

The build is currently healthy — no chunk exceeds 500 kB gzip — but there was no tooling to verify that or to detect regressions. rollup-plugin-visualizer is wired in vite.config.ts but its mode === 'production' conditional doesn't reliably emit dist/stats.html on the current Vite version, leaving no post-build view of the bundle.

Current baseline

Total: 2.97 MB gzip / 13.6 MB raw across 294 chunks
Largest chunk: export-vendor (182 kB gzip / 608 kB raw)
> 500 kB gzip: 0 chunks ✅
> 250 kB gzip: 0 chunks ✅

What's added

scripts/bundle-analysis.mjs

Standalone analyzer that walks dist/assets/*.js, computes raw + gzip sizes, buckets chunks by category (vendor:*, page:admin, page:other, hook, ui:overlay, app:entry, lazy:chunk), and emits:

• Human table to stdout (default)
• JSON to stdout (--json)
• Markdown to docs/BUNDLE_REPORT.md (--md)
• Exit 1 if any chunk > 500 kB gzip (--check) — for CI gate

npm scripts

"build:analyze":       "vite build && node scripts/bundle-analysis.mjs",
"build:analyze:md":    "vite build && node scripts/bundle-analysis.mjs --md",
"build:analyze:check": "vite build && node scripts/bundle-analysis.mjs --check",

docs/BUNDLE_ANALYSIS.md + docs/BUNDLE_REPORT.md

• BUNDLE_ANALYSIS.md — narrative: current state, top offender table, prioritized optimization plan (medium: lucide-react tree-shaking ≈ 80–100 kB gzip savings; medium: split AdminConexoesPage explain-mode), CI workflow snippet
• BUNDLE_REPORT.md — auto-generated machine output (top 15 chunks, by-category breakdown, flagged offenders)

CI gate (suggested follow-up)

- name: Bundle size budget
  run: npm run build:analyze:check

Hard error at 500 kB gzip rather than soft warn — that's the threshold where mobile TTI starts to degrade meaningfully.

Test plan

• node scripts/bundle-analysis.mjs — works on current dist/
• node scripts/bundle-analysis.mjs --md — writes docs/BUNDLE_REPORT.md
• node scripts/bundle-analysis.mjs --check — exits 0 (no offenders today)
• npm run build:analyze — full pipeline

https://claude.ai/code/session_01KWeDG

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• Create PR with unit tests
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[adm01-debug]

Update on the lucide-react tree-shaking suggestion (§ Optimization opportunities, 🟡 Medium)

I tested the suggested codemod (rewriting import { X } from 'lucide-react' to import X from 'lucide-react/dist/esm/icons/<x>') on a branch off main:

• 1568 source files scanned
• 880 import blocks rewritten across 869 files
• 4375 icon specifiers converted

Result: zero size change. icons-vendor chunk stayed at exactly 680171 bytes / 120.96 kB gzip before and after.

Why it's a no-op

lucide-react@0.309.0 declares "sideEffects": false in its package.json, which is the canonical signal to Rollup/Vite that all named exports from the barrel can be tree-shaken individually. The 285 icons our app actually imports are exactly what ends up in the bundle, regardless of whether they come via import { Foo } from 'lucide-react' or import Foo from 'lucide-react/dist/esm/icons/foo'.

Implication for docs/BUNDLE_ANALYSIS.md

The 80–100 kB savings claim in the doc isn't reachable on this lucide version. The icons-vendor chunk size is already at the tree-shaken minimum — it's 285 icons × ~2 kB each (raw) plus the runtime helper. The only ways to shrink it further:

1. Use fewer icons (product policy, not technical optimization)
2. Bump lucide-react if a future version exposes a smaller per-icon helper
3. Switch to a different icon library (heroicons, radix-icons, etc.)

I'd suggest editing the relevant section of the doc on this branch before merging — replacing the "Medium savings" claim with the no-op finding and the three actual options above. I won't push that change here without your input since it's your PR; happy to do a follow-up PR if preferred.

The 869-file refactor was verified locally (tsc --noEmit and full vite build both passed) but is not being shipped because the trade-off (massive diff, no measurable benefit) doesn't pencil out.

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