From 02ea2d3588f7eeb3357dfa625559442fa9167310 Mon Sep 17 00:00:00 2001
From: Miguel Angel Simon Sierra <miguel.sierra@heygen.com>
Date: Fri, 23 Oct 2026 09:38:14 -0400
Subject: [PATCH] fix(ci): a package fails its size budget only when more than
 1% over it

The budgets are the exact packed sizes people last measured, so a few hundred bytes of ordinary code failed Build. The exact budget stays the number to bump and the 15% ratchet stays; only the over-budget comparison gets 1% of tolerance.
---
 scripts/verify-packed-manifests.mjs      |  6 ++++--
 scripts/verify-packed-manifests.test.mjs | 26 +++++++++++++++++++++---
 2 files changed, 27 insertions(+), 5 deletions(-)

diff --git a/scripts/verify-packed-manifests.mjs b/scripts/verify-packed-manifests.mjs
index 89860db5b22..ef4ff74b39c 100644
--- a/scripts/verify-packed-manifests.mjs
+++ b/scripts/verify-packed-manifests.mjs
@@ -28,8 +28,10 @@ const PACKED_JAVASCRIPT_FILE_PATTERN = /\.(?:js|mjs|cjs)$/;
 const SIZE_BUDGETS_FILE = "scripts/package-size-budgets.json";
 // A budget sits 5% above the measured size; a package that shrinks 15% below
 // its budget fails until the budget follows it down, so budgets only ratchet down.
+// A few hundred bytes over the budget is not bloat: only more than 1% over fails.
 const SIZE_BUDGET_HEADROOM = 1.05;
 const SIZE_BUDGET_RATCHET = 0.85;
+const SIZE_BUDGET_TOLERANCE = 1.01;
 
 function listWorkspacePackageDirs() {
   return readdirSync(PACKAGES_DIR)
@@ -568,9 +570,9 @@ export function listPackageSizeIssues(name, sizes, budget) {
     if (!Number.isFinite(budget[kind]) || budget[kind] <= 0) {
       return [`${name} has an invalid ${kind} budget in ${SIZE_BUDGETS_FILE}: use a byte count.`];
     }
-    if (sizes[kind] > budget[kind]) {
+    if (sizes[kind] > budget[kind] * SIZE_BUDGET_TOLERANCE) {
       return [
-        `${name} ${kind} size ${sizes[kind]} bytes is over its budget of ${budget[kind]}. Keep source maps, tests and unused assets out of the tarball; raise the budget in ${SIZE_BUDGETS_FILE} only with the reason in the PR.`,
+        `${name} ${kind} size ${sizes[kind]} bytes is over its budget of ${budget[kind]} by more than 1%. Keep source maps, tests and unused assets out of the tarball; raise the budget in ${SIZE_BUDGETS_FILE} only with the reason in the PR.`,
       ];
     }
     if (sizes[kind] < budget[kind] * SIZE_BUDGET_RATCHET) {
diff --git a/scripts/verify-packed-manifests.test.mjs b/scripts/verify-packed-manifests.test.mjs
index 06af0d7abeb..36b511f07e6 100644
--- a/scripts/verify-packed-manifests.test.mjs
+++ b/scripts/verify-packed-manifests.test.mjs
@@ -28,14 +28,34 @@ describe("packed manifest verifier", () => {
     assert.deepEqual(listPackageSizeIssues("pkg", { packed: 950, unpacked: 3900 }, budget), []);
   });
 
-  it("fails a package over its size budget", () => {
+  it("passes a package a few hundred bytes over its budget, within 1%", () => {
+    const budget = { packed: 73369, unpacked: 266805 };
+    // The sizes the 0.8.187 publish job measured for aws-lambda: 115 B and 208 B over.
+    assert.deepEqual(listPackageSizeIssues("pkg", { packed: 73484, unpacked: 267013 }, budget), []);
+    assert.deepEqual(
+      listPackageSizeIssues(
+        "pkg",
+        { packed: 1010, unpacked: 4040 },
+        {
+          packed: 1000,
+          unpacked: 4000,
+        },
+      ),
+      [],
+    );
+  });
+
+  it("fails a package more than 1% over its size budget", () => {
     const issues = listPackageSizeIssues(
       "pkg",
-      { packed: 1001, unpacked: 3900 },
+      { packed: 1011, unpacked: 3900 },
       { packed: 1000, unpacked: 4000 },
     );
     assert.equal(issues.length, 1);
-    assert.match(issues[0], /pkg packed size 1001 bytes is over its budget of 1000/);
+    assert.match(
+      issues[0],
+      /pkg packed size 1011 bytes is over its budget of 1000 by more than 1%/,
+    );
   });
 
   it("makes a budget follow a package down once it shrinks", () => {