Design review: bug fixes, token convergence, and a consolidated design-system guide

[BigSimmo]

Summary

• Bug fixes
  • Applications launcher: the three mobile detail rows ("Check first" / "Needed input" / "Output") were buttons with a chevron affordance but no handler — they now expand as accessible disclosures (aria-expanded/aria-controls, chevron rotation with motion-reduce handling).
  • Applications launcher: the hand-rolled detail modal (Escape + backdrop only) is replaced by the shared Sheet primitive, gaining focus trap, initial focus, and return-focus-on-close.
  • New styled src/app/not-found.tsx (modeled on the root error boundary, info-toned) — notFound() calls in differentials and unknown URLs no longer render the unstyled Next.js default.
  • /documents/[id]?page=abc no longer leaks NaN into the viewer header and page input — the param is parsed and clamped to ≥ 1.
• Accessibility & dark mode
  • Launcher filter tablists gained aria-controls and a role="tabpanel" results region (matching the dashboard upload-tabs precedent); answer images get a fallback alt; launcher icon tones and the safety selection state move from raw Tailwind palette classes to the categorical --type-* / semantic danger token triads so they respond to dark mode and forced-colors.
• Design convergence
  • Deleted services-navigator-preview.tsx (dead export carrying ~80 pre-token hex hardcodes) and tokenized the live /services navigator's residual hardcodes — the route now follows dark mode like every other surface.
  • Type-scale migration: arbitrary px font sizes reduced 168 → 20 (remaining are accepted rem display headings + one mockup file); leading pinned where Tailwind's baked line-heights would have shifted layout.
  • Z-index ladder documented in globals.css; one rounded-[var(--radius-md)] → rounded-md; /mockups/* layout now emits robots: noindex.
• Durable deliverable: docs/design-system.md — a consolidated front-door design guide (token contract, legacy-hex migration table, type-scale rules and ratchet, tap targets, z-ladder, Sheet-only modal policy, a11y requirements, do/don't gallery, UI Definition of Done). docs/redesign/* deep docs gain entry-point pointers; docs/process-hardening.md records the ratchet baseline and cleared debts.
• Dev-environment hardening (needed to run the UI gates in a sandboxed container, useful generally): port probes in dev-free-port.mjs/run-playwright.mjs no longer treat a missing IPv6 stack as "every port busy"; playwright.config.ts honours an optional PLAYWRIGHT_CHROMIUM_EXECUTABLE_PATH override.

Verification

• npm run verify:cheap (lint, typecheck, 1097 vitest tests, runtime + sitemap checks — green)
• npm run verify:ui when UI, routing, styling, browser behavior, reduced-motion, or forced-colors behavior changed — 103/103 Chromium Playwright tests passed (smoke, stress, accessibility incl. reduced-motion + forced-colors, tools, overlap)
• npm run verify:release before release or handoff confidence claims — not run (not a release/handoff PR)
• npm run format:check
• npm run eval:retrieval:quality — not applicable: no retrieval, ranking, selection, chunking, or scoring behavior changed
• npm run eval:rag / eval:quality --rag-only — not applicable: no answer generation or post-processing changed
• npm run check:production-readiness — not applicable: no clinical workflow, privacy, environment, Supabase, source governance, or deployment behavior changed
• npm run check:deployment-readiness — not applicable: no deployment startup/hosting changes

Manual checks on the running app: styled 404 at unknown URLs and bad differential slugs; ?page=abc / ?page=-3 render page 1 with no NaN; /applications and /services?q=crisis&run=1 render correctly.

Clinical Governance Preflight

This change is UI-only: no ingestion, answer generation, search/ranking, source rendering, document access, privacy, production env, or clinical output behavior was touched. For completeness:

• Source-backed claims still require linked source verification before clinical use
• No patient-identifiable document workflow was introduced or expanded without explicit governance approval
• Supabase target remains Clinical KB Database (sjrfecxgysukkwxsowpy)
• Service-role keys and private document access remain server-only
• Demo/synthetic content remains clearly separated from real clinical sources
• Source metadata, review status, and outdated/unknown-source behavior remain conservative
• Deployment classification/TGA SaMD impact was checked when clinical decision-support behavior changed — no decision-support behavior changed

Notes

• The type-scale ratchet baseline (20 hits / 9 files) is recorded in docs/process-hardening.md; UI PRs must not raise it. Flip check:type-scale --strict into verify:cheap only once the accepted rem display exceptions are tokenized.
• Mockup routes stay shipped (they're a working design tool); they are robots-disallowed and now also emit noindex metadata.

🤖 Generated with Claude Code

https://claude.ai/code/session_01QEEkTKt4eS4oqftBsaQKpG

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Generated by Claude Code

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Note

Low Risk
UI, documentation, and dev-script changes only; no auth, RAG, or data-path changes. Launcher modal migration is the main behavioral surface area and aligns with an existing Sheet primitive.

Overview
Adds docs/design-system.md as the day-to-day UI contract and points docs/redesign/* and docs/process-hardening.md at it (type-scale ratchet baseline 20 hits, cleared debts).

Behavior & a11y: Applications launcher mobile detail sections become real disclosures; the detail overlay moves to Sheet; filter tabs wire aria-controls and a role="tabpanel" results region. New token-styled not-found, safe ?page= parsing on document routes, and fallback image alt in answer content.

Design convergence: Removes dead services-navigator-preview and tokenizes live services UI; swaps arbitrary px type for named scale steps across dashboard/launcher surfaces; documents z-index in globals.css; mockups layout gets robots: noindex.

Tooling: Playwright can use PLAYWRIGHT_CHROMIUM_EXECUTABLE_PATH; dev port probes ignore IPv6 EAFNOSUPPORT so sandboxes can start the app and run UI gates.

^{Reviewed by Cursor Bugbot for commit 78ccd3a. Configure here.}

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[cursor]

Cursor Bugbot has reviewed your changes using high effort and found 1 potential issue.

Bugbot Autofix prepared a fix for the issue found in the latest run.

• ✅ Fixed: Tabpanel label ignores active filter
  • The tabpanel aria-label now derives from the active filter via launcherFilterPanelLabel(activeFilter), so screen readers announce Assess, Evidence, Treat, Saved, More, or All tools to match the filtered list.

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^{Reviewed by Cursor Bugbot for commit 78ccd3a. Configure here.}