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## Thinking Path > - Paperclip is the open source app people use to manage AI agents for work. > - Release checks must test the exact package that a new user installs. > - The canary onboarding smoke uses a fresh npm dependency graph. > - An upstream package can reference a dependency before that version is available. > - The smoke then exits before Paperclip onboarding starts. > - This pull request retries only that npm acquisition failure within the existing startup limit. > - Onboarding still runs once, and all other errors remain visible. ## Linked Issues or Issue Description **What happened?** [Release run 37986221440](https://github.com/paperclipai/paperclip/actions/runs/37986221440) published `2026.1009.0-canary.13`, then failed the onboarding smoke. The retained server log contains npm `ETARGET` for `@aws-sdk/credential-provider-env@^3.972.73`. The upstream parent package was published before this dependency. The missing version became available during the smoke startup. Paperclip onboarding never ran. **Expected behavior** Retry a short dependency publication window before onboarding starts. Stop on a permanent install failure. Never repeat onboarding to hide a startup failure. **Steps to reproduce** 1. Start the exact-version canary smoke with an empty npm cache. 2. Make the first npm install return `ETARGET` because a dependency version is not available. 3. Make the next install succeed after registry metadata changes. 4. Confirm that onboarding starts once. Repeat with permanent `ETARGET` and an unrelated failure; onboarding must not start. **Paperclip version or commit** The observed release source was `cb291bf1298ab484a2792c05eb977f3440f1f351`. **Deployment mode** Linux release CI. The change affects the canary smoke harness. Related: #15712 fixes a separate lockfile mismatch in the smoke's repository dependency install. This change covers the fresh published-package npm install. ## What Changed - Separate npm package acquisition from the onboarding command. - Retry only the final npm `ETARGET` error, up to three attempts with online metadata and clean temporary prefixes. - Share a two-minute acquisition budget across attempts and backoff. Keep the existing five-minute Playwright startup limit. - Run the installed exact-version CLI once. Preserve authentication, network, lifecycle, and onboarding failures. - Stop owned process groups on cancellation and remove owned install prefixes. Keep server logs and instance data for diagnostics. - Keep dependency-free helper subprocess tests in the required policy lane. Run real Playwright lifecycle tests in the required release-registry lane after its dependencies are installed. - Document the bounded behavior in the release runbook. ## Verification - `node --test scripts/__tests__/release-verify-workflow.test.mjs`: 24 passed in a clean source snapshot with no `node_modules`. These cover transient and permanent missing versions, other npm errors, nested error codes, onboarding failure, deadline expiry, and cancellation. - `pnpm test:release-registry`: 153 passed, including real Playwright teardown with a descendant that ignores SIGTERM and startup-timeout cleanup of a detached npm installer. - `pnpm -r typecheck`: passed. - `pnpm build`: passed. - `pnpm test:run`: deliberately stopped after complete hosted CI passed; this is not a local full-suite pass. The run's 15 warm-runtime real-DB cases failed before assertions because the local macOS PostgreSQL package lacked library symlinks after installation with `--ignore-scripts`. After running the package's local hydration step, all 15 affected cases passed in a targeted rerun. The remaining aggregate was stopped with exact owned-process cleanup. - [Hosted CI](https://github.com/paperclipai/paperclip/actions/runs/37994486323) is complete and green at `1c80e6f`: all tests, build, typecheck, policy, release registry, E2E, and canary dry run passed. Greptile scored the same head 5/5 with no unresolved comments. - Independent review covered all seven changed files and the exact policy and release-registry commands. It also used real npm 11.9 against a loopback registry: a required version was absent, then became available. The retry refreshed metadata and started the installed exact-version CLI once. The one-attempt negative control failed. - The new subprocess tests use local npm and CLI fixtures. They do not contact a registry or start a real Paperclip instance. - The patch preserves the exact-version clean-install check. It adds no dependency pins, credentials, or workflow reruns. ## Risks The install phase now has a two-minute budget inside the existing five-minute startup limit. An unusually slow valid install can still fail the smoke. Permanent missing versions remain failures after the bounded retry. The lifecycle tests cover the Linux release runner behavior; Playwright does not support graceful SIGTERM on Windows. No application, database, or deployment behavior changes. ## Model Used OpenAI GPT-6 through Codex, with reasoning and code execution tools. The exact service variant and context window are not exposed in this session. ## Checklist - [x] I have included a thinking path that traces from project context to this change - [x] I have specified the model used (with version and capability details) - [x] I have checked ROADMAP.md and confirmed this PR does not duplicate planned core work - [x] I have searched GitHub for duplicate or related PRs and linked them above - [x] I have either (a) linked existing issues with `Fixes: #` / `Closes: #` OR (b) described the issue in-PR following the relevant issue template - [x] I have not referenced internal/instance-local Paperclip issues or links (only public GitHub `#NNN` / `github.com/paperclipai/paperclip` URLs) - [x] My branch name describes the change (e.g. `docs/...`, `fix/...`) and contains no internal Paperclip ticket id or instance-derived details - [x] I have run tests locally and they pass - [x] I have added or updated tests where applicable - [x] I have updated relevant documentation to reflect my changes - [x] I have considered and documented any risks above - [x] All Paperclip CI gates are green - [x] Greptile is 5/5 with no open P2s, recommendations, or follow-ups - [x] I will address all Greptile and reviewer comments before requesting merge --------- Co-authored-by: Paperclip <noreply@paperclip.ing>