From c9ad90b52f7a0b75f5bfb47e38bc820d187264ed Mon Sep 17 00:00:00 2001
From: hyperpolymath <6759885+hyperpolymath@users.noreply.github.com>
Date: Mon, 6 Jul 2026 17:23:54 +0100
Subject: [PATCH] feat(rust-ci-reusable): real owned coverage gate (llvm-cov +
 ratcheted floor)
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The coverage job was opt-in tarpaulin -> external codecov with NO enforced
threshold (just an upload), so 'covered' claims were unbacked estate-wide.

Now, when enable_coverage is set, it:
  - measures line coverage with cargo-llvm-cov (accurate, no external service);
  - enforces a caller-supplied coverage_floor (new input, default 0 = report-only)
    and FAILS the job below it — a gate we OWN on our own runner;
  - reports the % to the job summary.

Ratchet model: set coverage_floor at the repo's honest baseline and raise it
toward target over time; never lower it. First consumer: hybrid-automation-router
(floor 84). This is the banked 'reusable tests for all repos' coverage gate.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
---
 .github/workflows/rust-ci-reusable.yml | 41 +++++++++++++++++++-------
 1 file changed, 30 insertions(+), 11 deletions(-)

diff --git a/.github/workflows/rust-ci-reusable.yml b/.github/workflows/rust-ci-reusable.yml
index 8cc9ad52..e1ef5cef 100644
--- a/.github/workflows/rust-ci-reusable.yml
+++ b/.github/workflows/rust-ci-reusable.yml
@@ -65,10 +65,15 @@ on:
         required: false
         default: false
       enable_coverage:
-        description: Run `cargo tarpaulin` + upload to codecov (slow; off by default)
+        description: Measure line coverage with cargo-llvm-cov and enforce `coverage_floor` (off by default)
         type: boolean
         required: false
         default: false
+      coverage_floor:
+        description: Minimum line-coverage percent when enable_coverage is set; ratchet upward, never lower.
+        type: string
+        required: false
+        default: "0"
       clippy_args:
         description: Args appended to `cargo clippy`
         type: string
@@ -254,8 +259,8 @@ jobs:
         run: cargo audit
 
   coverage:
-    timeout-minutes: 20
-    name: Coverage (tarpaulin + codecov)
+    timeout-minutes: 25
+    name: llvm-cov line coverage
     runs-on: ${{ inputs.runs-on }}
     needs: detect
     if: ${{ inputs.enable_coverage && needs.detect.outputs.has_cargo == 'true' }}
@@ -264,6 +269,9 @@ jobs:
     defaults:
       run:
         working-directory: ${{ inputs.working_directory }}
+    env:
+      # Ratcheted line-coverage floor (from the caller). Raise toward target; never lower.
+      FLOOR: ${{ inputs.coverage_floor }}
     steps:
       - name: Checkout repository
         uses: actions/checkout@9c091bb21b7c1c1d1991bb908d89e4e9dddfe3e0 # v7.0.0
@@ -276,14 +284,25 @@ jobs:
         uses: dtolnay/rust-toolchain@67ef31d5b988238dd797d409d6f9574278e20537 # stable
         with:
           toolchain: stable
+          components: llvm-tools-preview
 
-      - name: Install tarpaulin
-        run: cargo install cargo-tarpaulin --locked
+      - name: Install cargo-llvm-cov
+        run: cargo install cargo-llvm-cov --locked
 
-      - name: Generate coverage
-        run: cargo tarpaulin --out Xml
+      - name: Measure line coverage
+        id: cov
+        # Self-contained: no external coverage service. Own the gate on our runner.
+        run: |
+          set -euo pipefail
+          cargo llvm-cov --workspace --locked --json --output-path cov.json
+          PCT=$(jq -r '.data[0].totals.lines.percent' cov.json)
+          printf '### Line coverage: %.2f%% (floor %s%%)\n' "$PCT" "$FLOOR" >> "$GITHUB_STEP_SUMMARY"
+          echo "pct=$PCT" >> "$GITHUB_OUTPUT"
 
-      - name: Upload to codecov
-        uses: codecov/codecov-action@fb8b3582c8e4def4969c97caa2f19720cb33a72f # v7.0.0
-        with:
-          files: cobertura.xml
+      - name: Enforce ratchet floor
+        run: |
+          set -euo pipefail
+          awk -v p="${{ steps.cov.outputs.pct }}" -v f="$FLOOR" 'BEGIN {
+            if (p + 0 < f + 0) { printf "FAIL: line coverage %.2f%% is below floor %s%%\n", p, f; exit 1 }
+            printf "OK: line coverage %.2f%% >= floor %s%%\n", p, f
+          }'