FN-5808: skip onboarding auto-launch for non-interactive and existing setups

Prevent onboarding autolaunch when invocation is non-interactive or an existing central+project setup is detected.

- Add a project initialization probe in onboard autolaunch flow and skip when both central DB and project DB already exist.
- Preserve skip behavior for serve/daemon and all non-TTY invocations so agent/headless runs never block.
- Expand CLI autolaunch coverage with backward-compat and seam tests, and add a changeset for the published package.

Files changed:
 .changeset/fn-5808-onboard-backcompat-guard.md     |   5 +
 .../onboard-autolaunch-backcompat.test.ts          | 135 +++++++++++++++++++++
 .../commands/__tests__/onboard-autolaunch.test.ts  |   9 ++
 packages/cli/src/commands/onboard-autolaunch.ts    |  16 ++-
 4 files changed, 164 insertions(+), 1 deletion(-)

Fusion-Task-Id: FN-5808

Fusion-Task-Lineage: b859aa93-44d5-4d93-bc07-8149b95b4042

.changeset/fn-5808-onboard-backcompat-guard.md

@@ -0,0 +1,5 @@
+---
+"@runfusion/fusion": patch
+---
+
+Harden CLI onboarding auto-launch backward compatibility by adding an explicit skip when both the central DB and local project DB already exist. This preserves established agent/headless behavior by ensuring non-TTY, `serve`, and `daemon` invocations continue without onboarding prompts or blocking.

packages/cli/src/commands/__tests__/onboard-autolaunch-backcompat.test.ts

@@ -0,0 +1,135 @@
+import { afterEach, describe, expect, it, vi } from "vitest";
+
+import {
+  maybeAutoLaunchOnboarding,
+  shouldAutoLaunchOnboarding,
+} from "../onboard-autolaunch.js";
+
+describe("onboard autolaunch backward-compat guard", () => {
+  afterEach(() => {
+    vi.restoreAllMocks();
+  });
+
+  it("skips with explicit reason when central DB and project both exist", () => {
+    expect(
+      shouldAutoLaunchOnboarding({
+        command: "task",
+        args: ["task", "list"],
+        centralDbExists: true,
+        projectInitialized: true,
+        isTTY: true,
+      }),
+    ).toEqual({ launch: false, reason: "central-db-and-project-exist" });
+  });
+
+  it("keeps central-db-exists skip when only central DB exists", () => {
+    expect(
+      shouldAutoLaunchOnboarding({
+        command: "task",
+        args: ["task", "list"],
+        centralDbExists: true,
+        projectInitialized: false,
+        isTTY: true,
+      }),
+    ).toEqual({ launch: false, reason: "central-db-exists" });
+  });
+
+  it("still launches when central DB is missing even if project is initialized", () => {
+    expect(
+      shouldAutoLaunchOnboarding({
+        command: "task",
+        args: ["task", "list"],
+        centralDbExists: false,
+        projectInitialized: true,
+        isTTY: true,
+      }),
+    ).toEqual({ launch: true, reason: "central-db-missing" });
+  });
+
+  it("never launches on non-TTY agent/headless path", () => {
+    expect(
+      shouldAutoLaunchOnboarding({
+        command: "task",
+        args: ["task", "list"],
+        centralDbExists: false,
+        projectInitialized: false,
+        isTTY: false,
+      }),
+    ).toEqual({ launch: false, reason: "non-tty" });
+  });
+
+  it("never launches for serve/daemon", () => {
+    for (const command of ["serve", "daemon"]) {
+      expect(
+        shouldAutoLaunchOnboarding({
+          command,
+          args: [command],
+          centralDbExists: false,
+          projectInitialized: false,
+          isTTY: true,
+        }),
+      ).toEqual({ launch: false, reason: "command-skip" });
+    }
+  });
+
+  it("agent-run simulation: non-TTY task list resolves and does not prompt", async () => {
+    const runOnboard = vi.fn();
+    const errorSpy = vi.spyOn(console, "error").mockImplementation(() => undefined);
+
+    Object.defineProperty(process.stdout, "isTTY", { value: false, configurable: true });
+    Object.defineProperty(process.stdin, "isTTY", { value: false, configurable: true });
+
+    await expect(
+      maybeAutoLaunchOnboarding({
+        command: "task",
+        args: ["task", "list"],
+        centralDbPath: "/virtual/central.db",
+        pathExists: () => false,
+        runOnboard,
+      }),
+    ).resolves.toBeUndefined();
+
+    expect(runOnboard).not.toHaveBeenCalled();
+    expect(errorSpy).not.toHaveBeenCalled();
+  });
+
+  it("derives projectInitialized from cwd/pathExists seam", async () => {
+    const runOnboard = vi.fn();
+    const pathExists = vi.fn((path: string) => path.endsWith(".fusion/fusion.db"));
+
+    await maybeAutoLaunchOnboarding({
+      command: "task",
+      args: ["task", "list"],
+      centralDbPath: "/virtual/central.db",
+      cwd: "/workspace/demo",
+      isTTY: true,
+      pathExists,
+      runOnboard,
+    });
+
+    expect(pathExists).toHaveBeenCalledWith("/virtual/central.db");
+    expect(pathExists).toHaveBeenCalledWith("/workspace/demo/.fusion/fusion.db");
+    expect(runOnboard).toHaveBeenCalledTimes(1);
+  });
+
+  it("isolates onboard launch failures as non-fatal diagnostics", async () => {
+    const runOnboard = vi.fn().mockRejectedValue(new Error("boom"));
+    const errorSpy = vi.spyOn(console, "error").mockImplementation(() => undefined);
+
+    await expect(
+      maybeAutoLaunchOnboarding({
+        command: "task",
+        args: ["task", "list"],
+        centralDbPath: "/virtual/central.db",
+        isTTY: true,
+        pathExists: () => false,
+        runOnboard,
+      }),
+    ).resolves.toBeUndefined();
+
+    expect(errorSpy).toHaveBeenCalledTimes(1);
+    expect(errorSpy).toHaveBeenCalledWith(
+      expect.stringContaining("[onboard-autolaunch] non-fatal onboard launch failure: boom"),
+    );
+  });
+});

packages/cli/src/commands/__tests__/onboard-autolaunch.test.ts

@@ -12,6 +12,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "task",
         args: ["task", "list"],
         centralDbExists: false,
+        projectInitialized: false,
         isTTY: true,
       }),
     ).toEqual({ launch: true, reason: "central-db-missing" });
@@ -23,6 +24,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "dashboard",
         args: ["dashboard"],
         centralDbExists: false,
+        projectInitialized: false,
         isTTY: true,
       }),
     ).toEqual({ launch: true, reason: "central-db-missing" });
@@ -36,6 +38,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "task",
         args,
         centralDbExists: false,
+        projectInitialized: false,
         isTTY: true,
       }),
     ).toEqual({ launch: false, reason: "skip-flag" });
@@ -47,6 +50,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "task",
         args: ["task", "list"],
         centralDbExists: true,
+        projectInitialized: false,
         isTTY: true,
       }),
     ).toEqual({ launch: false, reason: "central-db-exists" });
@@ -58,6 +62,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "task",
         args: ["task", "list"],
         centralDbExists: false,
+        projectInitialized: false,
         isTTY: false,
       }),
     ).toEqual({ launch: false, reason: "non-tty" });
@@ -69,6 +74,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "serve",
         args: ["serve"],
         centralDbExists: false,
+        projectInitialized: false,
         isTTY: true,
       }),
     ).toEqual({ launch: false, reason: "command-skip" });
@@ -78,6 +84,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "daemon",
         args: ["daemon"],
         centralDbExists: false,
+        projectInitialized: false,
         isTTY: true,
       }),
     ).toEqual({ launch: false, reason: "command-skip" });
@@ -89,6 +96,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "onboard",
         args: ["onboard"],
         centralDbExists: false,
+        projectInitialized: false,
         isTTY: true,
       }),
     ).toEqual({ launch: false, reason: "onboard-command" });
@@ -100,6 +108,7 @@ describe("shouldAutoLaunchOnboarding", () => {
         command: "task",
         args: ["task", "list"],
         centralDbExists: false,
+        projectInitialized: false,
         isTTY: true,
         env: { FUSION_SKIP_ONBOARDING: "1" },
       }),

packages/cli/src/commands/onboard-autolaunch.ts

@@ -1,4 +1,5 @@
 import { existsSync } from "node:fs";
+import { join } from "node:path";
 import { getDefaultCentralDbPath } from "@fusion/core";
 
 import { isTTYAvailable } from "./dashboard-tui/index.js";
@@ -7,6 +8,7 @@ export interface AutoLaunchInput {
   command: string;
   args: string[];
   centralDbExists: boolean;
+  projectInitialized: boolean;
   isTTY: boolean;
   env?: NodeJS.ProcessEnv;
 }
@@ -48,6 +50,10 @@ export function shouldAutoLaunchOnboarding(input: AutoLaunchInput): AutoLaunchDe
     return { launch: false, reason: "skip-env" };
   }
 
+  if (input.centralDbExists && input.projectInitialized) {
+    return { launch: false, reason: "central-db-and-project-exist" };
+  }
+
   if (input.centralDbExists) {
     return { launch: false, reason: "central-db-exists" };
   }
@@ -74,6 +80,8 @@ export interface MaybeAutoLaunchDeps {
   command: string;
   args: string[];
   centralDbPath?: string;
+  projectInitialized?: boolean;
+  cwd?: string;
   isTTY?: boolean;
   env?: NodeJS.ProcessEnv;
   runOnboard?: RunOnboard;
@@ -85,9 +93,14 @@ export async function maybeAutoLaunchOnboarding(deps: MaybeAutoLaunchDeps): Prom
   const isTTY = deps.isTTY ?? isTTYAvailable();
 
   let centralDbExists = true;
+  let projectInitialized = false;
   try {
+    const pathExists = deps.pathExists ?? existsSync;
     const centralDbPath = deps.centralDbPath ?? getDefaultCentralDbPath();
-    centralDbExists = (deps.pathExists ?? existsSync)(centralDbPath);
+    const cwd = deps.cwd ?? process.cwd();
+    const projectDbPath = join(cwd, ".fusion", "fusion.db");
+    centralDbExists = pathExists(centralDbPath);
+    projectInitialized = deps.projectInitialized ?? pathExists(projectDbPath);
   } catch (error) {
     const message = error instanceof Error ? error.message : String(error);
     console.error(`[onboard-autolaunch] central DB probe failed; skipping auto-launch: ${message}`);
@@ -98,6 +111,7 @@ export async function maybeAutoLaunchOnboarding(deps: MaybeAutoLaunchDeps): Prom
     command: deps.command,
     args: deps.args,
     centralDbExists,
+    projectInitialized,
     isTTY,
     env,
   });