fix: resolve analytics data gaps and resize validation failures

- Fix resize 20% failure rate: add Zod refine requiring at least one
  dimension, enforce integer/max constraints, clamp percentage scaling
  to minimum 1px, and guard against missing metadata in withoutEnlargement
- Fix PostHog init race condition: move consent check before async import
  so frontend events (search, pageview) are no longer silently dropped
- Fix identify() passing nested $set/$set_once wrappers instead of flat
  properties, so version person property now appears on PostHog profiles
- Add error_code and error_message to failed tool_used analytics events
  for debugging tool failures from PostHog

apps/web/src/App.tsx

@@ -5,7 +5,7 @@ import { Toaster } from "sonner";
 import { ConnectionMonitor } from "./components/common/connection-monitor";
 import { KeyboardShortcutProvider } from "./components/common/keyboard-shortcut-provider";
 import { useAuth } from "./hooks/use-auth";
-import { identify, initAnalytics } from "./lib/analytics";
+import { identify, initAnalytics, setAnalyticsConsent } from "./lib/analytics";
 import { useAnalyticsStore } from "./stores/analytics-store";
 
 // Lazy-load all pages so each page's JS (and its icons/deps) is only
@@ -190,11 +190,13 @@ export function App() {
     )
       return;
     void (async () => {
+      setAnalyticsConsent(true);
       await initAnalytics(analyticsConfig);
-      identify(analyticsConfig.instanceId, {
-        $set: { version: APP_VERSION },
-        $set_once: { instance_id: analyticsConfig.instanceId },
-      });
+      identify(
+        analyticsConfig.instanceId,
+        { version: APP_VERSION },
+        { instance_id: analyticsConfig.instanceId },
+      );
     })();
   }, [analyticsConfigLoaded, analyticsConfig, analyticsConsent.analyticsEnabled]);
 

apps/web/src/lib/analytics.ts

@@ -15,13 +15,10 @@ function scrubString(str: string): string {
 }
 
 export async function initAnalytics(config: AnalyticsConfig): Promise<void> {
-  if (initialized || !config.enabled) return;
+  if (initialized || !config.enabled || !consentGranted) return;
 
   try {
     const posthogJs = (await import("posthog-js")).default;
-    if (!consentGranted) {
-      return;
-    }
     posthog =
       posthogJs.init(config.posthogApiKey, {
         api_host: config.posthogHost,
@@ -45,9 +42,6 @@ export async function initAnalytics(config: AnalyticsConfig): Promise<void> {
   try {
     if (config.sentryDsn) {
       const Sentry = await import("@sentry/react");
-      if (!consentGranted) {
-        return;
-      }
       Sentry.init({
         dsn: config.sentryDsn,
         sendDefaultPii: false,
@@ -110,10 +104,14 @@ export function setAnalyticsConsent(enabled: boolean): void {
   }
 }
 
-export function identify(instanceId: string, properties: Record<string, unknown>): void {
+export function identify(
+  instanceId: string,
+  properties: Record<string, unknown>,
+  propertiesSetOnce?: Record<string, unknown>,
+): void {
   if (!posthog || !consentGranted) return;
   try {
-    posthog.identify(instanceId, properties);
+    posthog.identify(instanceId, properties, propertiesSetOnce);
   } catch {
     // never throw
   }