Fix Healthspan activity and HealthKit steps

[Asherlc]

Fixes HealthKit incremental sync to request daily quantity samples from the local day boundary instead of a rolling 24-hour window, preventing partial step totals from replacing full-day values. Updates Healthspan scoring to use weekly exercise minutes from daily metrics as the aerobic activity floor when heart-rate zone minutes undercount activity. Adds mobile and server regressions for the step sync window and Healthspan activity score behavior, and records the production incident analysis in docs/production-incident-baseline.md. Validation: pnpm lint; pnpm test:changed; pnpm tsc --noEmit; cd packages/server && pnpm tsc --noEmit; cd packages/web && pnpm tsc --noEmit.

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Summary by cubic

Fixes undercounted steps and aerobic minutes by syncing HealthKit daily stats from the local day boundary and using device-reported weekly exercise minutes as a floor. Bounds all Healthspan reads to the selected date window and the user's access window.

• Bug Fixes
  • Mobile: Incremental HealthKit sync now starts at the local calendar-day boundary instead of a rolling 24 hours to avoid partial-day overwrites.
  • Server: Healthspan bounds all reads (RHR, steps, strength, HR‑zone) to the date window and access window, adds an exclusive end bound to the HR‑zone query, and uses weekly exercise minutes from fitness.v_daily_metrics as the aerobic floor when zone minutes are lower or missing.
  • Tests/Docs: Added regressions for day-boundary sync, aerobic fallback, and SQL bounds; documented the production incident.

^{Written for commit cbe1a9b. Summary will update on new commits. Review in cubic}

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📥 Commits

Reviewing files that changed from the base of the PR and between 5accc61 and cbe1a9b.

📒 Files selected for processing (6)

• docs/production-incident-baseline.md
• packages/mobile/lib/health-kit-sync.test.ts
• packages/mobile/lib/health-kit-sync.ts
• packages/server/src/routers/healthspan-query.test.ts
• packages/server/src/routers/healthspan-query.ts
• packages/server/src/routers/healthspan.test.ts

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[github-actions]

Storybook previews for aa7486bb are ready:

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• Mobile Storybook

This comment updates automatically on each PR push.

[cubic-dev-ai]

No issues found across 6 files

Confidence score: 5/5

• Automated review surfaced no issues in the provided summaries.
• No files require special attention.

<sub>Auto-approved: The changes fix two specific, well-documented bugs with targeted logic updates, add regression tests, and include a production incident analysis, presenting low risk as they are isolated to HealthKit sync window alignment and Healthspan scoring floor logic without altering core infrastructure...

Re-trigger cubic</sub>

[github-actions]

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[Copilot]

Pull request overview

This PR addresses a production issue where (1) HealthKit incremental sync could overwrite full-day step totals with partial-day values and (2) Healthspan aerobic activity could undercount when HR/power-derived zone minutes are missing or low. It adjusts the mobile HealthKit sync window to start at the local day boundary and updates server-side Healthspan aggregation to floor aerobic minutes using device-reported weekly exercise minutes, with regression tests and an incident write-up.

Changes:

• Mobile: Start incremental HealthKit daily-statistics queries from the local calendar-day boundary (instead of a rolling 24h window).
• Server: Add a Postgres query for weekly exercise_minutes from fitness.v_daily_metrics and use it as a floor for weekly aerobic minutes when HR-zone minutes undercount.
• Quality/docs: Add regression tests for both behaviors and document the incident analysis.

Reviewed changes

Copilot reviewed 6 out of 6 changed files in this pull request and generated 3 comments.

Show a summary per file

File	Description
packages/server/src/routers/healthspan-query.ts	Adds weekly exercise-minute aggregation and uses it as an aerobic-minutes floor in Healthspan raw data.
packages/server/src/routers/healthspan.test.ts	Updates router/unit tests to account for the additional DB query and adds coverage for the new activity-floor behavior.
packages/server/src/routers/healthspan-query.test.ts	Adjusts raw-data tests for the additional DB call.
packages/mobile/lib/health-kit-sync.ts	Changes incremental sync start date to local midnight of the lookback window.
packages/mobile/lib/health-kit-sync.test.ts	Adds regression test for day-boundary incremental sync behavior.
docs/production-incident-baseline.md	Records incident symptoms, root cause, mitigation, and follow-ups.

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[cubic-dev-ai]

0 issues found across 3 files (changes from recent commits).

<sub>Auto-approved: The changes are targeted bug fixes for undercounted HealthKit steps and Healthspan aerobic minutes, with thorough regression tests and no risky refactors or critical-path modifications.

Re-trigger cubic</sub>

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