feat(check): add the opt-in Vapi checks PR workflow and user docs

.github/workflows/vapi-checks.yml runs `npm run check` on pull requests
(opened, synchronize, reopened, ready_for_review) and on manual dispatch,
only when the repository variable VAPI_CHECKS_ENABLED is 'true' and a
vapi-checks.yml exists — so on the upstream template it is dormant.

- Live runs only for same-repository, non-Dependabot PRs and dispatch;
  forks and Dependabot get a keyless dry run, and secrets are passed only
  to live runs. Never pull_request_target.
- Checks out the head SHA with full history (for --changed-since against
  origin/<base>) and persist-credentials: false.
- --all posts the aggregate `Vapi Evals` status; dispatching one named
  check doesn't. The run step execs node so GitHub's cancel reaches it,
  inside a 22-minute budget under a 30-minute job timeout; concurrency
  cancels a superseded push's runs.
- permissions: contents: read, statuses: write.

Docs: a README "PR Checks" section (setup from test files to required
status, the build-failure table, fork/Dependabot handling, CI orgs, cost
and what stays real), the AGENTS.md simulations step, a "Inline PR
Checks" section in docs/learnings/simulations.md, and improvements.md #34.

Refs TEST-141

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>

Author: scott-lowe-vapi

.github/workflows/vapi-checks.yml

@@ -0,0 +1,118 @@
+name: Vapi checks
+
+# Runs the simulation checks in vapi-checks.yml against the PR branch's own
+# files: each target is built inline and sent in one simulation run, so
+# nothing is deployed. Opt in with the repository variable
+# VAPI_CHECKS_ENABLED=true; see "PR checks" in the README.
+#
+# Never `pull_request_target`: the branch's code runs here, so it must only
+# ever get this repository's secrets when the branch is this repository's.
+
+on:
+  pull_request:
+    types: [opened, synchronize, reopened, ready_for_review]
+  workflow_dispatch:
+    inputs:
+      check:
+        description: >-
+          Check name from vapi-checks.yml. Leave blank to run every check and
+          update the Vapi Evals status on the dispatched commit.
+        required: false
+        type: string
+
+permissions:
+  contents: read
+  # Only to post the `Vapi Evals` commit statuses that link to each run.
+  statuses: write
+
+concurrency:
+  group: vapi-checks-${{ github.event.pull_request.number || github.ref }}
+  cancel-in-progress: true
+
+jobs:
+  vapi-checks:
+    if: vars.VAPI_CHECKS_ENABLED == 'true'
+    runs-on: ubuntu-latest
+    # The run step's budget (22 min) leaves time to cancel runs and report.
+    timeout-minutes: 30
+    env:
+      HEAD_SHA: ${{ github.event.pull_request.head.sha || github.sha }}
+
+    steps:
+      - uses: actions/checkout@v4
+        with:
+          ref: ${{ github.event.pull_request.head.sha || github.sha }}
+          fetch-depth: 0
+          persist-credentials: false
+
+      - name: Look for vapi-checks.yml
+        id: config
+        shell: bash
+        run: |
+          if [[ -f vapi-checks.yml ]]; then
+            echo "present=true" >> "$GITHUB_OUTPUT"
+          else
+            echo "No vapi-checks.yml at the repository root; nothing to check."
+            echo "present=false" >> "$GITHUB_OUTPUT"
+          fi
+
+      # Live runs only for this repository's own branches (not forks, not
+      # Dependabot) and for manual dispatch. Everything else builds the
+      # payloads without a key, and an affected PR gets an error status
+      # until a maintainer dispatches the check on it.
+      - name: Choose live or dry run
+        id: mode
+        if: steps.config.outputs.present == 'true'
+        shell: bash
+        env:
+          EVENT: ${{ github.event_name }}
+          HEAD_REPO: ${{ github.event.pull_request.head.repo.full_name }}
+          ACTOR: ${{ github.actor }}
+          AUTHOR: ${{ github.event.pull_request.user.login }}
+        run: |
+          live=false
+          if [[ "$EVENT" == "workflow_dispatch" ]]; then
+            live=true
+          elif [[ "$HEAD_REPO" == "$GITHUB_REPOSITORY" && "$ACTOR" != "dependabot[bot]" && "$AUTHOR" != "dependabot[bot]" ]]; then
+            live=true
+          fi
+          echo "live=$live" >> "$GITHUB_OUTPUT"
+          echo "Live run: $live"
+
+      - uses: actions/setup-node@v4
+        if: steps.config.outputs.present == 'true'
+        with:
+          node-version: 22
+          cache: npm
+
+      - run: npm ci
+        if: steps.config.outputs.present == 'true'
+
+      - name: Run Vapi checks
+        if: steps.config.outputs.present == 'true'
+        shell: bash
+        env:
+          LIVE: ${{ steps.mode.outputs.live }}
+          CHECK: ${{ inputs.check }}
+          BASE_REF: ${{ github.base_ref }}
+          GITHUB_TOKEN: ${{ github.token }}
+          VAPI_CHECK_TOKENS: ${{ steps.mode.outputs.live == 'true' && secrets.VAPI_CHECK_TOKENS || '' }}
+          VAPI_PRIVATE_API_KEY: ${{ steps.mode.outputs.live == 'true' && secrets.VAPI_PRIVATE_API_KEY || '' }}
+        run: |
+          set -euo pipefail
+          args=()
+          if [[ -n "$CHECK" ]]; then args+=("$CHECK"); else args+=(--all); fi
+          if [[ "$LIVE" == "true" ]]; then
+            args+=(--refresh-bindings)
+          else
+            args+=(--dry-run)
+          fi
+          if [[ "$GITHUB_EVENT_NAME" == "pull_request" ]] &&
+            git rev-parse --verify --quiet "origin/$BASE_REF" > /dev/null; then
+            args+=(--changed-since "origin/$BASE_REF")
+          fi
+          [[ -n "$VAPI_CHECK_TOKENS" ]] || unset VAPI_CHECK_TOKENS
+          [[ -n "$VAPI_PRIVATE_API_KEY" ]] || unset VAPI_PRIVATE_API_KEY
+          # exec, so GitHub's cancel signal (a newer push) reaches node,
+          # which cancels its in-flight simulation runs.
+          exec node --import tsx src/check-cmd.ts "${args[@]}" --budget-minutes 22

AGENTS.md

@@ -1032,4 +1032,4 @@ When transferring to human:
 2. Create scenarios (what the simulated caller says + evaluation criteria)
 3. Create simulations (pair personality + scenario)
 4. Create suites (batch simulations together)
-5. Run via Vapi dashboard or API
+5. Run against the deployed resources with `npm run sim`, or against the local files (nothing deployed) with `npm run check` — see "PR Checks" in the README. The PR workflow runs `npm run check` on every affected PR when `VAPI_CHECKS_ENABLED=true`

README.md

@@ -456,6 +456,165 @@ from the destination without touching unrelated destination resources.
 
 ---
 
+## PR Checks: simulations against your branch
+
+`npm run check` runs your simulation suites against the **PR branch's own
+files** — prompts, tools, handoffs, structured outputs — without deploying
+anything. Each check target (an assistant or a squad) is built from
+`resources/<org>/` and sent inline, with its scenarios and judges, in one
+simulation run. Nothing is created in the org, so there is nothing to clean
+up, and it works with a single org.
+
+### 1. Write tests
+
+Under `resources/<org>/simulations/`:
+
+- `personalities/calm-caller.yml` (or reference a stock personality by ID)
+- `scenarios/books-appointment.yml` — instructions, at least one **required
+  text judge**, and `toolMocks` for the tools this scenario calls:
+
+  ```yaml
+  name: Books an appointment
+  instructions: >
+    You are John Smith calling to book a cleaning next Tuesday. End the call once it's confirmed.
+  evaluations:
+    - structuredOutput:
+        name: booking-confirmed
+        type: ai
+        schema: { type: boolean, description: "Did the assistant confirm a booking time?" }
+      comparator: "="
+      value: true
+      required: true
+  toolMocks:
+    - toolName: book_appointment
+      result: '{"success": true, "time": "Tuesday 10:00"}'
+  ```
+
+  Judges may also reference a file with `structuredOutputId: <name>`. Over
+  chat, yes/no judges (`=` with `value: true`) are the verified shape; don't
+  use `hooks` or `messages-with-audio` judges with chat.
+- `tests/books-appointment-calm.yml`: `{ name, personalityId: calm-caller, scenarioId: books-appointment }`
+- `suites/core.yml`: `{ name: Core, simulationIds: [books-appointment-calm] }`
+
+### 2. Configure the check
+
+```bash
+cp vapi-checks.example.yml vapi-checks.yml
+```
+
+```yaml
+version: 1
+checks:
+  core:
+    org: my-org
+    targets: [squads/main-squad]
+    suites: [core]
+```
+
+### 3. Dry run locally (no key, nothing sent)
+
+```bash
+npm run check -- core --dry-run --print-payload
+```
+
+`tmp/check-payloads/` shows exactly what would be sent. The build fails,
+naming the field, when it can't make a safe, faithful payload:
+
+| Problem | Fix |
+| --- | --- |
+| A tool that can't be mocked (SMS, MCP, code, integrations), or an `apiRequest` with no `name` | Remove it, name the `apiRequest`, or set `toolMocks: off` with a dedicated CI org |
+| A tool referenced by ID, or a `toolRefs` pin, with no file in `resources/<org>/tools/` | Pull the tool into gitops |
+| A handoff leaving the squad (`dynamic`, another squad, a non-member), or an assistant target that hands off | Make the target a squad of those assistants |
+| A legacy `assistantDestinations` entry naming an assistant by ID | Convert it to a handoff tool |
+| Tools by ID inside `assistantOverrides`, `membersOverrides` or `targetOverrides` | Put them inline in `tools:append` |
+| Tools outside `model.tools` / `model.toolIds` (`model.functions`, reasoner skills, a recording-consent decline tool) | Move them to `model.tools` |
+| `model.knowledgeBaseId`, a custom knowledge base, or a knowledge base / `query` tool when the check runs in another org | Use a knowledge-base tool in the same org |
+| Personality tools beyond `endCall`-style ones | Keep the personality free of side-effect tools |
+| Two tools with the same type and name on one assistant | Rename one |
+| Audio judges, scenario hooks, or no required text judge over chat | Add a text judge, or use `transport: voice` |
+
+Two things to know:
+
+- **Transfers never happen.** Every `transferCall` becomes a mocked
+  function, so a scenario that needs a real transfer fails rather than
+  falsely passing.
+- **Handoff names.** The check warns when a prompt mentions an
+  auto-generated `handoff_to_…` name — those differ between inline and
+  deployed assistants. Give that handoff an explicit `function.name`.
+
+### 4. Live run locally
+
+```bash
+npm run check -- core
+```
+
+Uses `.env.<org>`, prints the run link, and exits 0 passed, 1 failed, 2
+config or build error, 3 incomplete. It uses simulation minutes.
+
+### 5. Turn on the PR workflow
+
+In GitHub → Settings → Secrets and variables → Actions:
+
+- Secret `VAPI_PRIVATE_API_KEY` (single org), or `VAPI_CHECK_TOKENS` =
+  `{"my-org":"<private key>"}` (several orgs, or a CI org).
+- Variable `VAPI_CHECKS_ENABLED=true`.
+
+`.github/workflows/vapi-checks.yml` then runs every affected check on each
+PR push. It asks for `statuses: write` only to post the direct links.
+
+### 6. What a PR shows
+
+- `Vapi Evals`, plus `Vapi Evals / <check> / <target>` per target. **Details**
+  opens the run in Vapi.
+- A job summary: per-target result, failing judges with expected vs actual,
+  and any "unmocked tool called" notices. No PR comments.
+- PRs that touch neither a check's org, its state, `vapi-checks.yml`,
+  `promotion.yml`, the engine (`src/**`, `package*.json`), nor the check's
+  own `paths` skip it, and `Vapi Evals` posts success.
+- A newer push cancels the older run.
+
+### 7. Make it required (after a burn-in)
+
+Require the **commit status `Vapi Evals`** in branch protection — not the
+`vapi-checks` job (fork dry runs succeed) and not the per-target statuses
+(PRs that don't touch a check never get them).
+
+- **Fork PRs** run a dry run without secrets and can't post statuses (the
+  token is read-only), so a required `Vapi Evals` blocks them.
+- **Dependabot PRs** that change `package*.json` post `error`.
+- **To unblock either**, a maintainer runs Actions → Vapi checks → Run
+  workflow on the PR's branch with `check` blank (push a fork's branch into
+  the repository first). A later PR event on the same commit resets the
+  status, so dispatch again after that. Running one named check by hand
+  never changes `Vapi Evals`.
+
+### Dedicated CI org (optional; recommended with `toolMocks: off`)
+
+1. `npm run setup -- my-ci-org --resources none`.
+2. Create the credentials your agents need there, with the same names as
+   production.
+3. `npm run pull -- my-ci-org --bootstrap --bindings-only`, then commit
+   `.vapi-state.my-ci-org.json` so the state knows those credentials. The PR
+   workflow refreshes bindings on every live run.
+4. Add `runOrg: my-ci-org` (and `baseUrl` for EU) to the check, and
+   optionally `bindings:` (same shape as `promotion.yml`). Phone numbers are
+   omitted by default.
+5. Put only the CI org's key in `VAPI_CHECK_TOKENS`.
+
+### Cost and safety
+
+- Every affected push starts paid runs; chat transport is the default.
+- Tool calls get their scenario mock or an error, and every assistant and
+  function-tool server points at `https://vapi-gitops-ci.invalid`.
+- Still real in the run org: custom LLM, voice and transcriber servers see
+  the conversation; org-wide and assistant monitors run; `observabilityPlan`
+  exports transcripts; prompts are stored with the run. A CI org avoids all
+  of these.
+- `.ts` resource files execute during the check, with the workflow's secrets
+  on same-repository PRs.
+
+---
+
 ## How to Use This Repo
 
 1. **Run `npm run setup`** to configure your first org (or `npm run setup -- <org>` without a terminal)
@@ -812,7 +971,8 @@ vapi-gitops/
 │   ├── resources.ts            # Resource loading (YAML, MD, TS)
 │   ├── resolver.ts             # Reference resolution
 │   ├── credentials.ts          # Credential resolution (name ↔ UUID)
-│   └── delete.ts               # Deletion & orphan checks
+│   ├── delete.ts               # Deletion & orphan checks
+│   └── check-cmd.ts            # Entry point: PR simulation checks (check-*.ts)
 ├── resources/
 │   └── <org>/                  # One directory per configured org
 │       ├── assistants/
@@ -831,6 +991,7 @@ vapi-gitops/
 │   ├── path-matching.test.ts   # Short-form path matching (P0-7 regression suite)
 │   ├── cleanup-safety.test.ts  # --confirm + empty-state gates (P0-4 regression suite)
 │   └── cli-arg-parsing.test.ts # Bare-id refusal, --confirm pass-through (P0-7)
+├── vapi-checks.example.yml     # Copy to vapi-checks.yml for PR simulation checks
 ├── .env.<org>                  # Private API key per org (gitignored)
 └── .vapi-state.<org>.json      # State file per org
 ```

docs/learnings/README.md

@@ -44,7 +44,7 @@ Gotchas and silent defaults for each resource type:
 | [assistants.md](assistants.md) | Model defaults, voice, transcriber, firstMessage, outbound modes, voicemailMessage, hooks, idle messages, endpointing, interruption, analysis, artifacts, background sound, server messages, HIPAA, tool resolution |
 | [squads.md](squads.md) | Name uniqueness, tools:append, assistantDestinations, handoff context, contextEngineeringPlan, VM detection relay pattern, override merge order, `membersOverrides` structuredDataPlan + fullMessageHistory |
 | [structured-outputs.md](structured-outputs.md) | Schema type gotchas, assistant_ids, default models, target modes, KPI patterns, squad `membersOverrides` vs standalone SOs |
-| [simulations.md](simulations.md) | Personalities, evaluation comparators, chat-mode gotcha, missing references, full `/eval/simulation/*` API reference |
+| [simulations.md](simulations.md) | Personalities, evaluation comparators, chat-mode gotcha, missing references, inline PR checks (`npm run check`), full `/eval/simulation/*` API reference |
 | [webhooks.md](webhooks.md) | Default server messages, timeouts, unreachable servers, credential resolution, payload shape |
 | [voice-providers.md](voice-providers.md) | Per-provider voice block layout (Cartesia vs 11labs vs OpenAI/Azure/Rime/LMNT/Minimax/Neuphonic/SmallestAI) — saves 400s at push time |
 

docs/learnings/simulations.md

@@ -227,6 +227,51 @@ Base URL: `https://api.vapi.ai`
 
 ---
 
+## Inline PR Checks (`npm run check`)
+
+`npm run check` sends the target and its tests **inline** in one
+`POST /eval/simulation/run` (`target.assistant` / `target.squad`, and
+`{type: "simulation", name, scenario, personality}` entries), built from the
+branch's files. Setup is in the README's "PR Checks" section; these are the
+behaviours worth knowing when a check surprises you.
+
+- **Inline matches stored, with two known differences.** A 2026-10-01 parity
+  run (TEST-141) scored inline and stored versions of the same squad 15/15
+  each, with the same handoff and business-tool sequences. The differences:
+  - **Generated handoff names:** `handoff_to_<assistantName>` inline vs
+    `handoff_to_<uuid>` stored. A prompt or judge that names the generated
+    function behaves differently — give the handoff an explicit
+    `function.name`. The check warns when it sees `handoff_to_` in text.
+  - **Tool order** decides which tool the model reaches for. The runtime
+    puts `model.tools` first, then `toolIds` in order, then `toolRefs`; the
+    check builds inline tools in that same order.
+- **Tool mocks fail closed.** Function tools are mocked by `function.name`,
+  `apiRequest` tools by their top-level `name`. A tool the scenario doesn't
+  mock answers `{"error":"vapi-gitops-ci: <tool> is not mocked in this
+  scenario"}`, and the report lists it as "unmocked tool called". A scenario
+  mock with `enabled: false` is replaced by that error.
+- **Hook-fired tools bypass scenario mocks.** Scenario `toolMocks` apply on
+  the LLM tool-call path; tools fired from an assistant's `hooks[].do[]`
+  probably don't consult them. Their safeguard is the dead server: expect an
+  error result for them in transcripts, not a mock.
+- **Servers are replaced, never deleted.** Every assistant and function tool
+  gets `server: https://vapi-gitops-ci.invalid` (1 s timeout) and
+  `serverMessages: []`. A *deleted* server falls back to the phone number's
+  or the org's server URL, which would leak the conversation.
+- **Transfers can't happen.** `transferCall` becomes a mocked dead-server
+  function under the same name. A scenario that needs a real transfer fails.
+- **What still reaches real systems** in the run org: custom LLM, voice and
+  transcriber providers, org-wide and assistant monitors, and
+  `observabilityPlan` exports. Use a dedicated CI org (`runOrg`) to avoid
+  them.
+- **Over chat**, `messages-with-audio` judges and scenario `hooks` don't
+  work, and a scenario with no required text judge can't fail; the build
+  refuses all three.
+- **Run items echo the scenario.** `metadata.scenario.toolMocks` includes the
+  default error mocks whether or not a tool was called; read tool results
+  from `metadata.call.messages` (`tool_calls` carry the ids and names,
+  `tool_call_result` the answers by `toolCallId`).
+
 ## Simulations (`/eval/simulation`)
 
 ### Create simulation — `POST /eval/simulation`