fix: Remove PR commenting from size analysis workflow

- Replace PR comments with workflow summary output
- Add size analysis script for local development
- Remove unnecessary PR write permissions
- Add workflow failure on significant size increases
- Provide fallback size analysis without external dependencies

Author: rusty1968

.github/workflows/size-analysis.yml

@@ -16,7 +16,6 @@ jobs:
     runs-on: ubuntu-22.04
 
     permissions:
-      pull-requests: write
       contents: read
 
     steps:
@@ -91,11 +90,25 @@ jobs:
           head -20 target/pr-bloat-report.txt >> size_report.md 2>/dev/null || echo "No function data available" >> size_report.md
           echo '```' >> size_report.md
 
-      - name: Comment PR with size analysis
-        uses: thollander/actions-comment-pull-request@v2
-        with:
-          filePath: size_report.md
-          comment_tag: size-analysis
+      - name: Output size analysis to workflow summary
+        run: |
+          echo "## 📊 Binary Size Analysis" >> $GITHUB_STEP_SUMMARY
+          cat size_report.md >> $GITHUB_STEP_SUMMARY
+          
+      - name: Output size analysis to console
+        run: |
+          echo "=== Binary Size Analysis ==="
+          cat size_report.md
+          
+      - name: Check for significant size increase
+        run: |
+          # Extract size difference from the report
+          if grep -q "⚠️ Binary size increased by more than 10KB" size_report.md; then
+            echo "::error::Binary size increased by more than 10KB! Please review."
+            exit 1
+          elif grep -q "🚨 Binary size increased significantly" size_report.md; then
+            echo "::warning::Binary size increased significantly. Consider optimization."
+          fi
           
       - name: Upload detailed reports
         uses: actions/upload-artifact@v4

scripts/size-analysis.sh

@@ -0,0 +1,76 @@
+#!/bin/bash
+# Binary size analysis script for local development
+# Usage: ./scripts/size-analysis.sh [baseline-branch]
+
+set -e
+
+BASELINE_BRANCH=${1:-main}
+CURRENT_BRANCH=$(git rev-parse --abbrev-ref HEAD)
+
+echo "🔍 Analyzing binary size changes..."
+echo "Baseline: $BASELINE_BRANCH"
+echo "Current:  $CURRENT_BRANCH"
+echo ""
+
+# Function to build and analyze
+analyze_size() {
+    local branch=$1
+    local output_file=$2
+    
+    echo "Building $branch..."
+    git checkout $branch >/dev/null 2>&1
+    cargo build --release --target thumbv7em-none-eabihf >/dev/null 2>&1
+    
+    # Check if cargo bloat is available
+    if command -v cargo-bloat >/dev/null 2>&1; then
+        cargo bloat --release --target thumbv7em-none-eabihf -n 20 > $output_file 2>/dev/null || {
+            echo "cargo bloat failed, using basic size info"
+            ls -la target/thumbv7em-none-eabihf/release/aspeed-ddk > $output_file
+        }
+    else
+        echo "cargo-bloat not found, install with: cargo install cargo-bloat"
+        ls -la target/thumbv7em-none-eabihf/release/aspeed-ddk > $output_file
+    fi
+}
+
+# Store current branch
+ORIGINAL_BRANCH=$CURRENT_BRANCH
+
+# Analyze baseline
+analyze_size $BASELINE_BRANCH target/baseline-size.txt
+
+# Analyze current branch
+analyze_size $CURRENT_BRANCH target/current-size.txt
+
+# Restore original branch
+git checkout $ORIGINAL_BRANCH >/dev/null 2>&1
+
+echo "📊 Size Analysis Results:"
+echo "========================"
+
+# Extract binary sizes if using cargo bloat
+if grep -q "File" target/baseline-size.txt 2>/dev/null; then
+    BASELINE_SIZE=$(grep "File" target/baseline-size.txt | awk '{print $3}' | head -1)
+    CURRENT_SIZE=$(grep "File" target/current-size.txt | awk '{print $3}' | head -1)
+    
+    if [[ $BASELINE_SIZE =~ ([0-9.]+)([A-Za-z]+) ]]; then
+        echo "Baseline size: $BASELINE_SIZE"
+    fi
+    if [[ $CURRENT_SIZE =~ ([0-9.]+)([A-Za-z]+) ]]; then
+        echo "Current size:  $CURRENT_SIZE"
+    fi
+else
+    # Fallback to file size
+    BASELINE_BYTES=$(stat -c%s target/thumbv7em-none-eabihf/release/aspeed-ddk 2>/dev/null || echo "0")
+    echo "Binary size: $BASELINE_BYTES bytes"
+fi
+
+echo ""
+echo "Top functions in current build:"
+echo "==============================="
+head -20 target/current-size.txt
+
+echo ""
+echo "Full reports saved in:"
+echo "- target/baseline-size.txt"
+echo "- target/current-size.txt"