Do game developers list any hard rules for design to avoid glitches or technical issues? For example, if the trigger to activate a save point is 12 units around the point, any wall that the save point the save point has to be 13 units wide to avoid players touching it, or a fight cannot have more than 100 NPCs loaded at once as the engine pathfinding breaks and it cannot be fixed without causing worse issues?
Yes, we absolutely have these kind of established rules. We generally call these metrics and we try to establish them very carefully because they are the assumptions around which design can build levels, environments, combat, and other core gameplay. We often have to establish metrics for most core gameplay actions - how fast a player can run, how high/far a player can jump, how many party members a player can have, and so on. This also includes lots of other smaller details like the size of doors, the allowed angle ranges for stairs/slopes, the width and minimum heights of ladders, the minimum width of corridors, height for cover walls, heights for mantling/hopping over obstacles, maximum height a player can step up without getting stopped by the wall, etc. We use these limits to design our gameplay.
A large part of this is, as you alluded to, staying within our technical limitations. If we can't animate more than X characters on screen at once, then we can't have scenes with more than X characters in them. If we can't run more than Y particles in a frame, then we can't create scenes with more than Y particles running at the same time.
However, there are also user experience and design considerations for this. Imagine that the farthest range the player can jump is 15 feet after a full sprint. Any gap in the game that is 15 feet or less is jumpable. Any gap that is more than 15 feet is jumpable. Now imagine that some level designer sets a 15 foot + 1 inch gap. How frustrating do you think it would be to a player who tries to make that jump and fails because it isn't possible? How can we expect a player to evaluate whether that gap is jumpable if it looks so close to an actually jumpable gap? In order to reduce player frustration, we probably need to set up a metric for minimum un-jumpable gaps so that players can recognize them on sight so they don't have to try and fail at every gap that's pretty close to maximum length.
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