In the variational calculus, we find the Euler-Lagrange equation by using the following:
$S[x(t) + \epsilon f(t)] = S[x(t)] + \delta S + O(\epsilon^2)$ (1)
$S[x(t) + \epsilon f(t)] = S[x(t)] + \frac{d}{d\epsilon}S[x(t) + \epsilon f(t)]\Bigr|_{\epsilon=0}\epsilon + O(\epsilon^2)$
Now, I understand that in (1), the LHS's value has to be less (over all - including all orders) than the RHS's value because $x(t)$ is what minimizes the action, but I also understand that $\delta S$ must be $0$. So, even if $\delta S = 0$, (1) still obeys the principle such that the LHS is less than the RHS because the RHS also has $O(\epsilon^2)$. So we say actions are equal in first order.
Now, if I look at i.e $\delta S = \frac{d}{d\epsilon}S[x(t) + \epsilon f(t)]\Bigr|_{\epsilon=0}\epsilon$, what this tells me in words is how much action changes between our paths, so since we set this to $0$, then we're officially saying that action values are the same on both paths, even though, on true path, the value has to be less. What's going on? Can this be explained in layman's terms?
The term $$\frac{d}{d\epsilon} S[x(t)+\epsilon f(t)]\vert_{\epsilon=0}\epsilon$$ does not tell you how much the action changes between the paths $x(t)$ and $x(t)+\epsilon f(t)$. That would simply be the difference
$$S[x(t)+\epsilon f(t)] - S[x(t)].$$
What it does tell you is how much the action, $S[x(t)]$, changes (either increases or decreases) if you start to change the path $x(t)$ by adding a multiple of $f(t)$.
As $x(t)$ is a minimizer, this quantity should only be able to increase. However, if $\delta S$ is nonzero, then for a small positive $\epsilon$ we would either see the quantity increase or decrease, and for $-\epsilon$ we would observe the other behavior by linearity. The only logical conclusion is that this quantity must be 0.