RoboFAC: A Comprehensive Framework for Robotic Failure Analysis and Correction

Recent advances in robotic manipulation have integrated low-level robotic control into Vision-Language Models (VLMs), extending them into Vision-Language-Action (VLA) models. Although state-of-the-art VLAs achieve strong performance in downstream robotic applications, supported by large-scale crowd-sourced robot training data, they still inevitably encounter failures during execution. Enabling robots to reason and recover from unpredictable and abrupt failures remains a critical challenge. Existing robotic manipulation datasets, collected in either simulation or the real world, primarily provide only ground-truth trajectories, leaving robots unable to recover once failures occur. Moreover, the few datasets that address failure detection typically offer only textual explanations, which are difficult to utilize directly in VLA models. To address this gap, we introduce FailSafe, a novel failure generation and recovery system that automatically produces diverse failure cases paired with executable recovery actions. FailSafe can be easily adapted to a wide range of manipulation tasks in simulators with motion planning support, enabling scalable creation of failure-action data. To demonstrate its effectiveness, we fine-tune LLaVA-OneVision-7B (LLaVA-OV-7B) to build FailSafe-VLM. Experimental results show that FailSafe-VLM successfully helps robotic arms detect and recover from potential failures, improving the performance of three state-of-the-art VLA models (Pi-0-FAST, OpenVLA, OpenVLA-OFT) by up to 22.6% on average across several tasks in ManiSkill. Furthermore, FailSafe-VLM could generalize across different spatial configurations, camera viewpoints, object and robotic embodiments.

Vision-language-action (VLA) models provide a promising paradigm for scalable robotic manipulation, yet their reliance on success-only behavioral cloning leaves them brittle; lacking corrective training signals, minor execution errors rapidly compound into unrecoverable, out-of-distribution failures. To address this limitation, we propose Adaptive Failure-Informed Learning (AFIL), an end-to-end framework that leverages failure trajectories as adaptive negative guidance for diffusion- and flow-based VLA policies. AFIL uses a pretrained VLA to generate failure rollouts online, avoiding the need for handcrafted failure-mode design or human-in-the-loop recovery. It then jointly trains Dual Action Generators (DAGs) for successful and failed behaviors while sharing a common vision-language backbone, enabling efficient failure-aware policy learning with limited parameter overhead. During sampling, the failure generator adaptively steers action generation away from failure-prone regions and toward more reliable success modes, with guidance strength determined by the per-diffusion-step distance between success and failure distributions. Experiments across in-domain and out-of-domain robotic manipulation tasks, covering both short- and long-horizon settings, show that AFIL consistently improves task success rates and robustness over existing VLA baselines, demonstrating its effectiveness, efficiency, and generality.

Vision-Language-Action (VLA) models follow a data-driven paradigm and are constrained by the coverage of training data, making them prone to failure on edge-case configurations after deployment. To mitigate such risks, it is essential to expose high-quality failure modes and convert the resulting failures into supervisory data for model enhancement. Existing studies largely stop at failure detection and lack a mechanism for leveraging discovered failures for model repair. We propose VLAMotor, the first analysis framework for VLA enhancement, which integrates distance-aware model testing for failure exposure and agent-based data synthesis for model finetunning. First, VLAMotor estimates input uncertainty based on the distance to training samples, and combines uncertainty ranking with redundancy elimination to build compact test sets that expose diverse failures. Then, VLAMotor abstracts failure trajectories into structured semantic representations, and plans parameterized repair-skill sequences, which are then realized as executable trajectories through inverse kinematics and motion execution. The resulting successful trajectories are automatically labeled and used to fine-tune the original VLA model, yielding an enhanced VLA model. Evaluation on four representative robotic manipulation tasks shows that 92.33% of the in-simulation test cases generated by VLAMotor trigger VLA failures, and VLAMotor improves test coverage over the state-of-the-art tool by 18.93%. By fine-tuning VLA models with synthetic data derived from failed test cases, VLAMotor further enhances the overall success rate of VLA models by 49.25%. When deployed on real hardware, the simulation-enhanced models improve the success rate over the original VLA models by 57.50%, demonstrating an effective and low-cost direction for VLA enhancement.