Learning Actionable Manipulation Recovery via Counterfactual Failure Synthesis

Vision-Language-Action (VLA) models have recently advanced robotic manipulation by translating natural-language instructions and visual observations into control actions. However, existing VLAs are primarily trained on successful expert demonstrations and lack structured supervision for failure diagnosis and recovery, limiting robustness in open-world scenarios. To address this limitation, we propose the Robotic Failure Analysis and Correction (RoboFAC) framework. We construct a large-scale failure-centric dataset comprising 9,440 erroneous manipulation trajectories and 78,623 QA pairs across 53 scenes in both simulation and real-world environments, with systematically categorized failure types. Leveraging this dataset, we develop a lightweight multimodal model specialized for task understanding, failure analysis, and failure correction, enabling efficient local deployment while remaining competitive with large proprietary models. Experimental results demonstrate that RoboFAC achieves a 34.1% higher failure analysis accuracy compared to GPT-4o. Furthermore, we integrated RoboFAC as an external supervisor in a real-world VLA control pipeline, yielding a 29.1% relative improvement across four tasks while significantly reducing latency relative to GPT-4o. These results demonstrate that RoboFAC enables systematic failure diagnosis and recovery, significantly enhancing VLA recovery capabilities. Our model and dataset are publicly available at https://github.com/MINT-SJTU/RoboFAC.

The real-world performance of current vision-language-action models is fundamentally constrained by the limited coverage of expert demonstrations and their insufficient understanding of physical interactions. A common remedy is to collect additional real-world demonstrations of newly encountered failures. However, this process is costly, inefficient, potentially unsafe, and difficult to scale. To address this challenge, we propose Failure for Rising (F4R), a failure-driven real-to-sim-to-real closed-loop learning framework that converts real-world failures into targeted policy improvement. F4R first uses an agent to automatically identify and diagnose failures from rollouts. It reconstructs each failure as an interactive, object-centric table-top environment that preserves the task-relevant spatial and physical conditions. The policy is then refined through failure-conditioned sim-real co-training followed by targeted reinforcement learning in the reconstructed environments. The improved policy is subsequently redeployed, while newly observed failures are continuously fed back into the next reconstruction and learning cycle. Real-world evaluations on four manipulation tasks show that F4R achieves 93.75% In-Distribution and 90.0% Out-of-Distribution (OOD) success, outperforming the budget-matched Targeted BC baseline by 18.75 percentage points under OOD conditions without collecting additional real-world corrective demonstrations.

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.