VLA-FAIL: Efficient Task Failure Detection for Finetuned Vision-Language-Action Models
Authors: Florian Seligmann, Emiliyan Gospodinov, Enes Ulas Dincer, Gerhard Neumann
Abstract
Vision-language-action models (VLAs) achieve state-of-the-art performance on many robotic manipulation tasks, yet they can still behave unpredictably in out-of-distribution scenarios. Runtime failure detection is therefore essential for the safe real-world deployment of VLAs. However, existing task failure detectors require computationally expensive action sampling, are based on architectural assumptions that limit their applicability to VLAs, or need access to failure rollouts. We propose VLA-FAIL, a lightweight and broadly applicable failure detection framework for VLAs that combines two novel failure detectors with minimal overhead, without requiring failure data. The first, last-layer Mahalanobis distance (LLMD), detects out-of-distribution states by measuring token-wise deviations in last-layer features relative to the training data. The second, action chunk consistency (ACC), exploits the temporal overlap induced by receding-horizon control and detects failures when consecutive action chunks become inconsistent. To capture the trade-off between detection accuracy and detection latency, we introduce AUCPDT, a threshold-independent metric that jointly evaluates precision, recall, and detection time. Through extensive real-world and simulation experiments, we demonstrate that LLMD and ACC capture complementary failure modes whose combination enables reliable and early failure detection across diverse tasks, frequently outperforming significantly more expensive baseline methods.
Vision-Language-Action (VLA) models enable robots to follow natural language instructions and generalize across diverse tasks, but they remain vulnerable to execution failures that compromise reliability in real-world deployment. Detecting such failures during execution is therefore critical for the robust deployment of embodied systems. Existing failure detection methods either rely on expensive action resampling or external models, while alternatives propagate trajectory-level labels uniformly across every timestep, obscuring localized failure signals. In this paper, we propose \textbf{Hide-and-Seek}, a framework that formulates VLA failure detection as a coarsely supervised learning problem. By combining inter-trajectory and intra-trajectory contrastive objectives, Hide-and-Seek localizes failure-indicative actions and induces temporally structured failure signals from trajectory-level supervision alone, without any step-level annotation. We evaluate Hide-and-Seek on LIBERO, VLABench, and a real-world robotic platform across three representative VLA policies: OpenVLA, π0, and π0.5.Our method achieves state-of-the-art multi-task failure detection performance with a practical accuracy--timeliness trade-off under conformal prediction, and generalizes well to both seen and unseen tasks.
Vision-Language-Action (VLA) models are increasingly used as generalist robot policies, yet their evaluation still relies largely on static benchmarks that randomly sample task scenes. In high-dimensional embodied spaces, failures are sparse and clustered, so static benchmarking can underestimate robustness risks. We reframe VLA evaluation as an active failure-discovery problem and propose a failure-aware test-generation approach that combines diversity-driven exploration with surrogate models learned from observed executions. The method steers testing toward high-risk yet diverse scene regions. Across four state-of-the-art VLA models, it uncovers substantially more failures (up to +29.7 % over selected baselines) while revealing more diverse failure modes. This mean that, for instance, in the case of GR00T-N1.6, success rate dropped from 64.4% to 34.7%. More broadly, our findings call for a shift in VLA evaluation: from passive measurement on fixed task suites to adaptive, failure-seeking test generation that exposes the structure of model weaknesses before deployment.
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.