FLARE: A Failure-Aware Framework for Autonomous Correction and Recovery in Visual-Language Robotic Manipulation

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) policies achieve strong performance in robotic manipulation but remain brittle once execution deviates from nominal trajectories. We propose CARE (Corrective Atomic Robotic Execution), a framework that improves recovery by learning from failures encountered during execution. Instead of generating corrective data from manually designed or random perturbations, CARE collects failed rollouts, models stage-conditioned post-failure deviations, and uses the resulting empirical distributions to synthesize representative failure states and corrective demonstrations. At inference time, CARE combines stage-wise planning with physically grounded 3D monitoring to trigger atomic adjustments or re-operations while preserving task progress. We further introduce the Failure State Recovery Benchmark (FSR-Bench), which evaluates recovery from intermediate failure states under local deviations and structural anomalies. Experiments across multiple VLA backbones, simulation benchmarks, and real-world dual-arm tasks show consistent improvements, with average task-success gains of 14.5 points in simulation and 15.9 points in the real world. Code, models, and data are available at https://github.com/xiaojunlan/care

Vision-Language-Action (VLA) models remain brittle in long-horizon, contact-rich manipulation because success-only imitation provides little supervision for execution drift, while failed rollouts are often discarded. We introduce RePO-VLA, a recovery-driven policy optimization framework that assigns distinct roles to success, recovery, and failure trajectories. RePO-VLA first applies Recovery-Aware Initialization (RAI), slicing recovery segments and resetting history so corrective actions depend on the current adverse state rather than the preceding failure. It then learns a Progress-Aware Semantic Value Function (PAS-VF), aligning spatiotemporal trajectory features with instructions and successful references. The resulting labels salvage useful failure prefixes via reliability decay, while low-value labels mark drift and terminal breakdowns, teaching differences among nominal, failed, and corrective actions. The data engine turns adverse states into planner-generated or human-collected corrective rollouts, teaching recovery to the success manifold. Value-Conditioned Refinement (VCR) trains the policy to prefer high-progress actions. At deployment, a fixed high value ($v=1.0$) biases actions toward the learned success manifold without online failure detectors or heuristic retries. We introduce FRBench, with standardized error injection and recovery-focused evaluation. Across simulated and real-world bimanual tasks, RePO-VLA improves robustness, raising adversarial success from 20% to 75% on average and up to 80% in scaled real-world trials.