Failure Prediction and Classification in Vision-Language-Action Models Via Calibrated Latent Probing

Vision-Language-Action models (VLAs) enable general-purpose embodied intelligence, but their performance is brittle under distribution shift, where unanticipated failures can damage equipment or endanger people. Deploying VLAs in real-world systems therefore requires a runtime monitor that is timely, calibrated, and informative while being efficient enough to run on the edge. Existing methods fail to fulfill these requirements. We present VLA-Tug, a lightweight probe over the latent layers of a VLA backbone that improves early failure detection and bounds the missed-detection and false-alarm rates, with minimal inference overhead. We show that supervising on the pre-failure segment of a trajectory increases early failure detection at matched false-positive rates by up to 30% over the strongest learned baseline. Under shift to unseen tasks, the bounds on missed-detection and false-alarm rates remain valid in up to 86% of runs, versus at most 21% for baselines. Unlike existing methods, VLA-Tug predicts the failure mode to enable corrective actions, raising top-3 accuracy on unseen tasks by up to 44% over a majority baseline. VLA-Tug enables real-time monitoring where the well-timed and informative probe supports lightweight steering that improves task success. We release a dataset of 3,180 annotated manipulation episodes to support future work on latent failure detection in VLAs at https://vla-tug.github.io.