Unsupervised Discovery of Failure Taxonomies from Deployment Logs

Abstract

As robotic systems become increasingly integrated into real-world environments, ranging from autonomous vehicles to household assistants, they inevitably encounter diverse and unstructured scenarios that lead to failures. While such failures pose safety and reliability challenges, they also provide rich perceptual data for improving system robustness. However, manually analyzing large-scale failure datasets is impractical and does not scale. In this work, we introduce the problem of unsupervised discovery of failure taxonomies from large volumes of raw failure logs, aiming to obtain semantically coherent and actionable failure modes directly from perceptual trajectories. Our approach first infers structured failure explanations from multimodal inputs using vision language reasoning, then clusters them in the resulting semantic reasoning space, discovering recurring failure modes rather than isolated episode-level descriptions. We evaluate our method across robotic manipulation, indoor navigation, and autonomous driving domains, demonstrating that the discovered taxonomies are consistent, interpretable, and useful in practice. In particular, we show that structured failure taxonomies guide targeted data collection for offline policy refinement and enhance runtime failure monitoring systems. Website: https://mllm-failure-clustering.github.io/