PREFAIL: Identifying Precursors to Failures in Robotic Lift-and-Place Tasks to Improve Task Execution Performance

Zeyu Shangguan, Rajas Chitale, Rutvik Patel, Satyandra K. Gupta, Daniel Seita

Non-prehensile manipulation enables flexible material handling with part carriers, but friction-based support makes high-speed motions failure-prone, while slower operation increases cycle time. Proactive failure prediction is therefore essential for efficient and reliable performance, yet existing approaches remain limited by key constraints, including sensitivity to dynamic actions and high dependence on known policy structures. Furthermore, existing methods and datasets lack a precise characterization of the latest intervention time, leaving it unclear whether a detected failure can still be prevented through timely intervention. In this paper, we investigate lift-and-place tasks for non-prehensile material handling manipulation and propose a more effective approach to predicting precursors to failures (PREFAIL) by analyzing the relative motion of target objects with respect to the carrier. We further introduce a dataset that precisely identifies the latest intervention time for risky manipulations, enabling rigorous evaluation of whether a failure prediction is actionable. We validate our approach on both simulation and real-world datasets. Our experimental results demonstrate that PREFAIL substantially improves both the accuracy and timeliness of responses to failure precursors.