Here's how you can navigate a major failure in a robotics project.

To solve a major failure in a robotics project, it is important to always have a risk mitigation plan. Robotics projects, like any technological project, must be managed under the premise of the triple restriction; time, scope and cost. Considering the above, the project management leader must generate, together with the technical team, a list of potential risks that could occur during the execution of the project, and generate specific mitigation plans for each potential risk.

Take stock of what went wrong and the extent of the issue. This could involve examining physical hardware for damage or reviewing code for errors. Approach this step objectively, focusing on identifying the problem areas without bias. Detailed documentation is essential during this process, as it provides a valuable record for developing a strategic solution and BOOM! You will get an easy understanding of what is the actual damage!

One of the critical components of effective evaluation is to rely on measurable or classifiable criteria. It is imperative not to base any research or analysis on subjective emotions but rather on factual evidence. In this regard, a robust logging system can prove to be a valuable tool for identifying root causes

After identifying the cause, it is essential to conduct a comprehensive analysis to fully comprehend the reasons why it occurred. This may involve investigating whether it was due to unexpected behavior, a programming bug, or human intervention. A reliable approach to uncovering the underlying reasons is to recreate the same situation in a safe and controlled environment and observe the outcomes.

Once the root cause has been identified, it is advisable to conduct a workshop or brainstorming session with the team to determine the best approaches to address the issue. This collaborative process can help generate a range of viable solutions and enable the team to select the most appropriate one. Additionally, the team should plan the necessary steps to develop and release the solution.

The development phase of the solution can be challenging, as there is often pressure to deliver it as soon as possible. However, with proper planning and a clear understanding of the root causes, this phase can proceed without any major issues. It is crucial to ensure that the team adheres to a well-defined timeline and that all tasks are clearly assigned and monitored. This can help ensure that the solution is delivered on time and meets the desired quality standards.

After fixing a major failure in a robotics project, thorough testing is key. Put your robot through various scenarios, either in a controlled environment or with simulation software like in Gazebo, to see how it performs. This helps ensure everything is working as it should. Rigorous testing not only verifies your repairs but also builds confidence that your project can handle real-world conditions, making sure it’s reliable and ready for anything.

During the testing phase, it is advisable to use simulators in the initial attempts, followed by emulators for more detailed results. The use of simulators and emulators can help to recreate the failure scenarios in a controlled and safe environment. This approach can significantly reduce the risk of introducing new issues when deploying the solution. Additionally, the testing phase provides an opportunity to identify areas for improvement and gain further insights into the problems. By addressing these issues during the testing phase, the final solution can be enhanced to better meet the needs of the end-users.

Navigating a major failure in a robotics project can be daunting, but it's also a golden opportunity to learn and adapt! The tech world moves at an amazingly rapid pace, and keeping up means constantly evolving. Reflect on what led to the failure and how you can improve your response in the future. Update your documentation, processes, and team training to incorporate these lessons. It's not just about what you know, but how much effort you put into learning more. Embracing this mindset drives innovation and prepares you for future challenges, making you more resilient in the face of adversity.

Share your learnings with others. As one team, company, industry or mankind we will get much better when we learn collectively from each other and don’t do same same wrong things again and again.

I remember one major failure in the past, and we turned the correction into a team building exercise. We found that talking through the problem and accepting the hardship gave us the resiliency to push through. It took time, but we became a better organization because of it. While I don’t recommend anyone have a major failure, I will say it can be a defining moment for you and your company. The strong stand and the weak fall.

From multiple automation rescue effort I have found that getting the team of process owners to evaluate part and process variability as a major contributor to the problem. In many cases this huge risk is not properly evaluated before the project is launched. Of course the best case is to complete a comprehensive risk evaluation BEFORE starting the project.