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Thresor
FAILED-RUN REVIEW
Customer Rialto Logistics
Period Week 17 · Apr 14–20, 2026
Report # RL-W17-0014
487
Runs reviewed
23h
Avg turnaround
94%
Agreement on sample
31
Escalations
8
Sites covered
14
Robots active
Section 01

Top failure modes

Ranked by count. Parentheses show change vs. Week 16.

Blocked aisle · temporary 142 (-18)
Navigation failure 89 (+11)
Missed zone · incomplete clean 71 (+4)
Mapping · site change 48 (+22)
Docking · charging issue 37 (-6)
Human interference 29 (±0)
Unclear · needs technical review 21 (-3)
Robot behavior issue 14 (+2)
Section 02

Repeat site issues

Sites with 3+ failures of the same type this week.

Site Failure mode Count Weeks running Recommendation
RL-PHX-03 Mapping · site change 14 4 Refresh map — new rack layout installed 3/31 not yet in deployment.
RL-DFW-07 Blocked aisle · zone 4B 22 3 Ops to review pallet parking SOP for third shift.
RL-ATL-02 Docking · charger C-3 9 2 Hardware check recommended; isolated to one dock.
RL-ORD-01 Human interference 11 2 Operational, not product. Raise with facility lead.
Section 03

Robots with unusual failure rates

Deviations > 2σ from fleet median this week.

Robot Site Runs Failures Rate Primary mode
R-12 RL-PHX-03 38 17 45% Navigation failure
R-24 RL-DFW-07 41 14 34% Blocked aisle
R-07 RL-ATL-02 35 9 26% Docking issue
Section 04

Operational vs. product signal

Our read on where each failure class originates.

Operational (62%)

Failures driven by environment, staffing, or site policy — not the robot or software.

  • 142 Blocked aisles (pallets, shrinkwrap, spills)
  • 48 Site layout changes not reflected in map
  • 29 Human interference during active runs
  • 11 Shift-handoff SOP gaps at DFW-07
Product (38%)

Failures where the root cause is robot behavior, firmware, planning, or perception.

  • 89 Navigation failures — R-12 disproportionate
  • 71 Missed zones (path planner conservative)
  • 37 Docking — hardware suspect at C-3
  • 14 Edge-case behavior, unclear classification
Section 05

Recommended actions

Concrete, ranked by expected impact.

  1. 01

    Refresh map at RL-PHX-03

    14 of 48 mapping failures trace to a rack layout change on 3/31. Updated map not yet deployed. Single change, ~30% weekly reduction in this mode.

  2. 02

    Hardware check on robot R-12

    45% failure rate vs. fleet median 8%. Primary mode navigation failure at dock pillars — consistent with encoder or LiDAR drift. Pull from rotation; bench-check.

  3. 03

    Operational review at RL-DFW-07

    Zone 4B pallet blockage recurring across 3 weeks, third-shift specific. Not a product problem; raise with facility lead.

  4. 04

    Dock C-3 at RL-ATL-02

    Charging failures isolated to one dock across 2 weeks. Likely contact or firmware-on-dock. Swap dock or firmware update.