Quality Sciences in Electrical Engineering

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Enhancing Product Reliability and Litigation Support at Discovery Engineering

Quality Sciences play a vital role in the design, manufacturing, and reliability of electrical and electronic systems. At Discovery Engineering, this discipline intersects directly with our core mission—supporting attorneys, insurers, and manufacturers with electrical engineering expert witness services and technical consulting in complex product liability and failure analysis cases.

Whether we’re analyzing a malfunctioning device or reviewing the design practices behind an electrical fire, the principles of quality sciences help us provide clarity, precision, and insight.

This article explores the foundational methods, tools, and regulatory considerations within quality sciences, and how they directly relate to electrical engineering and legal proceedings. From failure prediction to root cause analysis, these approaches ensure products are safer, more reliable, and legally defensible.

What Are Quality Sciences?

At its core, quality sciences is the structured study of how to design, produce, and maintain systems that consistently meet defined standards. It involves the application of engineering, statistical, and managerial tools to prevent failures, improve performance, and reduce variability. In the context of electrical engineering, quality sciences help identify when a product is at risk of failure—and more importantly, why.

This discipline often draws from established frameworks such as Six Sigma, Lean Six Sigma, risk management, and statistical process control. When these tools are integrated effectively, they reduce manufacturing defects, minimize safety risks, and ensure compliance with global standards.

Key Quality Science Methodologies in Electrical Engineering

Failure Mode and Effects Analysis (FMEA)

One of the most critical tools in quality sciences is FMEA. This methodology systematically identifies all the ways a product or process might fail and prioritizes them based on severity, likelihood of occurrence, and ability to detect the issue. These three factors are used to calculate a Risk Priority Number (RPN), which guides the development team in deciding where to allocate resources.

At Discovery Engineering, we often review existing FMEA documentation—or identify where it was absent entirely—to assess whether a manufacturer adequately considered foreseeable failure modes. For example, if an electrical appliance short-circuits due to moisture ingress and that scenario was not considered in the original FMEA, this could point to negligence or a lapse in industry best practices.

This analysis becomes crucial in product liability cases, where demonstrating the absence or inadequacy of a structured failure analysis process can support or refute claims of defective design.

Root Cause Analysis (RCA)

Another fundamental aspect of quality sciences is root cause analysis (RCA). This process is typically initiated after a failure has occurred and is aimed at understanding the underlying cause—not just the symptoms. RCA involves several steps: defining the problem, collecting relevant data, analyzing causal relationships, identifying corrective actions, and implementing long-term solutions.

In the context of electrical engineering litigation, RCA is particularly useful in accident reconstruction, equipment failure analysis, and cases involving fires, electrocution, or system outages. Discovery Engineering frequently uses RCA techniques to trace back through complex electrical systems and isolate the fault that triggered a larger failure. This process is data-driven and essential for credible expert testimony.

Statistical Process Control (SPC)

Statistical Process Control, or SPC, involves monitoring and controlling manufacturing processes through data analysis. It helps engineers understand whether a process is stable and capable, or if it’s trending toward producing defects.

SPC is commonly visualized through control charts, which track process variables over time. Unlike specification-based inspection, SPC focuses on the process itself rather than just the final product. This proactive approach allows engineers to correct issues before defective products reach the market.

One common mistake in using SPC is to confuse product specifications with process control limits. Adjusting a process to meet arbitrary output requirements—rather than understanding the process behavior—can actually increase defect rates. At Discovery Engineering, we’ve encountered numerous product failures where misuse or misunderstanding of SPC led to manufacturing inconsistencies that eventually resulted in injury, property damage, or litigation.

Six Sigma and Lean Six Sigma in Product Design

Six Sigma is a data-driven methodology designed to reduce defects and improve quality. Originally developed at Motorola, Six Sigma focuses on minimizing variability and achieving near-perfect output. Its core methodology, DMAIC—Define, Measure, Analyze, Improve, Control—is ideal for improving existing products or systems. In contrast, the DMADV—Define, Measure, Analyze, Design, Verify—approach is used for designing new products from the ground up.

Lean Six Sigma combines the process efficiency principles of Lean manufacturing with the analytical rigor of Six Sigma. This hybrid method emphasizes doing more with less while maintaining—or improving—quality. In electronics manufacturing, these approaches are vital for controlling cost, improving product lifespan, and meeting regulatory and customer requirements.

Discovery Engineering often reviews Six Sigma documentation in design and manufacturing cases to assess whether the methods were correctly applied. Improper implementation can lead to undetected failures that only surface during real-world use, which often triggers legal action.

Regulatory Compliance and Standards

Compliance is another critical aspect of quality sciences, especially in sectors governed by stringent regulations. Standards such as ISO 9001, GDPR, and PCI-DSS provide frameworks for managing quality, data security, and privacy. While these may not seem directly tied to electrical engineering at first glance, their impact is significant.

For example, failure to follow compliance protocols in data-driven electrical devices—such as smart meters, GPS systems, or embedded control systems—can lead to privacy violations, operational disruptions, or legal sanctions. Discovery Engineering is equipped to analyze whether compliance failures contributed to system malfunctions or security breaches, especially when assessing complex root causes.

The Legal Value of Quality Sciences

So why does all of this matter in a legal context?

Understanding and applying quality sciences can make or break a case. If a company failed to conduct FMEA or ignored SPC warning signs, it might be held liable for resulting damages. On the other hand, thorough documentation of these efforts can form a strong defense, demonstrating adherence to industry best practices and due diligence.

At Discovery Engineering, we bridge the gap between engineering rigor and legal clarity. Our team helps clients dissect the technical evidence and determine whether a failure was foreseeable, preventable, or the result of negligence. We present these findings in a way that courts, juries, and legal professionals can easily understand.

Hypothetical Scenarios

Consider a consumer electronics product that catches fire due to a battery defect. Our analysis might reveal that the manufacturer failed to model thermal runaway scenarios in their FMEA, or that they adjusted process parameters in response to customer feedback without updating their SPC model.

In another example, a smart device may have experienced repeated connectivity failures. Using RCA, we may uncover that a third-party firmware update disabled a voltage regulation subroutine, ultimately leading to hardware instability. Our role is to link this technical breakdown to process decisions and documentation—evidence that can carry significant weight in court.

These examples highlight how quality sciences aren’t just about technical performance—they’re about responsibility, accountability, and risk mitigation.

Discovery Engineering’s Expertise in Quality Sciences

With decades of experience in electrical engineering and litigation consulting, Discovery Engineering is uniquely positioned to apply quality science principles in real-world legal and insurance contexts. Mark McFarland works closely with legal teams to review quality assurance records, manufacturing protocols, design documents, and failure reports.

Whether you’re dealing with a class action lawsuit, wrongful death claim, or product recall, our objective, technically grounded insights help ensure that every angle is examined.

Quality Sciences in Electrical Engineering

Quality sciences provide a structured, evidence-based approach to understanding why systems fail and how they can be improved. In electrical engineering and litigation, these tools help uncover the root causes of defects, evaluate design decisions, and assess whether industry standards were met.

Discovery Engineering brings deep technical knowledge and clear communication to complex failure investigations. By applying methodologies like FMEA, RCA, SPC, and Six Sigma, we help our clients manage risk, ensure compliance, and present credible, defensible conclusions in high-stakes cases.

For clients seeking expert guidance in electrical failure analysis and quality-related litigation, Discovery Engineering stands ready to support your case with clarity, authority, and integrity.