Risk Management in Engineering Systems: Discovery Engineering’s Expertise

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Risk management is the systematic process of identifying, analyzing, and mitigating risks to protect people, systems, and assets. In engineering, it is an essential discipline for ensuring the reliability, safety, and compliance of complex systems. Discovery Engineering brings deep expertise in applying risk management practices to electrical systems, telecommunications, industrial equipment, and product liability cases. With a strong focus on failure analysis and litigation support, Discovery Engineering helps clients understand and manage risks across a range of engineering domains.

Core Concepts of Risk Management in Engineering

Key Standards and Frameworks

Risk management in engineering is guided by internationally recognized standards. ISO 31000 outlines the principles and guidelines for managing risk, providing a foundation that organizations can adapt to their specific needs. ISO 31010 supplements this framework by offering detailed risk assessment techniques.

Fault Tree Analysis (FTA) is one of the core techniques, providing a structured, top-down method to trace failures to their root causes. Similarly, Probabilistic Risk Assessment (PRA) quantifies the likelihood of different failure scenarios, helping decision-makers prioritize their mitigation efforts.

Risk Management Phases

• Risk Identification: Pinpointing potential hazards or failure points.
• Risk Analysis: Evaluating the likelihood and consequences of each risk.
• Risk Evaluation: Comparing estimated risks against acceptable criteria.
• Risk Treatment: Implementing measures to mitigate or eliminate risks.
• Monitoring and Review: Continuously tracking risk factors over the lifecycle of the system.

Techniques for Effective Risk Assessment

Fault Tree Analysis (FTA)

Fault Tree Analysis provides a visual representation of how failures in various components can combine to cause a system-level failure. Using logic gates like AND and OR, engineers can model the interdependencies between different events.

For example, if a machine fails to operate, FTA might reveal that either an electrical fault or a mechanical breakdown could independently cause the failure. Wiring issues might require further investigation as “undeveloped events,” while an overload could be classified as a “basic event” indicating a clear root cause.

Brainstorming for Risk Identification

Brainstorming remains a practical technique for early-stage risk identification. As outlined in ISO 31010, structured brainstorming sessions allow experts to freely share insights, generating a broad list of potential risks. Structured brainstorming involves prompting participants with specific topics, while unstructured brainstorming encourages open-ended discussion.

Discovery Engineering often employs structured brainstorming to capture expert knowledge during forensic investigations or product failure analyses, ensuring no potential risk is overlooked.

Probabilistic Risk Assessment (PRA)

PRA introduces a quantitative dimension to risk assessment by assigning probabilities to different failure scenarios. Rather than guessing outcomes, PRA uses real-world data and statistical models to predict the likelihood and impact of events. This approach is particularly valuable in industries like telecommunications, aerospace, and industrial manufacturing, where failures can have severe consequences.

Application of Risk Management in Discovery Engineering’s Services

Electrical Failure and Product Liability

Discovery Engineering frequently applies risk management techniques to cases involving electrical failures and product liability. For example, Failure Mode and Effects Analysis (FMEA) is used to systematically evaluate potential failure points in electrical devices and systems. Understanding how and why a product failed is critical in litigation and can inform future design improvements.

Telecommunications and GPS Systems

In the telecommunications sector, risk management helps ensure the reliability of cellular networks and GPS systems. Discovery Engineering conducts risk assessments to evaluate vulnerabilities to RF interference, signal loss, and equipment malfunctions, providing expert analysis for both preventive measures and litigation support.

Industrial Accidents and Lightning Strike Investigations

Industrial environments are fraught with risks, from machinery failures to lightning strikes affecting outdoor equipment. Discovery Engineering applies structured risk management frameworks to analyze incidents, determine root causes, and recommend mitigation strategies, helping clients manage exposure and liability.

Industry Best Practices for Risk Mitigation

Integration of Risk Management into Design and Operations

Incorporating risk management early in the design phase, known as “safety by design,” is critical. Risk assessments should be updated throughout the product or system lifecycle, from initial conception through deployment and eventual decommissioning. Discovery Engineering emphasizes lifecycle risk management to ensure ongoing safety and compliance.

Importance of Compliance

Adherence to industry standards such as the National Electrical Safety Code (NESC) and NFPA 70E for electrical workplace safety is vital. Compliance reduces the likelihood of incidents and strengthens a company’s legal position in the event of litigation. In regulated industries, meeting standards such as those set by the FDA or European Medical Device Regulation (MDR) is essential.

Data-Driven Risk Analysis

Data collection and analysis are cornerstones of effective risk management. Hazard traceability matrices help link identified risks to corresponding mitigation measures. Post-production monitoring and updates ensure that risk assessments remain accurate and that emerging threats are addressed promptly.

Challenges and Limitations in Engineering Risk Management

While risk management offers powerful tools, it is not without challenges. Group brainstorming sessions can sometimes suffer from social loafing, where individuals contribute less effort in a group setting. Dominant personalities can skew discussions, potentially overlooking important insights.

Achieving comprehensive risk identification is also difficult. Residual risks, those that remain even after mitigation efforts, must be carefully evaluated to determine if they are acceptable. Without rigorous follow-up, overlooked risks can lead to significant consequences down the line.

Discovery Engineering addresses these challenges by employing experienced facilitators, promoting open communication, and ensuring that technical and legal perspectives are both considered during assessments.

Ensure the Reliability, Safety, and Compliance of Engineering Systems

Risk management is indispensable for ensuring the reliability, safety, and compliance of engineering systems. Discovery Engineering applies industry-leading standards and techniques to help clients manage risks effectively, whether in electrical failure analysis, telecommunications, or industrial investigations.

By combining technical expertise with a structured, data-driven approach, Discovery Engineering supports attorneys, insurers, and corporate clients in making informed, defensible decisions. For those seeking expert witness services or in-depth engineering risk assessments, Discovery Engineering offers a trusted partnership built on experience, precision, and professionalism.