In this episode, Adrian is joined by Renaud Anjoran to explore fail-safe design principles: essential thinking for anyone developing most kinds of products.
Through real-world examples ranging from Tesla doors to Boeing and consumer electronics, they highlight how designers must ask: “If this fails, what happens to the user?”
They break down why it matters, what trade-offs exist, and how structured risk analysis, simplification, redundancy, and error-proofing can dramatically reduce hazards and costly failures.
Episode Sections:
- 00:00:03 – Introduction
- 00:01:00 – Tesla door handle fail-safe issue
- 00:02:32 – Building lock systems vs. car safety
- 00:05:55 – Structured thinking in fail-safe design
- 00:07:21 – Designing with users in mind
- 00:09:02 – Risk analysis methods: FMEA & fault tree analysis
- 00:11:10 – Catastrophic failures & extreme examples
- 00:12:18 – Everyday product applications
- 00:14:21 – Principle: Simplification in design
- 00:16:13 – Redundancy in critical systems
- 00:20:30 – Battery management & safety logic
- 00:20:34 – Human error and mistake-proofing
- 00:23:09 – Error-proofing examples: tables & plugs
- 00:23:41 – Trade-offs and cost considerations
- 00:26:03 – Testing, regulations & standards (UL, ETL, etc.)
- 00:27:11 – Summary & wrap-up
- 00:28:07 – Final thoughts & listener takeaway
- 00:28:19 – Outro
Are you designing a new product?
Ask yourself: “If this fails, what happens?”
Visit Sofeast.com to learn how our quality, reliability, and product development teams can support you in building safer, more reliable products.
Related content...
Get in touch with us
