Managing technical risks caused by indirect interactions: insights from tracking the use of risk assessment tools

Unintended technical interactions across system interfaces can lead to costly failures and rework, particularly in the early design stages of complex products. This study examines how structured risk assessment tools influence teams’ ability to identify, evaluate and mitigate risks from such indirect interactions. In a controlled experiment, 14 engineering teams (comprising professionals and graduate students) engaged in simulated design decisions across three system configurations. Tool usage – including models of direct and indirect risk propagation and value-based trade-offs – was continuously logged and linked to outcomes. Teams that engaged earlier and more deliberately with the tools identified risks sooner and selected mitigation actions with more favourable cost–benefit profiles. Results show that strategic, not merely frequent, tool use improves risk management performance, particularly when addressing cascading effects from indirect physical interactions. These findings support the use of structured supports to enhance both the efficiency of early-stage risk evaluation and the efficacy of risk treatment.