To study the failure rate of electrical components under the limitation of physical material properties, a factor influence analysis and control method was established through the influence of factors on the failure rate. The physical limitations of electrical component failures were first discussed; then, an analytical expression for the failure rate distribution was established, and the influence of factors on the failure rate was discussed; finally, a failure rate control scheme was constructed. Based on the failure types and influencing factors of electrical components, a 12-dimensional factor space and an analytical expression for the failure rate distribution were constructed. The characteristics of the failure rate of electrical components were obtained by deriving the analytical expression. That is, temperature has an exponential influence, current density has a square influence, electric field strength has an exponential influence in dielectric breakdown, and substrate current and humidity have little influence. The factor optimization approaches are dynamic parameters, environmental parameters, and manufacturing process parameters. Accordingly, a three-level failure rate control scheme was established, with the cost increasing and the effect decreasing in turn. Case studies obtained the influence of factors on components, and determined key failure rate change thresholds such as temperature 340K and activation energy 0.6eV. It provides a method for analyzing the failure characteristics of electrical components considering physical limitations.