Failure has to be built in as standard, as no one would ever buy new if it wasn't. However, with Dyson, 'failure' was widespread, consistent, and for the consumer, rather annoying. If the parts on Dyson cleaners which failed had done so because of 'built in' failure, I don't think Dyson would have bothered to replace the parts as readily as they did. No, I do think that most parts failed as a result of not being up to the job.
One has to remember though that the Dyson company is a strange one. Their contact centre is open 7 days a week, from 7 in the morning until 10 at night. Great for the consumer, but absolutely ridiculous for a profit making company who are selling a one-off product and not a continual service. Dyson do what they feel like, even if that means ignoring a persistent design fault and sending new parts to 'correct' it.
The DC04 is not the only cleaner to have has failure of the mains lead, as the DC01 did so too. The remedy was the introduction of a 'doughnut', which resulted in even more failure as this part was liable to cut into the lead instead of taking the stress. Electrolux had this problem with their 500 cleaners. They ran for a couple of years and then changed the flex sleeve from straight to right angle. This was in 1975. The 500 series as you know then ran for years and years and to this very day many examples are easily sourced. Would it have killed James Dyson to take one home and analyse it before making his own machines for the mass market in 1993?