BackPrinciple of a Design Verification Plan and Report (DVP&R)
How to standardize your DVP&R?
Standardization, including using the same wording instead of various synonyms,
allows for easier communication amongst different groups of people within an organization and
will automatically lead to better understanding of complex systems,
reducing mistakes and enabling better solutions.
Typically, a Design Failure Mode and Effect Analysis (DFMEA) is defining a
DVP&R to detect and evaluate potential product failures. Nevertheless, when a
new product is very similar to a previous product, an update of a DFMEA will
lead most probably to the same DVP&R. In a well-established development environment,
where the product is developed repeatedly, standardization of a DVP&R is recommended for:
Integration of lessons learned from previous projects into future DFMEA / DVP&R’s
Reduction of warranty risk
Easier understanding of data within an organization across departments (e.g. for capacity planning)
For the purpose of standardization, the activity can be split into filter definition and collection of standards.
In the first step, the influence factors are detected, which leads to a deviation of one DVP to another one. These influence factors will be used to define the filters. It can be done e.g. by an investigation on former DVPs or by workshops with experts.
Influence factors: Application & customer
The influence factors are, for example:
the application
the product itself
specific customer requirements
For combustion engines, an example of the application could be ‘On Highway’ like passenger cars or trucks, ‘Off Highway’ like tractors and construction equipment and ‘Non Road’ like gensets. The product itself is then the portfolio of component supplied. Customer specific requirements are simulations or tests, which are only done for specific customers, the factor would be then the customer’s name.
Influence factors: Technical targets
Next, the technical targets are listed. This categorization is particularly beneficial when different parties, such as different departments, are involved and working on different targets.
Influence factors: Project Phases
Additional categories are the different phases of a development. These 4 Project Phases include:
Concept - consists of Thumb rules, Benchmark data and Material Guidelines
Simulation - consists of CAE methods according to customer & internal specifications
Tuning - consists of CAE tuning methods according to customer & internal specifications.
Validation - consists of Measurement and Test specifications according to customer & internal specifications.
Note, during a Concept, Simulation or Tuning Phase, there may also be a need to include first Measurements and Tests for tuning the simulation results or for Concept Validation.
However, some OEM's requesting DVP&R’s only include the validation part. Nevertheless, it is recommended to track the complete Development, including Concept, Simulation and Tuning especially as cost for changes in the beginning are smaller. Any late design change will increase the costs exponentially.
The Validation Phase may have to be further subdivided into Design Validation and Process Validation. This may be required, when different tests are needed during different stages within a project, especially when the costs e.g. for prototypes are showing mayor differences.
Collection of Standards
In the second step, all existing standards and methods should be collected and categorized based on the influence factors described in previous sections.
In an ideal world, these methods and standards are already documented in the Quality Management System (e.g. in automotive according IATF 16949) and in the customer’s documentation. It is also recommended to track who is responsible for the execution of the standards (e.g. OEM, Tier I or Tier II).
Gap Analysis
Having an overview of requirements from the targets vs. the existing methods and tools, like in the displayed picture, makes it easier to finally analyze your gaps and close them.
