What is Design Verification Plan and Report?

In order to remain competitive in today's manufacturing climate, companies continuously improve current products and introduce new ones. In some cases, the brand-new product is brought to market without proper testing and validation. As a result, product design or performance problems are only identified after the product has been shipped. Too often the introduction of new products without proper testing results in errors, product recalls, failed campaigns, increased warranty costs and loss of brand value. Companies cannot afford such failures and costs. Designers and manufacturers have access to numerous tools for design analysis and product testing methods.

What is Design Verification Plan and Report?

Most companies are very diligent in performing design analysis and verification testing. Others have neither a good system nor a tool to organize and document the results. The data may be located in a folder on a public drive. In some cases, it also consists of data folders that are only understandable to design and test engineers. Currently, the automotive, heavy machinery and aerospace industries use a tool that addresses this problem. This tool is relatively easy to understand, use and very effective in organizing, describing, documenting and reporting the results of design analysis and product testing. The tool is the Design Verification Plan and Report.

The Design Verification Plan and Report

The Design Verification Plan and Report or DVP&R is a planning tool for the systematic identification of required tests and validations. Design FMEA anticipates possible errors and risks. Both work closely together and need to be synchronized for a smooth start into serial production.

In the Design Verification Plan and Report, the Design Review Panel (DVP) documents all test activities (tests) during product or process development. It also supports the planning and execution of experiments. Development results must be reviewed with the Design Verification Plan and Report to ensure that they are suitable for use. This includes systematic test planning. Responsible persons, tests and deadlines should be defined and test performance should be evaluated later.

With Design Verification Plan and Report, you can demonstrate that the specification meets customer requirements. The current status of the project verification can be viewed by all project participants at any time. Requirements, functions, specifications from requirements, hazard analysis or FMEA are automatic, up-to-date and available in Design Verification Plan and Report. Data is added to the Design Verification Plan and Report. Thus testing is fully integrated into the development process.

All DVP&R are different - this is a feedback from practice. Service providers adapt the Design Verification Plan and Report to the respective data and working style. The modular engineering method concept supports customer-specific forms and design options. The Design Verification Plan and Report summarizes the important information collected in the quality management process and provides information about the quality of the processes and their end products. This process is complex, but is mandatory depending on the industry.

Tasks of DVP&R

DVP&R is an easy-to-use tool that documents the plan to confirm that a product, system or component meets the design specifications and performance requirements. Each of the design specifications or product requirements is stated on the DVP&R form along with the analysis or test to determine whether the specification or requirement has been met. Upon completion, the results of each analysis or test should be recorded in the "Report" section of the DVP&R Form. DVP&R is closely related to Design FMEA (DFMEA), but each serves a very different purpose in the product development cycle. The DFMEA defines the "what" and the DVP&R defines the "how". The "What" is the list of analysis and verification tests developed during the FMEA activity. The "How" is the test methods or the way the analysis or test is performed, including acceptance criteria and reporting of results.

Implementation of DVP&R

As mentioned above, in some companies, the verification information consists of a new product development project or design change and is made up of a large amount of data spread across many folders and only understandable to the design or validation engineer. The DVP&R format ensures complete and accurate documentation of the analysis and verification activities performed during a new product launch, design change, or recertification of brands. The design review plan and report provides a clear picture that is understandable to the sponsor, stakeholders and team members. It enables everyone to understand the status of the analysis and verification tests. In addition, the DVP&R is a very useful tool for investigating quality issues during the life of the product.

The right time for a DVP&R software

The DVP&R tool is most often used in conjunction with DFMEA during a New Product Development (NPD) project or when making significant changes to an existing product. However, the design review plan and report is also useful for other applications. The DVP&R methodology and DVP&R software format can be used when performing a verification analysis or test. DVP&R software can be used with:

  • Performing tests as part of a problem solution or root cause analysis (RCA)
  • Plan and document test information to validate product performance after a design change or improvement
  • Testing during recertification for regulatory requirements

The DVP&R is useful throughout the product's life cycle, even after the product has been discontinued or redesigned. It can be a valuable historical document when the next iteration of the design is developed or when a similar product design is evaluated.

Implementing with the DVP&R Software

The DVP&R software format can vary greatly from company to company depending on individual preferences and business requirements. The core information is generally the same regardless of the format used. The initial "DVP" or design review plan is completed prior to performing the analysis or testing. The plan may evolve throughout the design review process. The DVP can come from a variety of sources, including, but not limited to

  • FMEA activities
  • Product improvement exercises
  • Product certification or recertification activities
  • Cause analysis or investigation of a quality problem

The "R" or "Report" sections are documented as with any test. The body is the main part of the DVP&R form, which is divided into four main sections. The sections contain several columns to record all details of the analysis and test methods that make up the "DVP" and later the "R".