DVP&R, or Design Verification Plan and Report, is a tool that organizes the process of product verification and validation during its development. It serves as a guide to ensure that the design meets both specification requirements and customer expectations.
For professionals in the automotive and industrial sectors who face the demands of standards like IATF 16949 daily, it is not just a document but a vital tool supporting quality management.
Why is DVP&R so important?
The primary goal of DVP&R is to structure and document the design verification process. This ensures that:
- You can monitor the progress of verification.
- Collaboration among project, engineering, and quality teams is simplified.
- You create robust documentation that serves as a reference for future project iterations or new products.
Key elements of DVP&R
Each document consists of several key sections. Here’s what it should include:
- Functions
Define what the product is supposed to do. These are the core objectives the product should achieve. - Requirements
Detailed specifications regarding quality, performance, and compliance with standards or regulations. - Verification plans
This section describes specific tests, analyses, or inspections. For each requirement, a clear testing method should be defined. - Verification reports
Test results, including their status (pass/fail, OK/NOK, etc.), as well as any issues or deviations from the specification. - Schedule
Timelines for tests and analyses to help manage time effectively. - Responsible parties
Assign responsibility for conducting tests and documenting results. - Resources needed for verification
Identify tools, equipment, and materials required for testing.
How to create an effective Design Verification Plan and Report?
The process of creating DVP&R can be divided into several steps:
- Define project goals
Clearly outline what the product is supposed to achieve and which functions are critical. - Identify requirements
Document requirements for quality, performance, and compliance with standards. - Develop a verification plan
Create a detailed test schedule and assign responsibilities for execution. - Allocate resources
Ensure access to the necessary tools and equipment. - Conduct tests and document results
Results should be thoroughly described to indicate whether requirements are met. - Analyze results and review
Identify areas for improvement or further development.
DVP&R and DFMEA – How are they connected?
DVP&R works hand-in-hand with DFMEA (Design Failure Mode and Effects Analysis) in the design process.
- DFMEA identifies potential design risks and their effects (“What could go wrong?”).
- DVP&R focuses on verifying and testing those risks (“How will we confirm it works?”).
Together, these tools provide a strong foundation for ensuring quality in the design.
DVP&R and APQP
DVP&R is a critical element of APQP (Advanced Product Quality Planning). Throughout all phases of APQP, this document plays a significant role in the verification and validation process, supporting documentation efforts. The test results, in turn, form the basis for further optimization, often guided by lessons learned.
Pro Tip!
As we know, the team uses the plan and report during the validation of a new project. If you’re involved in such a launch, it’s important to remember one key aspect: the storage time of parts designated for testing.
Ideally, this period should align with the timeframe during which requalification tests will be conducted. Why is this so important?
This approach allows you to provide physical parts to the customer, especially when they report an issue in the warranty network that should have been detected during testing. Physical verification of the parts may also be necessary to check for cracks or other defects not included in the report.
Not all tests need to be conducted simultaneously
What does this mean? For components that are injected, thermoformed, or stamped, initial tests can be conducted on parts produced by the tool manufacturer. Subsequently, after they are transferred to the organization’s plant, additional tests are performed when tooling status is available – Off Tool Off Process: the definitive process at the definitive location.
Of course, some tests can be repeated. This is typically agreed upon between the client’s engineering team and yours during the initial meeting.
Remember client requirements
Some clients have their own DVP&R formats. A prime example is Stellantis, which requires the test plan to be prepared based on the Design Verification Plan And Report (DVP&R) (Stellantis Harmonized) procedure, identified by QR.10022.
Summary
DVP&R is an essential tool in the arsenal of every quality specialist, engineer, or project manager in the automotive industry. It organizes the validation process and minimizes the risk of errors. By implementing it, you lay a solid foundation for product quality and effective team collaboration.
On the Free Tools page, you can download the Excel form for the Design Validation Plan & Report (DVP&R) free of charge. Of course, you can edit it in any way you like.
Dariusz Kowalczyk
