DVP Design Validation Plan, Protocol,

DVP is sequential process; however performance/ durability failure at latter stage can compel us to repeat the DVP testing from beginning for subsystem or whole vehicle. So Front Loading concept is very popular in industry: - more resources are allocated at early stage of DVP for DFMEA, concept analysis, past quality data analysis and 1D/2D/3D simulation for perfoamce, fatigue and life.

Manufacturing starts only after successful child part level + part level + Assembly or Subsystem level + Vehicle Level Simulation result are satisfactory on each front such as crash, safety, NVH, electromagnetic emission, emission government standard, fuel efficiency, life, endurance, marketing feedback for styling body design and many more.

  

Step 1**	Step 2#	Step 3**	Step 4#	Step 5	Step 6
All Child Part	Subsystem	Child Part	Subsystem	Vehicle	Vehicle
Performance & Durability Simulation	Performance and Durability Simulation	Physical Performance & Durability	Physical Performance and Durability	Calibration and Performance	Durability and Endurance
Example: 1.Stress/strain, 2.Layout/Tolerance 3.Assembly 4.O-ring Gasket Leakage, 5.Flow Rate, 6.Pressure, 7.Discharge 8. Voltage/Current	Example:  1.Power Torque Optimization , 2. Wind tunnel 3. Suspension Chassis 4. Vehicle Crash 5.Steering Link Simulation	Example: Performance, Braking Load,  Corrosion, Thermal Shock, Sweep Vibration Composite Durability , Wear, Fatigue, Cyclic Load	Example: 1.Engine Dyno Calibration/ Durability 3. Physical Wind Tunnel 4. Suspension Dyno Test	Example: 1.Vehicle Chassis Dyno, 2. Emission, 3. Ergonomic 4.Drivability, 5.Braking  Distance /Time, 6.Steering  Angle	Example: Run Vehicle on Different Road Condition such as Dry /Wet Road, in Water , Bump Road, Corner, With wear Tyre

**: Simulation and Physical Tests have same/similar target and Pass/Fail criteria

#: Simulation and Physical Tests have same/similar target and Pass/Fail criteria 

A. Define Performance and Durability Requirement:  

Subsystem	Performance Requirement	Durability Requirement
Engine	High Constant Torque, High Power, Less Fuel Consumption, Less Vibration, High Cooling Efficiency, Low Frictional Loss	High Vibration, High Temperature , Cyclic Loading , High Rotating Parts
Body	High Downforce, Less air resistance , High Crash Strength , Light Weight , Comfortable	Impact Load, Concentric Load, High Vibration, High Temperature
Suspension	Smooth Damping , Low Centre of Gravity, Controlled Drivability , No Slip/Topple/Skit	Impact Load, Jerk Load, Damping Vibration
Brake	Less Driver Effort, High Braking Life, Smooth Braking, Low Braking Distance and time	Cyclic Loading ,High Temperature , High Pressure , Corrosion
Steering	Less Driver Effort,  High Sensitivity & Accuracy, Low Response Time, Quick Angle Ratio	Cyclic Loading, High Wear, Friction

Please go to next blog for next step of DVP. 

Next blog is related to - 

B.1. Child Parts Test Procedure and Criteria: (For these tests both simulation and physical test must be done)