Dvp Test Plan

Design Verification Plan and Report (DVP&R)

When to use

Use this skill when:

• Creating a DVP for a new part design during APQP Phase 2
• Reviewing a supplier's DVP for completeness and DFMEA alignment
• Determining which tests are required for a specific failure mode or design characteristic
• Tracking test completion and recording results (the "R" in DVP&R)
• Assessing whether a design change requires additional validation testing

Prerequisites

• DFMEA with all failure modes identified and AP ratings assigned
• Engineering drawing with all characteristics defined
• Customer design specifications and performance requirements
• List of applicable standards and test methods (customer spec, ISO, SAE, etc.)

Workflow

Step 1 — Understand the DVP structure

The DVP&R is a table with one row per test. Each test must address at least one failure mode or design characteristic from the DFMEA.

The linkage rule: Every H-AP (High Action Priority) failure mode in the DFMEA must have at least one corresponding test in the DVP. If a failure mode has no test, document why (e.g., analysis-only justification with sign-off).

Step 2 — Build each DVP row

Step 3 — Determine required tests

For each DFMEA failure mode, identify the test category:

Functional / performance tests:

• Tests that verify the product performs its intended function
• Examples: burst pressure, tensile strength, electrical resistance, flow rate
• Must demonstrate the product meets its design intent specifications

Environmental / durability tests:

• Tests that simulate the product's operating environment over its design life
• Examples: thermal cycling, salt spray, vibration, UV exposure, humidity
• Duration and cycles must represent the design life or accelerated equivalent

Safety / regulatory tests:

• Tests required by law, regulation, or homologation
• Examples: ECE R10 (EMC), FMVSS standards, ECE R94/R95 (crash), REACH, RoHS
• Must be performed by accredited lab; results must accompany PPAP

Dimensional / material tests:

• Verification that design dimensions and material properties are achieved
• Examples: 3D scan, CMM, tensile test, hardness test, chemical composition
• Must reference the specific drawing characteristic or material specification

Reliability / life tests:

• Tests that verify the product meets its reliability target (e.g., B10 life)
• Examples: fatigue testing, accelerated aging, wear testing
• Test plan must include correlation between accelerated test and field life

Step 4 — Populate timing per APQP phase

Not all tests need to run in all phases. Focus safety and regulatory tests on Pre-launch or Production parts.

Step 5 — Track completion (the "R" in DVP&R)

Update the DVP after each test:

• Record actual completion date
• Record Pass/Fail result
• For any Fail: log a DFMEA action (or open an 8D if failure escapes to customer)
• Re-test after corrective action — reference the re-test as a new row with the original DVP number + suffix (e.g., DVP-012-R1)

At PPAP submission: all DVP tests must show "Pass" or have a documented customer-approved deviation. If a test is still in progress at PPAP submission (e.g., a long-duration life test), a formal customer deviation request must be submitted with: the test in progress, the expected completion date, the interim risk assessment, and the customer's written acceptance. The PPAP approval will be conditional until the test completes with a Pass result.

Engineering changes: If the DFMEA is updated during the design phase and adds new H-AP failure modes, the DVP must be updated to cover them before the next gate review. A DVP revision that is behind the current DFMEA revision is a gap — the DVP&R revision must match or exceed the DFMEA revision at PPAP submission.