Design Report DFMEA & Validation Presentation

SAEINDIA organizedTwo day

Faculty Leadership Development

Programme

on 21st & 22nd June 2013

at Priyadarshini College of Engineering,

Nagpur.

Baja Design Report, DFMEA Baja Design Report, DFMEA & Validation Presentation& Validation Presentation

Dr. K.C. VoraDr. K.C. Vora

BROAD CLASSIFICATIONBROAD CLASSIFICATIONCHASSIS AND ROLL CAGE SUSPENSION SYSTEM

ENGINE AND TRANSMISSION BRAKES AND STEERING

Vehicle ConfigurationVehicle ConfigurationFourFour oror moremore wheelswheels..

CapableCapable ofof carryingcarrying singlesingle seatedseated personperson 190190..55 cmcm((6633)) talltall andand weighingweighing 113113..44 kgkg ((250250 pounds)pounds)..

MaximumMaximum vehiclevehicle widthwidth shouldshould bebe lessless thanthan 6464MaximumMaximum vehiclevehicle widthwidth shouldshould bebe lessless thanthan 6464includingincluding tyrestyres andand maximummaximum lengthlength shouldshould bebe lesslessthanthan 108108..

ItIt mustmust possesspossess allall terrainterrain capabilitycapability..

ItIt shouldshould havehave adequateadequate groundground clearanceclearance andand tractiontraction..

Top speedTop speed 50km/hr50km/hrApproximate weightApproximate weight 210kg210kgGround clearanceGround clearance 99--1010Wheel baseWheel base 5656

Typical Design TargetsTypical Design Targets

Wheel baseWheel base 5656Track widthTrack width 6060Turning radiusTurning radius 88

Different parts of vehicleDifferent parts of vehicle Engine/Air Filter/Silencer Transmission/Clutch/Differential Seat Roll Cage Body Axle/Balancing Rods Suspension Suspension Tyres Brakes Steering Fuel System Safety Asthetics/Colour Spares Manufacturing Kit/Tool KitInnovation

BAJABAJA SAEINDIASAEINDIA CompetitionsCompetitionsrequirerequire useuse ofof EngineEngine providedprovidedbyby BriggsBriggs && Stratton,Stratton, USAUSA ofoffollowingfollowing specificationsspecifications::

44 strokestroke airair--cooledcooled 1010hphp OHVOHV

ENGINEENGINE

44 strokestroke airair--cooledcooled 1010hphp OHVOHVIntekIntek ModelModel 205432205432305305cc,cc, 1919..6666Nm@[email protected] bore,bore, 6161..6767mmmm stroke,stroke,88::11 compressioncompression ratioratioAA governorgovernor restrictsrestricts thethemaximummaximum speedspeed toto 38003800 rpmrpm

POWERTRAIN EXHAUSTLombardini LGA 340 Briggs & Stratton

Standard Muffler of Sagar

Industries with integrated

Catalytic Converter

Integrated Exhaust

system

Engine Crankshaft

Key

Adapter

Spacer

Coupler

88

Fig. Modified coupler exploded view

Fig. F.E. Analysis of adapter Fig. Back pressure of Exhaust

PARAMETER VALUE

Max Equivalent

Stress176 MPa

Max Shear

Stress97.8 MPa

Max

Deformation0.06 mm

Factor of Safety 4.54

Roll CageRoll Cage

Roll cage must incorporate appropriate:Roll cage must incorporate appropriate:Rear roll hoop (RRH)Rear roll hoop (RRH)Lateral diagonal bracing (LDB)Lateral diagonal bracing (LDB)Roll hoop overhead members (RHO)Roll hoop overhead members (RHO)Lower frame side members (LFS)Lower frame side members (LFS)Side impact members (SIM)Side impact members (SIM)

Tubular frame to take the loading and protect the driver in a rollover.

Side impact members (SIM)Side impact members (SIM)Front bracing members (FBM)Front bracing members (FBM)Fore aft bracing members (FAB)Fore aft bracing members (FAB)Lateral cross member (LC)Lateral cross member (LC)

Helmet, Head Restraint, Helmet, Head Restraint, Firewall, FireFirewall, Fire--extinguisher, extinguisher, Safety Belt, Spares, Design Safety Belt, Spares, Design report, Cost report and report, Cost report and Insurance are mandatory. Insurance are mandatory.

The rear roll hoop functions The rear roll hoop functions to separate the driver from to separate the driver from the engine. the engine.

The fire wall is mounted on The fire wall is mounted on the RRH.the RRH.

Rear Roll Hoop (RRH)Rear Roll Hoop (RRH)

The driver seat may not The driver seat may not protrude the plane of RRH. protrude the plane of RRH.

The RRH should also be 29 The RRH should also be 29 inch or greater at a height of inch or greater at a height of 27 inch from the base of the 27 inch from the base of the drivers seat.drivers seat.

Rear Roll Hoop Lateral Diagonal Rear Roll Hoop Lateral Diagonal Bracing (LDB)Bracing (LDB)

Lateral bracing for the Rear Roll Hoop will begin at a Lateral bracing for the Rear Roll Hoop will begin at a point along the vertical portion of the RRH within 12.7 point along the vertical portion of the RRH within 12.7 cm (5 in) vertically of point BL or BR and extend cm (5 in) vertically of point BL or BR and extend diagonally to a point no farther than 12.7 cm (5 in) above diagonally to a point no farther than 12.7 cm (5 in) above point AR or AL. point AR or AL.

Roll Hoop Overhead Member (RHO)Roll Hoop Overhead Member (RHO)TheThe RHORHO shallshall bebelocatedlocated aboveabove thethedriversdrivers seatseat byby aaminimumminimum ofof 104104..11cmcm ((4141 inches)inches)..

PointsPoints CC shouldshould bebelocatedlocated forwardforward ofofthethe driversdrivers seatseat byby aaminimumminimum ofof 3030..55 cmcm((1212 inches)inches)..

Lower Frame Side Member (LFS)Lower Frame Side Member (LFS)

LowerLower frameframe sidesidemembersmembers shallshalljoinjoin thethe RRHRRH andandLCLC andand extendextend totoLCLC andand extendextend totopointspoints forwardforward ofofthethe driversdrivers heelheeltoto aa frontfront laterallateralcrosscross membermember..

Side Impact Member (SIM)Side Impact Member (SIM)Side impact members Side impact members shall join the RRH at shall join the RRH at points S and extend points S and extend horizontally to points horizontally to points SF forward of the SF forward of the drivers toes.drivers toes.The SIM should be The SIM should be The SIM should be The SIM should be between 8 to 12 inc as between 8 to 12 inc as measured from the measured from the base of the drivers base of the drivers seat.seat.The driver body The driver body should not be in should not be in contact with the SIM contact with the SIM members.members.

Front Bracing Member (FBM)Front Bracing Member (FBM)

FrontFront bracingbracingmembersmembers shallshall joinjointhethe RHO,RHO, thethe SIMSIMandand thethe LFSLFS..andand thethe LFSLFS..

TheThe angleangle betweenbetweenthethe FBMUPFBMUP andand thetheverticalvertical shouldshould bebelessless thanthan 4545degreesdegrees..

Rear Bracing Members.Rear Bracing Members.

The Rear bracing The Rear bracing acts as a cage acts as a cage carrying the engine carrying the engine and transmission and transmission and transmission and transmission box.box.

The bracing should The bracing should be fully triangulated.be fully triangulated.

FABRICATIONFABRICATIONFABRICATIONFABRICATION

USE OF DESIGN SOFTWARESUSE OF DESIGN SOFTWARES

PTC/ANSYS/ALTAIR SOFTWARES

Software design Software design

Vehicle Dynamics SimulationVehicle Dynamics SimulationAnimation

Math Model

Vehicle Data

Maneuver

Plots

Road and WindRoad course,skidpad, grades,cross-slopes,split-mu, crosswind

Hill Climb Test Hill Climb Test

At 20kmph

At 30kmph At 40 kmph

MATERIAL SELECTIONMATERIAL SELECTION

Steel members with at least Steel members with at least equal bending stiffness and equal bending stiffness and bending strength. The bending bending strength. The bending stiffness and bending strength stiffness and bending strength stiffness and bending strength stiffness and bending strength have to be calculated about an have to be calculated about an axis that gives the lowest value.axis that gives the lowest value.

Bending stiffness is proportional Bending stiffness is proportional by the EI product and bending by the EI product and bending strength is given by the value of strength is given by the value of SyI/c.SyI/c. M.S. 1.25 O.D. 16gauge

Material Material

Material for the frame and chassisMaterial for the frame and chassis1018 Circular steel tubing with OD 2.5 cm 1018 Circular steel tubing with OD 2.5 cm (1 inch) & wall thickness of 3.05 mm (1 inch) & wall thickness of 3.05 mm (0.120 inch).(0.120 inch).(0.120 inch).(0.120 inch).

Equivalent AIS 4130 or BIS 1875.Equivalent AIS 4130 or BIS 1875.

Dimensions Dimensions

Overall Length: 84 inchesOverall Length: 84 inchesWheel Base: 63.5 inchesWheel Base: 63.5 inchesTrack: Front 50 inches Track: Front 50 inches Track: Front 50 inches Track: Front 50 inches

Rear 52 inchesRear 52 inchesOverall Weight 300 kg (w/o Driver)Overall Weight 300 kg (w/o Driver)

Rods are cut and welded for Rods are cut and welded for chassis. Pipe bending can be chassis. Pipe bending can be used as an alternate measure.used as an alternate measure.

Aim should be to reduce excess weight Aim should be to reduce excess weight without compromising any structural without compromising any structural

rigidity or the safety of the driver.rigidity or the safety of the driver.

Centre of gravity should be maintained as Centre of gravity should be maintained as low as possible.low as possible.

The body panels protects the drivers body and provides a suitable enclosure.

Roll cage padding reduces the damage in case of impact.

Specifications Specifications

Frame was manufactured to fit a seat that Frame was manufactured to fit a seat that allowed for maximum driver comfort and safety, allowed for maximum driver comfort and safety, features consumers demand features consumers demand The swing arm requires the engine to be The swing arm requires the engine to be The swing arm requires the engine to be The swing arm requires the engine to be mounted rigidly to the frame, and out of the way mounted rigidly to the frame, and out of the way from the traveling suspension. This causes the from the traveling suspension. This causes the center of gravity to be moved higher, and center of gravity to be moved higher, and creates much more sprung mass.creates much more sprung mass.Roll cage padding protects drivers head from Roll cage padding protects drivers head from impact.impact.

Body Body

CAMBER ANGLE

a0

IMPORTANT SUSPENSION VARIABLES

TRACK WIDTH

DIRECTION OF SUSPENSION TRAVEL

ANGLE VARIATION

GROUND CLEARANCE

GENERAL OBJECTIVESGENERAL OBJECTIVESThe suspension system forms the link between the The suspension system forms the link between the frame and the wheels. The suspension of the car frame and the wheels. The suspension of the car prevents the shocks from the road to reach you. prevents the shocks from the road to reach you.

For All Terrain vehicles the suspension travel should For All Terrain vehicles the suspension travel should be as much as possible.be as much as possible.be as much as possible.be as much as possible.

The links and the shockers should be strong enough The links and the shockers should be strong enough to sustain various shocks and fatigue resistant.to sustain various shocks and fatigue resistant.

The geometry should aid maximum tyreThe geometry should aid maximum tyre--road road contact. contact.

There are many types systems available .There are many types systems available .

IMPORTANT DESIGN IMPORTANT DESIGN CONSIDERATIONSCONSIDERATIONS

The ground clearance should be optimum.The ground clearance should be optimum.The track width may be kept as much as The track width may be kept as much as possible but within the limits specified in the possible but within the limits specified in the rules.rules.rules.rules.Being the main features of all terrain vehicles, Being the main features of all terrain vehicles, the wheel travel should be as much as possible.the wheel travel should be as much as possible.The camber variation should be as less as The camber variation should be as less as possible to improve the possible to improve the tyretyre--ground contact ground contact which aids in traction..which aids in traction..

Safety FeaturesSafety FeaturesSafety is the primary consideration in the design of Baja Safety is the primary consideration in the design of Baja SAE vehicles and the conduct of the competitions. SAE vehicles and the conduct of the competitions. Teams need to include safety considerations in all parts Teams need to include safety considerations in all parts of their program.of their program.Roll cageRoll cageA head restraint must be provided on the car to limit A head restraint must be provided on the car to limit A head restraint must be provided on the car to limit A head restraint must be provided on the car to limit rearward motion of the head.rearward motion of the head.In all cases, a minimum of 15.2 cm (6 inches) vertical In all cases, a minimum of 15.2 cm (6 inches) vertical clearance must be provided from the helmet top of theclearance must be provided from the helmet top of theteams tallest driver to the bottom of the roll cage top teams tallest driver to the bottom of the roll cage top tubes or members.tubes or members.All drivers must be able to exit on either side of the All drivers must be able to exit on either side of the vehicle within five (5) seconds.vehicle within five (5) seconds.

AA firewallfirewall betweenbetween thethe cockpitcockpit andand thethe engineengineandand fuelfuel tanktank compartmentcompartment isis mandatorymandatory.. ItIt mustmustcovercover thethe areaarea betweenbetween thethe lowerlower andand upperupper LCLC..

All drivers must use a minimum of a 4 strap restraint All drivers must use a minimum of a 4 strap restraint harness.harness.

Harness Belt means a belt Harness Belt means a belt which is essentially a which is essentially a combination of lap strap and combination of lap strap and diagonal strap across the diagonal strap across the

What is 4 What is 4 -- Point Harness belt?Point Harness belt?

diagonal strap across the diagonal strap across the shoulder and chest.shoulder and chest.

It is called as SIt is called as S--type belt type belt in ECE Regulation. in ECE Regulation.

STANDARDADJUSTER

STANDARDADJUSTER

STANDARDFASTENER

STANDARDFASTENER

WEBBING LOOPS THROUGH THESE SLOTS FOR ADJUSTMENT

1500 MM (ADJUSTERFULLY EXTENDED)


Specification

STANDARDSTITCHING

STANDARDBUCKLE

STANDARDSTITCHING

STANDARDADJUSTER

STANDARDADJUSTER

STANDARDFASTENER

STANDARDFASTENER

170 MM700 MM (ADJUSTERFULLY EXTENDED)

WEBBING LOOPS THROUGH THESE SLOTS FOR ADJUSTMENT


HIGH G CRASH TEST

To Validate belt assembly or a restraint system affecting the restraint of the occupant shall break and no buckles or locking system or displacement system shall release or unlock

Engineering DesignEngineering DesignEngineering design assessment consists Engineering design assessment consists of two events of two events

1) Design Report 1) Design Report 1) Design Report 1) Design Report

2) Design Evaluation 2) Design Evaluation

The design report should clearly explain the engineering and design The design report should clearly explain the engineering and design process that was used in developing each system of the teams Mini process that was used in developing each system of the teams Mini Baja vehicle. Baja vehicle.

The process for each system could include:The process for each system could include:

1> Objectives1> Objectives

Design ReportDesign Report

1> Objectives1> Objectives2> Customer requirements2> Customer requirements3> Alternatives considered3> Alternatives considered4>The result(s) of design calculations4>The result(s) of design calculations5>Stress Analysis 5>Stress Analysis 6>Testing 6>Testing

Design reports must follow the format for SAE Technical Papers Design reports must follow the format for SAE Technical Papers

Design Report Design Report -- FormatFormatThe design report file must be named as follows:

Car #_college name

EXAMPLE: Car # 14 VIT

Design Report Design Report Page LimitPage LimitThe technical paper segment of design report is limited to ten (10) pages, excluding the cover page. Additionally the report may, at the teams option, include up to four (4) non-text, pages of plans, graphics, photographs or other data for a maximum of fourteen (14) pages of information. The only a maximum of fourteen (14) pages of information. The only text permitted on the four (4) optional pages are captions. All pages must be either 8 x 11 or A4.

NOTE: If your paper exceeds 10 pages of technical report or 4 pages of graphics, then only the first 10 technical and 4 graphic pages will be evaluated.

Design Report Design Report Deadline and Deadline and SubmissionSubmission

Design reports must be received not later than the due date of Design reports must be received not later than the due date of 1515thth Dec 2014Dec 2014. Any Design Report not received by the due . Any Design Report not received by the due date will be subject to a penalty of ten (10) points for each day date will be subject to a penalty of ten (10) points for each day after the deadline. Both soft & hard copies are required.after the deadline. Both soft & hard copies are required.after the deadline. Both soft & hard copies are required.after the deadline. Both soft & hard copies are required.

Teams that do not submit a Design Report will not be judged Teams that do not submit a Design Report will not be judged in either part of the Design Event and will receive zero (0) in either part of the Design Event and will receive zero (0) points.points.

Design EvaluationDesign EvaluationDesign Evaluation will be conducted at the event site on the Design Evaluation will be conducted at the event site on the first full day of the competition. Cars are expected to be first full day of the competition. Cars are expected to be presented for Design Evaluation in essentially finished presented for Design Evaluation in essentially finished condition, i.e. fully assembled, complete and readycondition, i.e. fully assembled, complete and ready--toto--run. run.

Vehicles presented in an unfinished condition may receive Vehicles presented in an unfinished condition may receive lower, or zero points for any incomplete areas that can not lower, or zero points for any incomplete areas that can not be fully assessed by the design judges. Additionally, the be fully assessed by the design judges. Additionally, the judges have the right to refuse to evaluate incomplete judges have the right to refuse to evaluate incomplete vehicles. Teams that are refused judging because of vehicles. Teams that are refused judging because of incompleteness will receive zero points for Design incompleteness will receive zero points for Design Evaluation. Evaluation.

Design EvaluationDesign EvaluationDuring design evaluation team members During design evaluation team members are expected to be able to fully explain are expected to be able to fully explain and discuss all aspects of their vehicles and discuss all aspects of their vehicles design and the rationale behind their design and the rationale behind their design decisions. Teams that are unable design decisions. Teams that are unable design decisions. Teams that are unable design decisions. Teams that are unable to adequately explain the various aspects to adequately explain the various aspects of their design to the judges satisfaction of their design to the judges satisfaction will receive lower scores down to, and will receive lower scores down to, and including, zero (0) points.including, zero (0) points.

DFMEADFMEADesign Failure Mode Design Failure Mode Design Failure Mode Design Failure Mode

& Effect Analysis& Effect Analysis

PotentialFailure Mode and Effects Analysis

(Design FMEA)__ System__ Subsystem__ Component

Model Year/Vehicle(s):Core Team:

Design ResponsibilityKey Date:

FMEA Number:Page 1 or 1Prepared by:FMEA Date (Orig.):

Item

Function

PotentialFailureMode

PotentialEffect(s) of

Failure

Potential Cause(s)/

Mechanism(s)Of Failure

CurrentDesign

ControlsPrevention

CurrentDesign

ControlsDetection

RecommendedAction(s)

Responsibility& Target

CompletionDate

ActionsTaken

Action ResultsSEV

CLASS

OCCUR

DETEC

R.P.N.

SEV

OCC

DET

R.P.N.

48

Recommend Consider effects, if abovefailure mode happens

List all conceivablefailure modes

Re- evaluate (New RPN )

Define Responsibility & Time- frame

FMEA ProcedureList all Function &

requirements

Recommend improvements

Look possible causes & mechanism for failures mode

failure mode happens

Assess the frequency ofoccurrence of

failure modes (O)

Assess the possibility of Failure being detected ( D )

Assess the Severity of effect (s)

Calculate the Risk Priority Number (RPN)

Subsystem

Function Requires

Potential failure mode

Potential Effect(s) of

Failure

SEV

CLASS

Potential Cause(s)

Mechanism(s) of Failure

OCCUR

Current Controls DETECTION

RPN

Recommended

Action(s)

Responsibility & Target

completion date

Action results

Act-ions take

SEV

OCC

DET

R.P.N.

FMEA Sequence

taken

V C T N.

What are the Functions, Features or

Require-ments?

What can go wrong?- No function- Partial/ over/

degraded function

- Intermittent function

- Unintended function

What are the effect(s)?

How badis it?

What are the

cause(s)?

How often does it

happen?

How can this be prevented and detected?

How good is this method at

detecting it?

What can be done?- Design changes- Process

changes- Special controls- Changes to

standards, procedures, or guides

S.O.D. Tables & its usageS.O.D. Tables & its usage

Probability of Failure Possible Failure Rates Ranking

Very High : Persistent failures

> 100 per thousand vehicles/ items 10

50per thousand vehicles/ items 9

Occurrence (o)Suggested Evaluation Criteria:

Occurrence table

failures 50per thousand vehicles/ items 9

High : Frequent failures 20 per thousand vehicles/ items 8

10 per thousand vehicles/ items 7

Moderate : Occasional failures




Low : Relatively few failures

0.5 per thousand vehicles/ items 3

0.1 per thousand vehicles/ items 2

Remote : Failure is unlikely

< 0.010 per thousand vehicles/ items 1

Effect Criteria : severity of Effect Ranking

Hazardous without warning

Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation without warning.

10

Hazardous with warning

Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation with warning.

9

Very High Vehicle/ item inoperable (loss of primary function). 8

Severity table

Very High Vehicle/ item inoperable (loss of primary function). 8

High Vehicle/ item operable but at reduced level of performance. Customer very dissatisfied.

7

Moderate Vehicle/ item operable, but Comfort/ Convenience item(s) inoperable. Customer dissatisfied.

6

Low Vehicle/ item operable, but Comfort/ convenience item(s) operable at a reduced level of performance. Customer somewhat dissatisfied.

5

Very Low Fit & Finish/ Squeak & Rattle item does not conform. Defect noticed by most customers (greater than 75%).

4

Minor Fit & Finish/ Squeak & Rattle item does not conform. Defect noticed by 50% of customers.

3

Very Minor Fit & Finish/ Squeak & rattle item does not conform. Defect noticed by discriminating customer (less than 25%).

2

None No discernible effect. 1

Detection Criteria : Likelihood of Detection by Design Control Ranking

Absolute Uncertainty

Design control will not and/or can not detect a potential cause/mechanism an subsequent failure mode; or there is no Designcontrol

10

Very Remote Very remote chance the Design control will detect a potentialcause/ mechanism and subsequent failure mode.

9

Remote Remote chance the Design control will detect a potential cause/mechanism and subsequent failure mode.

8

Very Low Very low chance the Design control will detect a potential cause/ 7

Detection tableSuggested Evaluation Criteria: For

detection

Very Low Very low chance the Design control will detect a potential cause/mechanism and subsequent failure mode.

7

Low Low chance the Design control will detect a potential cause/mechanism and subsequent failure mode.

6

Moderate Moderate chance the Design control will detect a potential cause/mechanism and subsequent failure mode.

5

Moderate High Moderate high chance the Design control will detect a potentialcause/ mechanism and subsequent failure mode.

4

High High chance the Design control will detect a potential cause/mechanism and subsequent failure mode.

3

Very High Very high chance the Design control will detect a potential cause/mechanism and subsequent failure mode.

2

Almost Certain Design control will almost certainly detect a potential cause/mechanism an subsequent failure mode.

1

RPN / Risk Priority NumberRPN / Risk Priority Number

Top 20% of FailureModes by RPN

RPN

Failure Modes

DVP&RDVP&RDesign Validation Design Validation Design Validation Design Validation

Plan & ReportPlan & Report

WhyWhy DesignDesign ValidationValidation????Are we building it right?Are we building it right?

Major costs of projects are incurred in early design stages.Major costs of projects are incurred in early design stages.

The cost of fixing a design and faulty decisions at later The cost of fixing a design and faulty decisions at later stages is exponentially greater than at an earlier stage.stages is exponentially greater than at an earlier stage.

Early involvement of CFT in product development saves Early involvement of CFT in product development saves time and money over product life.time and money over product life.

Validation DefinitionValidation DefinitionThe documented act of proving that any The documented act of proving that any procedure, process, equipment, material, procedure, process, equipment, material, activity or system, actually leads to the activity or system, actually leads to the expected results.expected results.expected results.expected results.

Design ValidationDesign Validation means establishing by means establishing by objective evidence that device specifications objective evidence that device specifications conform to user needs and intended uses.conform to user needs and intended uses.

RequirementsRequirements of of DesignDesign ValidationValidation

Design validation shall be performed under defined Design validation shall be performed under defined operating conditions on initial production units, lots or operating conditions on initial production units, lots or batches, or their equivalents.batches, or their equivalents.batches, or their equivalents.batches, or their equivalents.It includes testing of production units under actual or It includes testing of production units under actual or simulated use conditions.simulated use conditions.It includes software validation and risk analysis.It includes software validation and risk analysis.The Validation must be documented in Design The Validation must be documented in Design Validation Plan.Validation Plan.

Design Validation ProcessDesign Validation ProcessValidation PlanValidation Plan

Validation ReviewValidation ReviewValidation ReviewValidation Review

Validation MethodsValidation Methods

Validation ReportValidation Report

Comparison Between Validation, Comparison Between Validation, Verification & ReviewVerification & Review

DesignDesign ValidationValidation PlanPlan (DVP)(DVP)Design Validation is next step to DFMEA.Design Validation is next step to DFMEA.

Depending upon RPN in DFMEA the Depending upon RPN in DFMEA the components are arranged in DVP.components are arranged in DVP.components are arranged in DVP.components are arranged in DVP.

It contains all the information regarding the It contains all the information regarding the acceptance criteria, responsible person or acceptance criteria, responsible person or team, type of test and start team, type of test and start && finish dates.finish dates.

Validation MethodsValidation Methods

Testing ( Static as well as Dynamic)Testing ( Static as well as Dynamic)Analysis ( Using software's and simulations)Analysis ( Using software's and simulations)Inspection Methods(Visual or with Test Rigs)Inspection Methods(Visual or with Test Rigs)Compilation of relevant scientific literatureCompilation of relevant scientific literature

Study of historical evidences of similar designStudy of historical evidences of similar design

Examples of validation methods & activitiesExamples of validation methods & activities

Worst case analysis of an assembly.Worst case analysis of an assembly.Fault tree analysis of a process or design.Fault tree analysis of a process or design.Failure modes and effects analysis (FMEA).Failure modes and effects analysis (FMEA).Package integrity tests.Package integrity tests.Testing of materials.Testing of materials.Comparison of a design to previous vehicles Comparison of a design to previous vehicles having an established history of successful use.having an established history of successful use.

All the best for BAJA SAEINDIA 2014All the best for BAJA SAEINDIA 2014

Documents

Design Report DFMEA & Validation Presentation