DESIGN VALIDATION PLAN
S.NO
DESCRIPTION
ACCEPTENCE CRITERIA
ASSIGENED TO
TEST
RESOURCES
DIMENSIONAL STABILITY
SHOULD BE MATCHING WITH
TECHNICAL SPECIFICATION SHEET
PREPARED,CHECK FOR OVERALL
WIDTH(CRITICAL)
MANUFACTURING HEAD
TEMPLATES
CLEARENCE OVER
TRANSMISSION
ASSEMBLY
SHOULD BE MATCHING WITH
TECHNICAL SPECIFICATION SHEET
PREPARED
VALIDATION HEAD
MEASURING TAPE AND
TEMPLATE PREPARED
RULEBOOK CLAUSE
ADHERENCE
SHOULD NOT EXCEED THE PRESCRIBED
LIMIT
VALIDATION HEAD
RULEBOOK
TRANSMISSION SYSTEM
TRANSMISSION HEAD
FILTER PAPER
SUSPENSION SYSTEM
NO LEAKAGES, TRANSMISSION OIL
CONDITION
SPRING RATE SHOULD BE ACCORDING
TO THE DESIGN PARAMETERS
SUSPENSION HEAD
UTM
ENGINE SYSTEM
PROPER MOUNTING OF ENGINETRANSMISSION ASSEMBLY.ALL MOVING
PARTS TO BE COVERED
MANUFACTURING
HEAD, VALIDATION
TEAM
VISUAL INSPECTION
KNUCKLE
SHOULD NOT FAIL/DEFORM UNDER
STRESS DURING CORNERING
STEERING AND
SUSPENSION HEAD
UTM
ELECTRICALS
NO LOOSE CONNECTIONS
ELECTRICAL TEAM
TEST CIRCUITS
ELECTRICALS
PROPER WORKING OF KILL SWITCHES
ELECTRICAL TEAM
MULTIMETERS AND TEST
CIRCUITS
10
BRAKES
NO LEAKAGES
VALIDATION TEAM
VISUAL INSPECTION
11
FASTENERS
ALL FASTENERS CORRECTLY TIGHTENED
MANUFACTURING HEAD
TORQUE WRENCH
DESIGN FAILURE MODE AND EFFECT ANALYSIS
SUB
SYSTEM
ITEM NAME
FAILURE
CAUSES
OPERATIONS
EFFECT
SAFETY
EFFECTS
S
R
D
R
O
R
RP
N
SAFEGUARDS
ACTIONS
CHASSIS
FRAME
TO MUCH LOAD
OR SHOCK
THE FRAME
BENDS OR
BREAKS
INJURY TO THE
DRIVER
10
150
BRACKETS
EXCESS LOAD
OR VIBRATION
INJURY TO THE
DRIVER
72
SUPPORTS
TO MUCH LOAD
OR SHOCK
SERIOUS DAMAGE
TO THE DRIVER
72
DRIVE SEAT
BEARING YIELD
DUE TO EXCESS
LOAD
MECHANICAL AND
STRUCTURAL
COMPONENTS ARE
NOT USABLE
STRUCTURAL
DAMAGE LEADING
TO INABILITY OF
USE
DRIVERS SAFETY
COMPROMISED
DISCOMFORT TO
THE DRIVER
10
HIGH FOS TO
ENSURE
STRUCTURAL
INTEGRITY
HIGH FOS TO
ENSURE
STRUCTURAL
INTEGRITY
HIGH FOS TO
ENSURE
STRUCTURAL
INTEGRITY
DILIGENT TESTING
TO ENSURE
FUNCTIONALITY
ENGINE
LACK OF AIR
AND FUEL TO
MAINTAIN
OPERATION
LACK OF
STRUCTURAL
INTEGRITY
UNDER CYCLIC
LOADING
LACK IN MOTION
DUE TO LINK
FAILURE AND
WEAK
LUBRICATION
LACK OF
STRUCTURAL
INTEGRITY
POSSIBILITY OF
EXPLOSION,
INABILITY TO
OPERATE
INABILITY TO
OPERATE
WORST CASE
SCENARIO,
SERIOUS INJURY
10
140
SUDDEN FAILURE
LEADING TO
ACCIDENT
10
80
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
STRICT
ADHERENCE
TO SPECIFIED
WEIGHT
RANGE
USE OF GOOD
QUALITY AIR
AND FUEL
FILTERS
EXTENSIVE
TESTING
INABILITY TO
OPERATE
N/A
60
HIGH FOS
ENSURING
MECHANICAL
INTEGRITY
DILIGENT
TESTING
INABILITY TO
OPERATE
N/A
135
EXTENSIVE
TESTING
MOTOR
BACK EMF
DURING
BRAKING
POSSIBILITY OF
BURNING,
INABILITY TO
OPERATE
CAR WILL STOP,
WORST CASE
SCENARIO-FIRE
40
VERIFICATION OF
DESIGNED
SPECIFICATION OF
THE COMPONENT
KILL SWITCH &
REGENERATIVE
BRAKING
BATTERY
SHORT CIRCUIT,
IMPROPER
WIRING,
CRACKING
TO MUCH LOAD
OR SHOCK
POWER WASTAGE
VEHICLE STOPS
DUE TO
UNAVAILABILITY
OF POWER
SERIOUS
DISCOMFORT TO
THE DRIVER
30
PROPER AND
EFFICIENT
ELECTRIC SYSTEM
54
WRONG SPRING
CHOSEN FOR
APPLICATION
DEBRIS
DAMAGING
COMPONENTS
COMPROMISED
SUSPENSION
SERIOUS
DISCOMFORT TO
THE DRIVER
SERIOUS
DISCOMFORT TO
THE DRIVER
72
96
BELLCRANK
ROCKERS
JAMMING OF
BEARINGS
COMPROMISED
SUSPENSION
DISCOMFORT AND
ASSEMBLY
RUPTURE
120
KNUCKLE
ASSEMBLY
RUPTURE DUE
TO REPEATED
LOADING
VEHICLE
FUNCTIONING
STOPS
10
30
RACK AND PINION
OBSTRUCTION
IN TRAVEL OF
SYSTEM
INABILITY TO
STEER
12
VERIFICATION OF
DESIRED
SPECIFICATION OF
THE COMPONENT
STEERING
COLUMN
DEBRIS
DAMAGING
COMPONENTS
INABILITY TO
STEER
INJURY TO THE
DRIVER AND
SERIOUS
ACCIDENT
THE VEHICLE
CANNOT FOLLOW
THE COURSE AND
MAY HAVE AN
ACCIDENT
CAN CAUSE
SERIOUS INJURY
HIGH FOS
ENSURING
MECHANICAL
INTEGRITY
DILIGENT TESTING
TO ENSURE
FUNCTIONALITY
VERIFICATION OF
DESIRED
SPECIFICATION OF
THE COMPONENT
BEARING
MAINTAINENCE
AND PROPER
MOUNTING
MATERIAL
SELECTION AND
STRESS ANALYSIS
DILIGENT
TESTING
STEERING
WHEELS
EXCESS LOAD
APPLIED BY
DRIVER TO
COMPONENT
RUPTURE DUE
TO EXCESS
LOADING OR
IMPACT
INABILITY TO
PROVIDE
SUFFICIENT
BRAKING FORCE
INABILITY TO
STEER
FAILURE CAN
CAUSE SERIOUS
ACCIDENTS
18
INABILITY TO
OPERATE
FAILURE CAN
CAUSE SERIOUS
ACCIDENTS
10
30
EXTENSIVE
DAMAGE TO THE
VEHICLE IN
UNDESIRED
SCENARIO
INABILITY TO
OPERATE
CAN LEAD TO
SERIOUS INJURY
24
RELATIVELY HIGH
FOS ENSURING
MECHANICAL
INTEGRITY
VERIFICATION OF
DESIRED
SPECIFICATION OF
THE COMPONENT
VERIFICATION OF
DESIRED
SPECIFICATION OF
THE COMPONENT
DILIGENT TESTING
TO ENSURE
FUNCTIONALITY
CAN LEAD TO
SERIOUS INJURY
16
HIGH FOS
ENSURING
MECHANICAL
INTEGRITY
HIGH FOS AND
DILIGENT
TESTING
DRIVETRAIN
GEARBOX
GEAR SHIFTER
TRANSMISSION
SUSPENSION
A-ARMS
SPRINGS
SHOCK
ABSORBERS
STEERING
TIE RODS
BRAKING
BRAKE SYSTEMS
PEDALS
EXCESS LOAD
APPLIED BY
DRIVER TO
COMPONENT
COMPROMISED
SUSPENSION
COMPROMISED
SUSPENSION
ENGINE AND
DRIVER
SEPERATED BY
FIREWALL
HIGH FOS
ENSURING
MECHANICAL
INTEGRITY
USE OF GOOD
QUALITY
MOTOR WITH
PROPER
WINDING
EXTENSIVE
TESTING
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
EXTENSIVE
TESTING
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
DILIGENT
TESTING
DILIGENT
TESTING
REPEATED
TESTING FOR
WORST CASE
SCENARIOS
