How can you design and validate test methods for your products?

1 Identify the test objectives

The first step is to identify the test objectives, which are the outcomes that you want to achieve with your test methods. The test objectives should be aligned with the product specifications and requirements, as well as the customer needs and expectations. The test objectives should also be SMART: specific, measurable, achievable, relevant, and time-bound. For example, a test objective could be to verify that the product meets the dimensional tolerance of +/- 0.1 mm within 10 minutes.

2 Select the test parameters

The next step is to select the test parameters, which are the variables that you want to measure with your test methods. The test parameters should be relevant to the test objectives, the product characteristics, and the quality criteria. The test parameters should also be quantifiable, meaning that they can be expressed in numbers or units. For example, a test parameter could be the length, width, or height of the product.

3 Choose the test methods

The third step is to choose the test methods, which are the procedures and tools that you use to perform the test parameters. The test methods should be appropriate for the test objectives, the test parameters, and the product type. The test methods should also be feasible, meaning that they can be executed with the available resources, time, and budget. For example, a test method could be a caliper, a micrometer, or a coordinate measuring machine.

4 Validate the test methods

The fourth step is to validate the test methods, which is the process of verifying that the test methods are reliable, accurate, and efficient. Validation involves testing the test methods on samples of the product or similar materials, and comparing the results with the expected values or reference standards. Validation also involves evaluating the test methods for repeatability, reproducibility, sensitivity, specificity, linearity, range, and uncertainty. For example, a validation could be a gauge R&R study, a calibration certificate, or a statistical analysis.

5 Document the test methods

The fifth step is to document the test methods, which is the process of recording the details and results of the test methods in a clear and consistent format. Documentation helps you communicate the test methods to others, ensure compliance with regulations and standards, and facilitate traceability and improvement. Documentation also helps you integrate the test methods with other quality management systems, such as APQP, ISO 9001, or IATF 16949. For example, a documentation could be a test plan, a test report, or a standard operating procedure.

6 Review and improve the test methods

The sixth step is to review and improve the test methods, which is the process of monitoring and evaluating the performance and effectiveness of the test methods over time. Review and improvement help you identify and correct any problems, errors, or deviations that may occur with the test methods, and implement any changes or updates that may be needed. Review and improvement also help you optimize the test methods for efficiency, accuracy, and reliability. For example, a review and improvement could be a periodic audit, a feedback survey, or a continuous improvement cycle.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?