A formal product validation process helps ensure that steps are understood, well-defined, documented and rooted in proven fundamentals. Some may strive to validate via testing or simulation alone. Six D recommends a testing and simulation approach where real-world operating data (encompassing expected and unanticipated usage scenarios and conditions) feeds and verifies engineering analysis/simulation. In this way models are correlated by matching FEA predictions and test results (stresses, deflections, resonance frequencies, and mode shapes) ensuring that the model represents the actual behavior of the system. In addition, the FEA results are often used to guide the validation testing, for example identifying “hot spots” where strain gage measurements should be obtained.
Data collection techniques such as Unattended Testing allow product performance to be to be observed over extended time periods in the system’s natural operating condition – rather than in a laboratory or otherwise controlled environment. This helps ensure the likelihood of capturing the full range of conditions to which equipment is subjected – including anomalies and other rare but significant events. Armed with this information manufacturers can better quantify and predict future performance and develop products that satisfy the complete range of actual customer usage.