Design Review
Evaluates suitability, maturity, risks and problems at planned stages. It should include manufacturing, quality, materials, special-process, safety, supply-chain and support competence.
SPI
Special Processes Institute
sp-i.org
Engineering Design Process Control
Engineering Design Process Control
Plan, review and control engineering design through the complete product lifecycle. The app aligns design activities with ISO 9001 Clause 8.3 and the additional aviation, space and defence controls of AS9100, while bringing materials, special processes, product safety, configuration, verification, validation, production readiness and change control into one practical project.
ISO 9001 · 8.3 AS9100 SPECIAL PROCESSES DESIGN ASSURANCE
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Knowledge and project sections
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Technical knowledge items
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Selected review items
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Design risks
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Open actions
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Lifecycle project complete
Controlled Design Lifecycle
The design output is more than a drawing: it is the complete controlled definition needed to realise and support the product.
1. ApplicabilityDesign authority, scope and interfaces
2. PlanningStages, people, resources and gates
3. InputsCustomer, function, safety and regulation
4. ConceptTrade studies, architecture and DFMEA
5. Detailed DesignModels, drawings, BOM and specifications
6. ReviewMultidisciplinary suitability and action closure
7. VerificationOutputs satisfy inputs
8. ValidationProduct satisfies intended use
9. ReleaseApproved configuration baseline
10. Production / FAIProcess readiness and product verification
11. ChangeImpact, effectivity and re-assurance
Verification
Confirms the design outputs correctly satisfy the design inputs using checking, analysis, inspection, simulation or test.
Validation
Confirms the resulting product satisfies its intended use under actual or representative operating conditions.
Important: FAI verifies the planned production process can produce conforming product. It does not replace design verification or validation. Likewise, PFMEA controls manufacturing-process risk and does not replace DFMEA.
ISO 9001 and AS9100 Alignment
| Control | ISO 9001 alignment | AS9100 emphasis | Application in this app |
|---|---|---|---|
| General | 8.3.1: establish, implement and maintain an appropriate design process. | Product/service design; controlled interaction with aerospace product lifecycle. | Applicability and design-authority assessment. |
| Planning | 8.3.2: stages, reviews, V&V, responsibilities, interfaces, resources and records. | Operational risk, configuration, safety, obsolescence and production transition. | Design plan, gates, roles and assurance plan. |
| Inputs | 8.3.3: functional, performance, statutory, regulatory, prior knowledge and failure consequences. | Special requirements, critical items, key characteristics, product safety and obsolescence. | Requirement register, classifications and traceability. |
| Controls | 8.3.4: review, verification, validation and action control. | Additional planning and control of verification and validation testing. | Review checklist, evidence register and approval gates. |
| Outputs | 8.3.5: meet inputs and support purchasing, production, inspection and acceptance. | Complete product definition, configuration and critical controls. | Output checklist and release baseline. |
| Changes | 8.3.6: identify, review and control changes and adverse impacts. | Configuration effectivity, safety, qualification, FAI and delivered-product impact. | Change assessment and re-assurance prompts. |
| Special processes | 8.5.1: controlled production; validate processes where results cannot be fully verified later. | 8.5.1.2 special process validation/control and 8.5.1.3 production process verification. | Design-for-process review and external SPI process-control app callouts. |
This app is an educational and project-control aid. It does not reproduce standards or replace authorised copies, contractual requirements, regulatory obligations, customer design rules, competent engineering judgement or independent approval.
Material Selection
- Loads, life and environment
- Temperature and property allowables
- Corrosion and galvanic couples
- Availability, form and obsolescence
- Manufacturing and repair route
Special-Process Design
- Geometry and access
- Drainage, venting and masking
- Dimensional growth or distortion
- Inspection and testability
- Qualified supplier capability
Design Output
- Material grade and condition
- Process type/class and selective areas
- Acceptance criteria
- Sequence where technically essential
- Traceability and records
Special-Process Principle
Define the required product result. The drawing or product definition should identify the process, applicable specification, classification, selective areas and acceptance requirements. The approved process specification and manufacturing plan normally control bath chemistry, furnace settings, current density, spray parameters or other process variables unless a parameter is genuinely design-mandated.
Design responsibility: ensure the product geometry, material, tolerances, sequence and inspection requirements are compatible with a validated and capable special process. Do not discover plating, heat-treatment, welding, brazing, bonding, NDT or coating limitations during FAI.
Design Technical Considerations Database
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Related SPI Applications
Open specialist tools when the design project determines that activity is required.
Design and Development Plan
ISO 9001 / AS9100 Clause 8.3.2 project record
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Design Inputs and Traceability
| ID | Type | Requirement / input | Source | Classification | Verification / validation method | Status | Action |
|---|
Dynamic Design Review
Select considerations from the technical database, then record applicability and evidence.
Selected Review Record
Design Risks
Actions
Verification, Validation, Release and Production Readiness
Engineering Design Process Control Report
Complete the project and generate the report.