The changing role of physical testing in vehicle development programmes

The role of physical testing in product development is changing due to the requirements for faster new product development, reduced tolerance of failures in the field and the emergence of computer aided engineering (CAE) technologies. To be used most effectively, testing must be seen as an integral part of the process for reducing risks associated with new product introductions. Quality function deployment (QFD) and failure modes and effects analysis (FMEA) can be used to establish effective test and development plans that integrate the use of virtual and physical testing. By effectively integrating virtual and physical test technologies significant improvements in product performance can be achieved within shorter times and with reduced development and manufacturing costs. The approach was illustrated by a process of reducing in-cab noise during the design of a new truck.