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Industrialization roadmap · Milestone 3 of 8

Process validation

Process validation demonstrates that parts can be assembled and the intended manufacturing process can produce a conforming product. The focus is on repeatability, process controls and evidence from representative builds.

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Automotive industrialization: Process validation
Purpose and expected outputs

What this milestone should achieve

Objectives

Process validation demonstrates that parts can be assembled and the intended manufacturing process can produce a conforming product. The focus is on repeatability, process controls and evidence from representative builds.

  • Validate assembly feasibility
  • Confirm process capability
  • Verify quality controls and work instructions

Key deliverables to organize

  • Assembly feasibility and interfaces are confirmed
  • Workstations, tooling and process parameters are assessed
  • Quality checks and reaction plans are defined
  • Build findings are addressed and validation evidence is recorded

Questions for the project team

  • What evidence demonstrates that the milestone objective has been achieved?
  • Which risks could affect product quality, timing, cost or manufacturing feasibility?
  • Who owns each open action, and by when must it be closed?
  • Which decision or approval is required before moving forward?

Working principle

Use the applicable project plan, approved engineering requirements and quality procedures as the authority for exact criteria. This guide provides a transferable structure; it does not replace customer-specific or company-approved requirements.

APQP gate connection

Gate G4 — Production Part Approval Process (PPAP) acceptance

The APQP framework links product-process verification to the PPAP approval decision. Design Validation checks that the component meets product requirements; Process Validation demonstrates that the intended manufacturing process can repeatedly produce conforming parts. The evidence must be consistent with the final product definition and the process intended for series production.

Design Validation vs Process Validation

Design Validation: checks component conformity to design requirements using parts produced from the tool before the manufacturing process is fully validated.

Process Validation: checks whether the intended manufacturing process, controls and operating conditions consistently produce conforming parts; it is not a repeat of Design Validation.

  • Design Validation results and product requirements closed or formally controlled
  • Process Validation evidence gathered using the representative manufacturing process
  • Dimensional reports, measurement-system evidence and process capability reviewed
  • Control plan, process risk actions, supplier evidence and plant validation aligned

Use the approved APQP grid and applicable customer procedure for exact acceptance criteria; this public guide is a practical summary, not a substitute for controlled requirements.

See the APQP phase-to-gate map →

PRATIXUS guidance: adapt this checklist to the product, manufacturing process, supplier setup and applicable customer requirements. Avoid sharing confidential project records in public resources.