Automated Verification and Validation

Automated Verification and Validation with TofuPilot

Verification and validation (V&V) in hardware is still largely manual: engineers run tests, record results in documents, and someone reviews the evidence. TofuPilot automates the data capture side so engineers can focus on the analysis instead of the paperwork.

V&V in Hardware Development

Verification answers: "Did we build the product right?" (Does it meet its specifications?) Validation answers: "Did we build the right product?" (Does it meet user needs?)

Both require structured test evidence. In regulated industries (medical devices, aerospace, automotive), this evidence must be traceable, timestamped, and immutable.

Phase	Purpose	Typical tests	Evidence needed
EVT	Engineering validation	Functional, environmental, reliability	Test reports, measurement data
DVT	Design verification	Full spec compliance, regulatory	Formal test records, traceability
PVT	Production validation	Manufacturing process qualification	Statistical data, Cpk analysis
Production	Ongoing verification	In-line test, final test	Per-unit records, yield data

The Manual V&V Problem

Traditional V&V workflows look like this:

Engineer writes a test protocol (Word document)
Technician runs the tests manually or semi-automatically
Results are recorded in a spreadsheet or paper form
Engineer reviews results and writes a test report
Quality reviews and approves the report
Documents are filed in a QMS

This process is slow, error-prone, and disconnected from the actual test data. The spreadsheet is a copy of the data, not the data itself. If someone transcribes a number wrong, the V&V record is wrong.

Automating V&V with TofuPilot

Step 1: Define Your Verification Test Procedures

Create a procedure in TofuPilot for each verification test in your protocol.

evt_thermal.py

from tofupilot import TofuPilotClient

client = TofuPilotClient()

# EVT thermal cycling test
client.create_run(
    procedure_id="EVT-THERMAL-CYCLE",
    unit_under_test={
        "serial_number": "EVT-PROTO-003",
        "part_number": "PRODUCT-V2.1",
    },
    run_passed=True,
    steps=[{
        "name": "Post-Cycle Functional Check",
        "step_type": "measurement",
        "status": True,
        "measurements": [
            {
                "name": "output_voltage",
                "value": 5.02,
                "unit": "V",
                "limit_low": 4.90,
                "limit_high": 5.10,
            },
            {
                "name": "output_ripple_mv",
                "value": 12.3,
                "unit": "mV",
                "limit_high": 50.0,
            },
            {
                "name": "efficiency_pct",
                "value": 91.2,
                "unit": "%",
                "limit_low": 88.0,
            },
        ],
    }, {
        "name": "Thermal Performance",
        "step_type": "measurement",
        "status": True,
        "measurements": [
            {
                "name": "junction_temp_max",
                "value": 82.4,
                "unit": "°C",
                "limit_high": 105.0,
            },
            {
                "name": "thermal_resistance",
                "value": 3.8,
                "unit": "°C/W",
                "limit_high": 5.0,
            },
        ],
    }],
)

Step 2: Map Requirements to Measurements

Each measurement in TofuPilot corresponds to a requirement in your spec. Use consistent naming to create a clear mapping.

Requirement ID	Requirement	TofuPilot Measurement	Limit
REQ-ELEC-001	Output voltage: 5V +/- 2%	`output_voltage`	4.90-5.10 V
REQ-ELEC-002	Ripple: < 50mV	`output_ripple_mv`	< 50 mV
REQ-ELEC-003	Efficiency: > 88%	`efficiency_pct`	> 88%
REQ-THERM-001	Junction temp: < 105C	`junction_temp_max`	< 105 C

This mapping turns your test data into verification evidence. Every measurement in TofuPilot is a timestamped, immutable record that a requirement was tested.

Step 3: Run Tests Across V&V Phases

Use the same procedures across EVT, DVT, and PVT. TofuPilot stores all results, so you can compare performance across phases.

EVT (3 prototypes):     DVT (30 units):         PVT (300 units):
├── EVT-THERMAL         ├── DVT-THERMAL          ├── PVT-THERMAL
├── EVT-VIBRATION       ├── DVT-VIBRATION        ├── PVT-PROCESS-QUAL
├── EVT-FUNCTIONAL      ├── DVT-EMC              └── PVT-YIELD-ANALYSIS
└── EVT-RELIABILITY     ├── DVT-SAFETY
                        └── DVT-FUNCTIONAL

Step 4: Generate V&V Evidence

TofuPilot's stored test data serves as your verification evidence:

Per-unit test records: Every measurement for every unit, with timestamps and pass/fail status
Statistical summaries: Cpk, mean, standard deviation, distribution across the test population
Traceability: Link from requirement to test procedure to test result to specific unit
Trend data: How measurements changed across EVT, DVT, and PVT phases

Traceability for Audits

When an auditor asks "Show me the evidence that REQ-ELEC-001 was verified," you can:

Open TofuPilot
Filter by procedure (e.g., DVT-FUNCTIONAL)
Show all output_voltage measurements across the DVT population
Show the pass/fail status, limits, and statistical summary

No digging through binders. No searching shared drives. The data is structured, searchable, and timestamped.

Comparing V&V Across Design Revisions

When you make a design change between EVT and DVT, TofuPilot lets you compare the same measurements across phases.

Did the thermal performance improve with the new heatsink design? Compare junction_temp_max distributions between EVT and DVT. The data answers the question objectively.

Continuous Verification in Production

V&V doesn't end at PVT. Every unit tested in production is a data point that verifies the design continues to meet its specifications.

TofuPilot's production dashboards show ongoing verification:

Are all measurements still within limits?
Is the process capability (Cpk) maintained?
Are there any new failure modes that weren't seen during V&V?

If a measurement that was comfortably within limits during DVT starts approaching a limit in production, you know the process or components have changed. Investigate before it becomes a field issue.

Automated Verification and Validation