A test specification is the formal document that defines how a physical test will be executed and what constitutes a passing result. To produce valid verification evidence, a test specification must contain: a clear reference to the DVP&R requirement the test addresses; a precise description of the test sample including revision level, quantity, and manufacturing traceability requirements; exact test conditions including temperature, load levels, cycle counts, test media, and test sequence; instrumentation requirements specifying which quantities are measured, with what instruments, at what calibration interval; data acquisition requirements specifying sampling rate, channel configuration, and trigger conditions; pass-fail acceptance criteria with tolerance definitions; and failure mode definition distinguishing test item failure from test setup failure or sample manufacturing defect. EMUG’s BENCH Build phase prepares test specifications that satisfy all these requirements before laboratory submission.
EMUG evaluates accredited laboratories against five criteria for each test campaign. ISO 17025 accreditation scope: confirming that the laboratory’s accreditation certificate covers the specific test standard and test type required — a laboratory accredited for tensile testing is not necessarily accredited for fatigue testing. Technical competence: reviewing the laboratory’s test equipment specifications, data acquisition capability, and technical staff competence for the specific test requirement. Capacity and lead time: confirming that the laboratory can accommodate the required sample quantity within the program timeline. Track record: reviewing test reports from previous campaigns at the laboratory for evidence quality and completeness. Geographic access: for tests requiring EMUG witness attendance, selecting a laboratory within practical travel distance or confirming remote witness capability.
The EMUG BENCH Framework is EMUG’s five-phase physical testing support methodology, standing for: Build test specification, Equip and select laboratory, Note execution records, Confirm anomaly disposition, and Handover reports. It prevents test evidence failures through four mechanisms: test specifications are completed and approved by engineering authority before laboratory submission (preventing inadequate specifications that generate unusable data); sample traceability is documented before testing (preventing untraceable samples that regulators reject); real-time data quality is monitored during test execution (preventing data gaps discovered after the test window closes); and anomaly disposition is formally completed before the test report is issued (preventing open anomalies that block DVP&R closure).
NVH physical testing campaigns managed by EMUG cover the full measurement chain from test specification through data analysis. Test specification defines the measurement points, transducer types (accelerometers, microphones, force transducers), data acquisition system configuration (sampling rate, frequency range, anti-aliasing filter settings), operating conditions (speed, load, temperature), and analysis types (FFT spectra, octave analysis, operational deflection shapes, transfer functions). Data acquisition systems used include LMS SCADAS, National Instruments PXI, and Bruel and Kjaer systems. EMUG engineers attend test execution to monitor data quality in real time, identifying measurement anomalies (sensor dropout, ground loop noise, structural resonance of test rig) while the test is still running. Post-test data analysis covers frequency spectrum assessment, peak identification, and comparison against pass-fail criteria referenced in the DVP&R.
When a physical test anomaly is classified as a genuine design deficiency — a failure mode that the design does not prevent within the acceptance criteria — EMUG manages a structured resolution process. An engineering change is initiated in PLM (Teamcenter or Windchill) referencing the test anomaly as the initiating event. Root cause analysis is performed using 8D methodology or the AIAG-VDA DFMEA failure analysis approach to confirm the causal mechanism. A corrective design change is proposed, reviewed by the responsible design engineer, and approved through the engineering change process. A retest plan is defined confirming that the corrective action addresses the failure mode and does not introduce new failure modes for adjacent requirements. New samples reflecting the design change are fabricated and retested. All steps are documented in the anomaly investigation report, which becomes part of the formal test evidence package.
Regulatory authorities (EASA, FAA, TUV, IATF assessors) require test sample traceability that establishes an unbroken chain from the tested sample back to the design configuration it represents. Required traceability records include: design revision reference (the specific CAD model revision and drawing revision the sample was manufactured to), manufacturing records (production order, manufacturing date, process route, operator identity for each manufacturing step), material certificates (EN 10204 3.1 or 3.2 certificates for aerospace and pressure equipment; heat number and chemical composition for structural applications), dimensional inspection records confirming the sample is within drawing tolerance, and heat treatment or surface treatment records for components where these processes affect the tested properties. EMUG establishes the traceability documentation requirement for each test campaign during the Build phase and confirms traceability record completeness before samples are shipped to the test laboratory.
Yes. EMUG coordinates simultaneous physical test campaigns across multiple countries — a common requirement for global automotive and aerospace programs where different test types require specialist laboratories in different locations (crash testing in Germany, NVH in UK, salt spray in Netherlands, vibration in India). Multi-country test coordination is managed through a central test program manager who maintains the master DVP&R status, coordinates between laboratories in different time zones, manages consolidated test data delivery, and tracks anomaly resolution across all concurrent campaigns. EMUG has active laboratory relationships in Germany (TUV Sud, MPA Stuttgart), UK (Millbrook, MIRA), Netherlands (TNO), India (NATRAX, CIRT), UAE (ESMA accredited laboratories), South Korea (KAMA approved facilities), and the USA (MTS, Element, Intertek).
EMUG delivers physical testing support to automotive OEMs and Tier 1 suppliers (IATF 16949, LV 124, OEM DVP&R requirements), aerospace and defense organizations (AS9100, DO-160G, MIL-STD-810, ITAR compliance), industrial machinery manufacturers (EU Machinery Directive, EN 13849, PED, ATEX), energy and oil and gas companies (ASME, API 598, EN 10204, NDT standards), and engineering services and EPC firms. Delivery countries include Germany, France, UK, Netherlands, Sweden, Italy, Spain, Poland, Czech Republic, UAE, Saudi Arabia, Qatar, Kuwait, Bahrain, India, China, Japan, South Korea, Malaysia, Thailand, USA, Canada, Mexico, Brazil, South Africa, Nigeria, and Kenya.
