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Validation Standards Landscape
The cheat-sheet capstone. Every standard cited across the 10 prior modules pulled into a single navigable directory — organised by issuing body, then by topic. When a participant says “we tested to USCAR-2”, “our component meets IEC 60664-1”, or “our CSR calls out LV 215”, you can flip to the right section and follow. Less narrative, more reference density.
What’s in this module
- The issuing bodies — a 1-minute map of who writes what
- SAE / USCAR standards (US automotive)
- ISO standards (international)
- IEC and CISPR standards (electrotechnical)
- VDA / LV standards (German automotive)
- JASO standards (Japanese automotive)
- UN / ECE regulations (type approval)
- AIAG / IATF standards (quality framework)
- Regional regulations — India (AIS), China (GB), USA (FMVSS)
- The 7 anchor questions consolidated
- The 10 master facilitation patterns
- The cohort-grading rubric
- Self-check (10 questions)
1 The issuing bodies — who writes what
SAE / USCAR
SAE International + United States Council for Automotive Research. Industry-driven. USCAR standards typically physically-detailed component specs (USCAR-2, -21, -25, -37, -38).
ISO
International Organization for Standardization. Road vehicles standards under TC 22. The “global default” for safety, EMC immunity, HV, and many specifications.
IEC + CISPR
International Electrotechnical Commission and its subcommittee CISPR (radio interference). Source of CISPR 25 (automotive EMC emissions).
VDA / LV
Verband der Automobilindustrie. ASPICE custodian. LV (Lieferantenvorschrift) specifications used by VW Group / Daimler / BMW.
JASO
Japanese Automobile Standards Organization. Used by Toyota, Honda, Nissan, Suzuki, Mitsubishi.
UN / ECE
United Nations Economic Commission for Europe. Mandatory type-approval regulations — vehicles without these cannot be registered. India follows ECE framework.
AIAG / IATF
Automotive Industry Action Group + International Automotive Task Force. Source of the core tools (APQP, PPAP, FMEA) and IATF 16949.
AIS / BIS / ARAI
Automotive Industry Standards / Bureau of Indian Standards / Automotive Research Association of India. Indian-specific regulations and homologation.
2 SAE / USCAR — connectors, terminals, validation
| ID | Scope | Module ref |
|---|---|---|
| SAE/USCAR-2 | Performance specification for automotive electrical connectors — system-level test (mating force, vibration, thermal cycle, fluid resistance, etc.) | M5 |
| SAE/USCAR-21 Rev 4 (2020) | Cable-to-Terminal Electrical Crimp Performance — pull force, cross-section, compaction ratio 15–20%, crimp height ±0.05 mm | M5 |
| SAE/USCAR-25 | Header connector thermal cycling — used on ECU/PCB-mounted connectors | M5, M6 |
| SAE/USCAR-37 | High-voltage connector requirements — touch-proof, HVIL, partial discharge | M6 |
| SAE/USCAR-38 | Voltage-Temperature-Humidity-Load (VTHL) testing of connectors | M5 |
| SAE J551 family | Vehicle-level EMC test methods (mostly withdrawn in favour of CISPR/ISO equivalents) | M8 |
| SAE J1113 family | Component-level EMC test methods (mostly aligned with ISO 11452) | M8 |
| SAE J1739 | Recommended FMEA practices (US legacy; updating to AIAG-VDA aligned) | M3 |
| SAE J2980 | Considerations for ISO 26262 ASIL hazard classification — SAE companion guidance | M10 |
| SAE J1850, J1939, J2284 etc. | In-vehicle network protocols (CAN, CAN-FD physical/protocol) | M1 |
| SAE J3400 | NACS (North American Charging Standard) — Tesla-origin connector adopted by Ford, GM, Hyundai | M6 |
3 ISO standards — international consensus
ISO 11898 / 17987 / 26262 family — networks and safety
| ID | Scope | Module ref |
|---|---|---|
| ISO 11898 | CAN bus — physical layer, high-speed (250 kbps – 1 Mbps), CAN-FD up to 8 Mbps | M1 |
| ISO 17987 | LIN bus — Local Interconnect Network | M1 |
| ISO 17458 | FlexRay — deterministic 10 Mbps automotive bus | M1 |
| IEEE 802.3bw / 802.3bp / 802.3ch | Automotive Ethernet — 100BASE-T1, 1000BASE-T1, multi-Gbps (note: IEEE not ISO, listed here by topic) | M1 |
| ISO 26262:2018 (2nd Ed) | Road vehicles — Functional safety — 12 parts; ASIL A-D classification; covers all road vehicles except mopeds | M10 |
| ISO/SAE 21434:2021 | Road vehicles — Cybersecurity engineering — CSMS, TARA, CAL | M10 |
ISO HV and electrical safety family
| ID | Scope | Module ref |
|---|---|---|
| ISO 6469 series | Electrical safety of road vehicles — Part 1 (RESS battery safety), Part 2 (vehicle operational), Part 3 (isolation: 500 Ω/V rule) | M6 |
| ISO 6722 | HV cable specifications — temperature rating, insulation withstand | M6, M8 |
| ISO 17409 | Conductive charging — connection to external power supply | M6 |
| ISO 21498 | Electrified propulsion — voltage classification and testing | M6 |
| ISO 15118 | EV charging communication — “Plug and Charge”, ISO 15118-20 for higher-power scenarios | M6 |
| ISO 20653 | Road vehicles — degrees of protection (IP code automotive variant — “K” suffix denoting automotive-specific test) | M5, M6 |
ISO EMC, ESD, environmental
| ID | Scope | Module ref |
|---|---|---|
| ISO 11452 family | Component-level immunity — Part 2 (ALSE), Part 3 (TEM), Part 4 (BCI), Part 5 (Stripline), Part 9 (portable transmitter), Part 11 (reverberation) | M8 |
| ISO 7637 family | Conducted transient immunity on power lines — Part 2 (12 V/24 V supply transients: Pulse 1, 2a, 2b, 3a, 3b, 4, 5a/5b “load dump”) | M8 |
| ISO 10605 | ESD test methods for automotive — 330 Ω + 150 pF, 2 kΩ + 330 pF network options | M8 |
| ISO 16750 family | Environmental conditions and testing for road-vehicle electrical/electronic equipment — Part 2 (electrical), Part 3 (mechanical), Part 4 (climatic), Part 5 (chemical) | M2, M7, M8 |
ISO process / quality / GD&T
| ID | Scope | Module ref |
|---|---|---|
| ISO 9001 | Quality management systems — generic; the foundation IATF 16949 sits on | M4 |
| ISO/IEC 17025 | Calibration & testing laboratory competence — referenced in PPAP Element 12 | M4 |
| ISO 1101 / ASME Y14.5 | GD&T — Geometric Dimensioning and Tolerancing | M9 |
| ISO/IEC 33020 | Process measurement framework — underpins ASPICE | M10 |
| ISO 8092 | Connector terminology and basic dimensions | M5 |
| ISO 60270 (IEC) | Partial discharge measurement | M2, M6 |
4 IEC and CISPR standards — electrotechnical
| ID | Scope | Module ref |
|---|---|---|
| CISPR 25 Edition 5 (2021) | Automotive RF emissions — 150 kHz – 2.5 GHz, 5 classes; Ed 5 added EV/HEV setups | M8 |
| CISPR 12 | Vehicle emissions protecting external receivers (different from CISPR 25, which protects on-board) | M8 |
| CISPR 36 | EV/HEV emissions protecting off-board receivers below 30 MHz | M8 |
| IEC 60529 | IP code (Ingress Protection) — base international standard; automotive variant in ISO 20653 | M5 |
| IEC 60664-1 | Insulation coordination — creepage & clearance for HV applications | M6 |
| IEC 60068 family | Environmental testing of electrotechnical products (sometimes referenced alongside ISO 16750) | M2 |
| IEC 61508 | Functional safety of programmable electronic systems — the parent standard ISO 26262 derives from | M10 |
5 VDA / LV standards — German automotive
| ID | Scope | Module ref |
|---|---|---|
| LV 214 | German automotive connector specification — VW Group / MB / Audi default | M5 |
| LV 215 | HV-specific connector specification (LV 214 sibling) | M5, M6 |
| LV 216 | HV cable / harness specification | M6 |
| VDA QMC ASPICE 4.0 (Dec 2023) | Automotive Software Process Improvement & Capability Determination — current edition | M10 |
| AIAG-VDA FMEA Handbook (1st Ed 2019) | Joint AIAG-VDA approach — replaces AIAG FMEA 4th Edition; introduces 7-step DFMEA, AP table | M3 |
| VDA 6.3 | Process audit standard — supplier process assessment used by VW Group | M4 |
| VDA “Yellow Book” | Maturity Level Assurance for new parts — supplier-side gate-review tool | M4 |
6 JASO standards — Japanese automotive
| ID | Scope | Module ref |
|---|---|---|
| JASO D 611 | Japanese automotive connector standard — Toyota, Honda, Nissan, Suzuki default | M5 |
| JASO D 624 | Automotive wire harness specifications | M5, M6 |
| JIS D family | Japanese Industrial Standards for road vehicles (broader than JASO) | M2, M5 |
7 UN / ECE regulations — type approval
These are not “standards” — they are mandatory regulations. Vehicles without these cannot be registered in EU/India and many other ECE-aligned markets.
| ID | Scope | Module ref |
|---|---|---|
| UN R10 | Vehicle-level EMC type approval — both emissions and immunity | M8 |
| UN R100 | Electric power train — vehicle-level HV safety type approval; basis for India AIS 156 | M6 |
| UN R155 | Cybersecurity Management System (CSMS) — mandatory from July 2022 new types, July 2024 all new vehicles | M10 |
| UN R156 | Software Update Management System (SUMS) — same phase-in as R155; governs OTA update integrity | M10 |
| UN R79 | Steering equipment — type approval for steering systems including EPS | M10 (ASIL D context) |
| UN R13H | Braking systems — passenger car | M10 |
8 AIAG / IATF — quality framework
| ID | Scope | Module ref |
|---|---|---|
| IATF 16949:2016 | Automotive QMS — adds automotive-specific requirements on top of ISO 9001:2015. Section 8.3 governs design & development. | M4 |
| AIAG APQP 3rd Edition (Mar 2024) | Advanced Product Quality Planning — 5 phases, gated review, APQP Program Metrics; mandatory at GM/Stellantis Sept 2024, Ford Dec 2024 | M4 |
| AIAG Control Plan 1st Ed (2024) | Decoupled from APQP — Production / Pre-Launch / Prototype variants; Safe Launch period | M4 |
| AIAG PPAP 4th Edition (2006) | Production Part Approval Process — 18 elements, 5 submission levels, PSW | M4 |
| AIAG-VDA FMEA Handbook (2019) | Joint FMEA reference — 7-step approach, AP table replacing RPN | M3 |
| AIAG MSA 4th Ed | Measurement Systems Analysis — Gauge R&R methodology | M4 |
| AIAG SPC 2nd Ed (3rd in Jul 2026) | Statistical Process Control — capability indices Cp/Cpk/Pp/Ppk | M4 |
| AIAG CQI-9 / CQI-11 / CQI-12 / CQI-15 / CQI-17 / CQI-23 | Special-process self-assessments — heat treat, plating, coating, welding, soldering, moulding | M4, M9 |
| AIAG CQI-34 | Software Assurance Approval Process (SwAAP) — software-specific extension of PPAP | M4, M10 |
9 Regional regulations — India, China, USA
India — AIS / BIS / ARAI
| ID | Scope | Module ref |
|---|---|---|
| AIS 156 | Indian standard for EV safety — based on UN R100, strengthened after 2022 fire incidents to include thermal-propagation testing | M6 |
| AIS 038 | Vehicle-level electrical equipment specifications | M1 |
| AIS 004 (Part 3) | Vehicle EMC compatibility — Indian implementation of ECE R10 | M8 |
| CMVR (Central Motor Vehicles Rules) | The umbrella regulatory framework; references AIS standards | All |
| BIS / IS standards | Bureau of Indian Standards — material specs (often align with ISO/IEC) | M9 |
China — GB / GB-T
| ID | Scope | Module ref |
|---|---|---|
| GB/T 20234 | Chinese EV charging connectors (the GB/T charging standard) | M6 |
| GB 18384 | Chinese EV safety standard | M6 |
USA — FMVSS / NHTSA
| ID | Scope | Module ref |
|---|---|---|
| FMVSS 305 | Electric-powered vehicles — electrolyte spillage and electrical shock protection | M6 |
| FMVSS family | Federal Motor Vehicle Safety Standards — broad scope for US-market vehicles | M6, M10 |
10 The 7 anchor questions — consolidated
The “plant on the wall” facilitation questions, one per foundational/depth module. Each tests engineering rigour at a specific layer. Together they form a complete framing toolkit for any DMADV project at Yazaki.
Platform context
“Which OEM platform, what era, what voltage classes, what networks?”
APQP integration
“At what APQP gate does this DMADV project deliver value, and which PPAP element does it strengthen?”
USCAR-21 compliance
“What’s your compaction ratio target, and which USCAR-21 cross-section verdict do your samples land in?”
Isolation + HVIL + pre-charge
“What’s your isolation resistance spec, your HVIL response-time spec, and how does your DFMEA address pre-charge contactor weld?”
EMC + thermal + ESD
“What’s your target CISPR 25 class, your Tj design margin to the 150 °C limit, and which ISO 10605 strike scenario is in your DFMEA?”
Tolerance stack-up
“What’s your tolerance stack-up on the critical assembly dimension, RSS or worst-case, and what Cpk did you assume on each contributor?”
Safety / Process / Cyber
“What’s your product’s ASIL classification, your ASPICE CL target, and is there a TARA in scope — and how does your DFSS project feed evidence into the safety case?”
11 The 10 master facilitation patterns
Recurring patterns from across the 10 modules. Use these as facilitation prompts when a participant conversation needs to be reframed.
- “Physics statement” rule for DFMEA failure modes (M3). Instead of “broken contact”, insist on “contact resistance rises > 100 mΩ due to fretting under combined vibration + ΔT cycling”. The physics statement is the diagnostic of DFMEA quality.
- “Operationalised CTQ” rule (M5, M7). A CTQ must include the measurable threshold, the timeframe, and the noise factors. “USCAR-21 cross-section verdict ‘Ideal’ for 100% of samples through 5000 thermal cycles” — not “good crimp”.
- The single-CTQ DFMEA audit walk (M3). Take one CTQ and walk it through the entire DFMEA — function → failure mode → effect → cause → control → AP rating. If any step is weak, the whole DFMEA needs work.
- Severity dominates always (M3, M10). S=10 → AP=H regardless of O/D. Both AIAG-VDA AP and ISO 26262 ASIL share this property. Never let participants normalise away severity.
- The “noise factors / control factors” P-diagram (M5, M8). Every robust-design conversation should explicitly separate: signals + control factors → response, with noise factors as the explicit thing the design must be robust against.
- FMEA-MSR for in-operation safety (M3, M6, M10). When a function must detect and respond to failures during operation (not just at end-of-line), regular FMEA isn’t enough — use FMEA-MSR. Pre-charge sequence, HVIL, isolation monitoring all fit here.
- Selective skepticism on capability data (M4, M9). Ppk > 1.67 is the OEM ask. If a participant says “we’re at Ppk 2.5”, ask: which dimension? What sample size? Was MSA done first? Capability claims without MSA are not credible.
- The “wrong-windshield replacement” pattern (M7). Every product DFMEA should include the “service-life mis-handling” failure mode. Service-induced failures are a recurring warranty pattern across HUD, HV, ESD, and harness products.
- Defer to room SMEs strategically (M10). On deep ISO 26262 or ASPICE questions, elevate the SGM-EI Software Lifecycle in the room. On deep optical questions, elevate the AR HUD PM. On deep stamping/plating questions, elevate the Shared Service Advance Materials lead. This both gets correct answers and demonstrates good facilitation.
- Cross-module integration narrative (M5–M10). The most powerful illustration in any 9-day program is a single product example threading through 5+ modules. The signal-class terminal from Module 9 §11 and the HV connector from Module 6 §13 are the deepest examples — deploy them heavily.
12 The cohort-grading rubric
A practical tool for assessing where each participant team is operating by the end of Day 5. Use this to identify which teams need targeted facilitation in Days 6-9.
| Level | What you observe | Facilitator response |
|---|---|---|
| Level 1 — Engineering rigour | Team can fluently answer 5+ of the 7 anchor questions for their project. DFMEA failure modes are physics-statements. Capability claims are MSA-backed. | Push to Level 2 — challenge them on cross-module integration. Ask “what does your AR-HUD project share architecturally with the HV connector example from Module 6?” |
| Level 2 — Integration | Team explicitly connects their DFSS work to APQP gates and PPAP elements. They can articulate how their project produces evidence the safety/cyber/process frameworks need. | Push to Level 3 — challenge them to scope a follow-up project that strengthens the same product line. |
| Level 3 — Strategic framing | Team frames their project in terms of customer impact, business cycle, OEM CSR alignment, and competitive positioning (wireless BMS threat, 800V transition, etc.) | Recognise publicly. These teams are the seeds for an ongoing Yazaki DFSS practice — encourage them to mentor others. |
| Level 0 — Foundational gaps | Team uses vague vocabulary (“good crimp”, “passes EMC”). Cannot answer the anchor questions for their project. Capability claims without supporting data. | Concentrated facilitation. One-on-one with the SME participant in their function. Walk a single CTQ through the entire DFMEA chain in front of them. Use the Module-9 worked example as a model. |
13 Capstone observations
After 11 modules of preparation, three over-arching observations about the cohort and the program:
Instructor self-check
Ten capstone questions across the validation standards landscape.
