Design Review Checklist
Use this for the connector part of design review. It pulls together the selection checklist and the red flags so the meeting catches real interface risk instead of spending twenty minutes on connector color.
Readiness checks
- Interface definition is complete
- Electrical limits are defined and sourced where required
- Every rating/requirement is traced to a source document + revision, with verification status marked (verified / assumed / example / TBD)
- Assumptions are explicitly listed with the risk if each is wrong
- Current derating and wire-gauge compatibility are reviewed
- Locking, strain relief, and backshell strategy are defined
- Sealing and unmated protection are addressed
- Keying and mis-mate prevention are addressed
- Load-break / hot-plug / mate-under-power status recorded from the datasheet for every power-carrying interface (never assumed)
- Tooling and assembly process are defined
- Workmanship/acceptance standard identified (e.g. IPC/WHMA-A-620 or the program/customer equivalent)
- Qualification evidence exists — or is planned — for the exact configuration: family/QPL basis or a program-level plan (Qualification Plan Template)
- Supply integrity addressed: lifecycle status checked, approved alternates on record, authorized sourcing channel identified, PCN/EOL notice handling assigned (Lifecycle & Procurement)
- Documentation package exists (BOM, pinout, cable drawing, ICD)
Red-flag scan
| Red flag | Status | Notes |
|---|---|---|
| Pin-count-only selection avoided | TBD | |
| Power and signal segregation reviewed | TBD | |
| Backshells included where needed | TBD | |
| Tooling identified | TBD | |
| Dust caps / dummy plugs included where needed | TBD | |
| Torque specs documented | TBD | |
| Wire seal sizing checked | TBD | |
| Mating connector included in BOM | TBD | |
| Load-break / mate-under-power status verified, not assumed | TBD | |
| Ratings traced to manufacturer/standard documents, not distributor listings | TBD | |
| Shield strategy documented with rationale (not a default) | TBD | |
| Touch safety when unmated addressed for power paths | TBD | |
| Fusing / fault current / inrush documented for power paths | TBD | |
| Service access reviewed | TBD | |
| Cable labels / identification defined | TBD |
Risk summary
| Connector / interface | Risk | Severity (H/M/L) | Corrective action |
|---|---|---|---|
| TBD | TBD | TBD | TBD |
| TBD | TBD | TBD | TBD |