Optical components with complex surfaces, like aspherical or free-formed surfaces, can be
considered as typical examples for complex products. In the Transregional Research Project
SFB/TR4 the manufacturing of such optical components is analysed. One main aspect in the project
is the question of how to improve the production process planning in order to ensure that the
technical and financial objectives of the process chain are achieved. For that reason an approach has
been developed that is based on the concept of Quality Gates and the method of Design Review
bases on Failure Mode (DRBFM). The approach aims at comparing the capabilities of the single
process steps and the manufacturing demands resulting from the design phase using the concept of
Quality Gates. Therefore, the overall requirements on the whole process chain must be assigned to
the single process steps in a systematic way. Further one, with the help of a modified DRBFM
worksheet potential problems during production can be discovered and eliminated early in the
design phase.