A DFX Attribution Method Applied to Integrated Product Development within the Aerospace Domain

Copriva, Rogerio Greco; Oliveira, Wesley Rodrigues de; Trabasso, Luís Gonzaga

doi:10.1590/jatm.v16.1345

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Journal of Aerospace Technology and Management

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ORIGINAL PAPER • J. Aerosp. Technol. Manag. 16 • 2024 • https://doi.org/10.1590/jatm.v16.1345 copy

A DFX Attribution Method Applied to Integrated Product Development within the Aerospace Domain

Authorship SCIMAGO INSTITUTIONS RANKINGS

ABSTRACT

The aerospace industry continually seeks to optimize product development processes to remain competitive. Design for Excellence (DFX) plays a crucial role in meeting customer expectations while aligning with organizational capabilities. However, the diversity of DFX technological areas and methods can make it challenging for companies to select the appropriate ones for each project. Successful DFX application, ensuring projects stay within scope, time, cost, and quality constraints without overburdening the development process, often depends on the engineering team’s experience and the project phase. This work maps DFX technological areas to address the decision-making problem of selecting the most suitable ones for various projects. The objective is to evaluate, from the engineering team’s perspective, whether a general approach can guide project managers in selecting key DFX areas, considering a typical aerospace organization’s project portfolio and specific project phase characteristics. Starting with a literature review of DFX in aerospace, the research includes a survey along with senior product development engineers. Quantitative results are gathered using the Likert scale and analyzed through the analytic hierarchy process (AHP). The paper presents a method to guide the initial selection of DFX areas, aiding project managers and engineers in designing complex products.

Keywords
Design for excellence; Integrated product development; Product development processes; Analytical hierarchy process

Summary	References
This research highlights the integration of DFX areas such as design for manufacturability, assembly, and cost to optimize resource allocation during PDP to improve operational efficiency.	*Smith et al.* (2019)**Smith J, Johnson A, Brown C (2019) Aligning DFX strategies with resource utilization for operational efficiency. Journal of Product Development 23(3):45-62.
This work proposes a strategic approach for selecting DFXs to optimize resource allocation in new product development.	Chen and Wu (2020)Chen L, Wu S (2020) Strategic selection of DFXs for resource optimization in new product development. International Journal of Engineering and Innovation Management 15(2): 78-95.
This article addresses the integration of agile product development with DFX, considering DFX areas such as design for flexibility, scalability, and modularity to enhance resource efficiency in dynamic development environments.	*Gupta et al.* (2021)**Gupta R, Patel N, Singh M (2021) Integrating agile product development with DFX for resource efficiency. J Eng Technol Manag 32(1):112-130.
This work presents a framework for resource optimization in product development using DFX principles, emphasizing design for sustainability, reliability, and serviceability to achieve effective resource utilization.	*Wang et al.* (2019)**Wang Q, Li H, Zhang Y (2019) A framework for resource optimization in product development using DFX principles. Int J Manuf Technol Manag 28(4):312-328.
This paper examines the maximization of resource utilization through DFX integration in a case study in the electronics industry.	*Garcia et al.* (2018)**Garcia M, Rodriguez A, Martinez P (2018) Maximizing resource utilization through DFX integration: a case study in the electronics industry. Int J Prod Res 36(2):205-218.

Types of projects	Brief description
Competitiveness	Improve a company’s competitive position in the aerospace industry, involving research and development initiatives to enhance aircraft efficiency, increase performance, or introduce new technologies (Raymer 2012Raymer DP (2012) Aircraft design: a conceptual approach. Reston: American Institute of Aeronautics and Astronautics.).
Customer Request	Involve customized modifications to existing aircraft (Patel 2009Patel NV (2009) Project marketing implementation and its link with project management and project portfolio management. Communications of the IBIMA. Vol. 10. King of Prussia: IBIMA Publishing.) driven by the specific needs of a customer or group of customers
Reliability and Correction	Increase reliability and reduce failures (Cardoso 2007Cardoso RA (2007) Project portfolio management for new product development in the aerospace industry (doctoral dissertation). Massachusetts: Massachusetts Institute of Technology.) by ensuring aircraft reliability and safety, monitoring activities, performance data analysis, identification and correction of technical issues, and implementation of improvements.
Cost Reduction	Identify and implement cost reduction opportunities throughout the aircraft lifecycle, involving optimizing production processes, implementing maintenance, and repair improvements (Levine 2014Levine HA. (2014) Project portfolio management: a practical guide to selecting projects, managing portfolios, and maximizing benefits. Hoboken: Jossey-Bass.).
Continued Operation	Maintain the operation and sustainability of in-service aircraft. They may involve regulatory updates, modifications to extend the aircraft’s lifespan, and obsolescence management (*Shtub et al.* 2005**Shtub A, Bard JF, Globerson S (2005) Project management: processes, methodologies, and economics. New Jersey: Pearson Prentice Hall.).

Phase	Description	Key references
PDEC	Identification of new product opportunities; activities include market research, competitive analysis, trend tracking, and brainstorming.	Cooper (1994)Cooper RG (1994) Third-generation new product processes. J Prod Innov Manage 11(1):3-14. https://doi.org/10.1111/1540-5885.1110003 https://doi.org/10.1111/1540-5885.111000... , Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
PDS	Assessment of technical and economic viability; activities include feasibility studies, cost evaluation, risk assessment, and market studies.	Blank (2013)Blank S (2013) Why the lean start-up changes everything. Boston: Harvard Business Review., Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer..
ID	Submission of business plan for approval; activities include goal setting, requirements definition, in-depth analyses, and conceptual modeling.	PMI (2017)[PMI] Project Management Institute (2017) A guide to the project management body of knowledge (PMBOK® Guide). 6th ed. Newtown Square: PMI., Pugh (1990)Pugh S (1990) Total design: integrated methods for successful product engineering. Wokingham: Addison-Wesley..
CD	Detailed project definition: activities include creating product structures, computational models, prototypes, and conducting preliminary design reviews.	*Clarkson et al.* (2004)Clarkson J, Simons C, Eckert C (2004) Predicting change propagation in complex design. J Mech Des 126(5):788-797. https://doi.org/10.1115/1.1765117 https://doi.org/10.1115/1.1765117... , NASA (2018)**[NASA] National Aeronautics and Space Administration (2018) NASA Systems Engineering Handbook. [accessed Oct 10 2023]. URL: https://www.nasa.gov/wp-content/uploads/2018/09/nasa_systems_engineering_handbook_0.pdf https://www.nasa.gov/wp-content/uploads/... .
DD	Transformation of designs into components; activities include critical design reviews and initiation of part fabrication.	DOD (2001)[DOD] U.S. Department of Defense (2001) MIL-STD-499B (Draft), Systems Engineering.
CTA	Product testing to meet requirements; activities include in-flight tests, ground assessments, system rig testing, and qualification trials.	FAA (2011)[FAA] Federal Aviation Administration. Regulations & Policies. [accessed Jun 19 2023]. https://www.faa.gov/regulations_policies/ https://www.faa.gov/regulations_policies...
PP	Preparation for operational debut; activities include finalizing customer support services, crew training, and maintenance.	AIA (2013)[AIA] Aerospace Industries Association (2013) National Aerospace Standard: NAS9933, New Product Introduction. [accessed Oct 10 2023]. URL: https://www.aia-aerospace.org/wp-content/uploads/2018/12/AIA-Cybersecurity-standard-onepager.pdf https://www.aia-aerospace.org/wp-content...
LP	Commencement of large-scale production; activities include addressing customer demands, component obsolescence, regulatory compliance, and engineering modifications.	Pyzdek and Keller (2009)Pyzdek T, Keller PA (2009) The six sigma handbook. 3rd ed. New York: McGraw-Hill., Trott (2008)Trott P (2008) Innovation management and new product development. 4th ed. Upper Saddle River: Pearson Education..

Criteria	Description	Key DFX practices	References
Scope	Challenges in project scope lead to rework. DFX practices mitigate these issues.	DFM, DFT, DFR, DFQ	Haque (2017)Haque A (2017) Design for manufacturability and assembly: concepts, methodologies, and applications. New York: Springer., Kusiak (2013)Kusiak A (2013) Design for reliability. Boca Raton: CRC Press., *Boothroyd et al.* (2010)**Boothroyd G, Dewhurst P, Knight W (2010) Product design for manufacture and assembly. 3rd ed. Boca Raton: CRC Press..
Schedule	Product development complexity requires multi-team coordination, risking delays. DFX practices help keep projects on schedule.	DFM, DFQ	Azzi and Hansen (2015)Azzi G, Hansen CT (2015) A design for manufacturing framework to optimize production costs. J Manuf Syst 36:129-137., Anderson (2014)Anderson DM (2014) Design for manufacturability: how to use concurrent engineering to rapidly develop low-cost, high-quality products for lean production. Boca Raton: CRC Press..
Cost	Cost overruns are common due to early-stage design flaws. DFX practices help control costs.	DFM, DFR	Rea and Schmid (2014)Rea R, Schmid S (2014) Design for Six Sigma: a roadmap for product development. Boca Raton: CRC Press., Smith and Bliesner (2006)Smith DJ, Bliesner RD (2006) Design for reliability: developing assets that meet the needs of owners. Boca Raton: CRC Press..
Quality	Quality affects satisfaction and costs. DFX practices ensure high standards.	DFQ, DFM	*Swink et al.* (2017)Swink M, Melnyk SA, Cooper MB, Hartley JL (2017) Managing operations across the supply chain. New York: McGraw-Hill Education., Chowdhury (2002)**Chowdhury S (2002) Design for Six Sigma: the revolutionary process for achieving extraordinary profits. Chicago: Dearborn Trade Publishing..

DFX area	Brief description	Main references
DFT	Designs a product to be easily tested during the manufacturing/maintenance, playing a critical role in the CTA and LP phases.	Cooper (1993)Cooper RG (1993) Winning at new products: accelerating the process from idea to launch. New York: Basic Books., Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer..
DFM	Designs a product in a way that facilitates and optimizes the manufacturing process. Considered in from the PDEC to the LP.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DFR	Designs a product that is reliable and has an appropriate lifespan. Studies indicate that DFR is particularly important in the ID and DD phases.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DFE	Considers minimizing environmental impacts throughout the product’s lifecycle, being of great importance in the PDS and CD phases.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DFS	Incorporates of sustainable practices in product and development. Relevant in the PDEC and PP phases.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DFDA	Designs a product that is easy to disassembly, being relevant in the CD and DD phases.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DFSS	Applies Six Sigma principles and methods in product design. Interesting in the CTA phase.	Antony (2014)Antony J (2014) Design for Six Sigma: A practical approach through innovation. Boca Raton: CRC Press., Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer..
DFQ	Designs products incorporating quality characteristics, being highly relevant in all development phases, especially in the ID and CTA phases.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger 2015Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education.).
DFA	Designs a product that is easy to assembly, being in almost all the development phases.	*Boothroyd et al.* (2010)Boothroyd G, Dewhurst P, Knight W (2010) Product design for manufacture and assembly. 3rd ed. Boca Raton: CRC Press., Pahl and Beitz (2013)**Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer..
DFN	Considers the interoperability and connectivity interactions of the product in communication networks. It is relevant in the CD and CTA phases.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DTC	Designs a product emphasizing strictly the importance of controlling and optimizing costs throughout the entire development process.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DFMt	Designs a product easy for maintenance and repair, being particularly relevant in the CTA and LP phases, minimizing product downtime.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DFO	Designs a product considering its operational efficiency and effectiveness, being indicated in the ID and PP development phases.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..
DFB	Designs a product considering commercial and strategic aspects, mainly to strictly align the development with business objectives and market needs.	Pahl and Beitz (2013)Pahl G, Beitz W (2013) Engineering design: a systematic approach. New York: Springer., Ulrich and Eppinger (2015)Ulrich KT, Eppinger SD (2015) Product design and development. 7th ed. New York: McGraw-Hill Education..

Likert scale		Paper scale (Likert scale)
Strongly disagree	1	Not recommended	0
Disagree	2	Slightly recommended	1
Neutral	3	Recommended	2
Agree	4	Highly recommended	3
Strongly agree	5	Extremely recommended	4

RI – Average random index of AHP as a function of matrix size
1	2	3	4	5	6	7	8	9	10	11	12	13	14	15
0.00	0.00	0.58	0.90	1.12	1.24	1.32	1.41	1.45	1.49	1.51	1.48	1.46	1.57	1.59

Intensity of importance	Definition
1	Equal importance
2	Weak or slight
3	Moderate importance
4	Moderate plus
5	Strong importance
6	Strong plus
7	Very strong or demonstrated importance
8	Very, very strong
9	Extreme importance

Index	Competitiveness		Customer Request		Reliability and Correction		Continued Operation			Cost Reduction
CI	0.016		0.007		0.039		0.034			0.026
RI	1.570		1.570		1.570		1.570			1.570
CR (%)	1.64		0.73		3.92		3.39			2.59
Conclusion	OK		OK		OK		OK			OK
Index	PDEC	PDS	ID	CD		DD		CTA	PP		LP
CI	0.088	0.028	0.024	0.030		0.027		0.043	0.072		0.042
RI	1.570	1.570	1.570	1.570		1.570		1.570	1.570		1.570
CR (%)	5.61	1.81	1.55	1.91		1.71		2.74	4.57		2.69
Conclusion	OK	OK	OK	OK		OK		OK	OK		OK

Departamento de Ciência e Tecnologia Aeroespacial Instituto de Aeronáutica e Espaço. Praça Marechal do Ar Eduardo Gomes, 50. Vila das Acácias, CEP: 12 228-901, tel (55) 12 99162 5609 - São José dos Campos - SP - Brazil
E-mail: submission.jatm@gmail.com

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[1] * Correspondence author: rogerio.copriva@gmail.com