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Abstract. Design for Six Sigma (DFSS) has been implemented in many companies to enhance their business performance and customer satisfaction. However, DFSS has not been widely applied to the aircraft industry which operates large, complex development programs. In this paper, the characteristics of an aeronautical product development program are analyzed to figure out the limitations of current DFSS methodology and the prerequisite to deployment of DFSS at the program level is suggested.

While systems engineering has been widely applied to complex system development, some evidences are reported about major budget and schedule overruns in systems engineering applied. On the other hand, many organizations have been deploying Design for Six Sigma (DFSS) to build Six Sigma momentums in the area of design and development for their products and processes. To explore the possibility of having a DFSS complement systems engineering process, this process reviews the systems engineering with their categories of effort and DFSS with its methodologies. A comparison of the systems engineering process and DFSS indicates that DFSS can be a complement to systems engineering for delivering higher quality products to customers faster at a lower cost. We suggest a simplified framework of systems engineering process, that is, PADOV which was derived from the generic systems engineering process which has been applied to the development of T-50 advanced supersonic trainer aircraft by Korea Aerospace Industries (KAI) with technical assistance of Lockheed Martin. We demonstrated that each phase of PADOV framework is comprehensively matched to the pertinent categories of systems engineering effort from various standards.

Purpose: In this paper, a Design for Six Sigma(DFSS) methodology based on DMADV(Define-MeasureAnalyze-Design-Verify) roadmap is presented.Methods: DFSS tools are given for each DMADV phase which is suitable for the aircraft development process.A cost reduction case study of a navigation simulation is demonstrated.Results: DFSS roadmap are presented with implementation tools for each phase.Conclusion: We propose a DFSS methodology which can benefit the design and development personnel to implement DFSS not only in aircraft industry but also in other order-based industries in general.

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