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The Institute of Aerospace Medicine provides design consultancy on aircraft-aircrew compatibility on a number of fixed-wing as well as rotary-wing aircrafts during various stages of development. Till date, the cockpit compatibility of aircrew has been determined based on the percentile concept. Percentiles, though useful when dealing with a single parameter, pose major design and fitment problems when considering multiple parameters simultaneously as in aircraft cockpit design. The concept of multivariate analysis has been the solution which the aviation industry the world over has accepted in overcoming this problem. This paper presents the Institute of Aerospace Medicine initial foray into the field of multivariate analysis, specifically principal component analysis (PCA) to achieve desired aircrew fitment in the aircraft cockpit right from the design stage.    Materials and Methods:  The fighter aircraft of the near future is being designed using the anthropometric parameters available in the IAF aircrew anthropometry survey 2013. Of the 57 parameters available, six parameters critical to the design of the cockpit were subject to PCA to derive three principal components. About 96% confidence ellipse was drawn on the plot of the principal components. From this, along the different axes, 21 boundary individuals were identified defining the extreme individuals in various combinations of the six parameters.    Discussion:  The use of more than 2 parameters is not amenable to sequential use of percentiles. As the number of parameters considered increases, it leads to reduced fitment percentage. The use of PCA allows consideration of critical parameters together at one go. The design aim is changed from the 3rd to 97th percentile to an overall aim of fitting 96% of the target population in the cockpit. The boundary individual’s entire anthropometry data are used to create boundary manikins for use in computer-aided design models. The fitment of these boundary individuals ensures that if these individuals fit, all others would fit in the cockpit. This concept brings about a paradigm shift in the aircrew-aircraft compatibility in the aviation industry in India.

Principal component analysis: The path ahead for aircrew-aircraft compatibility at the Institute of Aerospace Medicine