Zonal safety analysis (ZSA) is considered as the analysing and checking processes taken place on a physical prototype to reduce the function performing risks of overall aircraft and systems from physical integrations like assembly and maintenance

including coordination and compliance checks between structure and systems

and between system and system. As the introduction of digital design

part of ZSA analysis is also trying to apply based on a digital mock-up. In civil aircraft design

SAE Aerospace Recommended Practice 4761(ARP 4761) introduced the ZSA method

implementation steps and practice cases

and suggested to apply ZSA through all the development phases. Aircraft final assembly stage

with systems installation and test

is the main stage for function implementation of an aircraft as well as a major stage for introduction of the overall aircraft quality and safety characteristics. This paper presents the scenes and implementations towards integration of ZSA and aircraft final assembly engineering activities. It introduces the classical common cause analysis tool ZSA

which is considered to be used for design

to the complicated final assembly integration process. With the help of its structured analysis and inspection methods

this research connects system functional block diagram

fault tree analysis (FTA)

design failure mode and effects analysis (DFMEA)

process design failure mode and effects analysis (PFMEA)

and ZSA. This would reduce quality risks from final assembly significantly and contribute fewer potential hazards from assembly integration that result in aircraft system risks in flight test and operation phases.