1.12 Feasibility Studies

Learning Outcomes:

By the end of this unit you should have developed a knowledge and understanding of:

the use of feasibility studies to assess the practicality for production of proposed designs, including the testing of prototypes with potential customers.

A level students need to understand how feasibility studies are used in the design process and in industrial contexts, and explain the reasons for their use.

Introduction

Before manufacturers invest large amounts of finance into the production of new products, they may use computer modelling to assess the practicality of making the item.

In the design of production and assembly lines, cells can be designed where parts and tools can be stored and robots, machines and humans can be placed along the line for maximum productivity and efficiency.

Using this system it is possible to predict bottlenecks and plan where ‘buffer zones’ might be needed.

Buffer zones are a type of holding area; temporary storage areas where partially completed work is stored while slower tasks or processes are completed so production is not compromised or slowed down unnecessarily.

Computer Modelling

Modern manufacturing industries usually adopt ‘lean manufacturing’ methods. This is an approach to efficient manufacturing that was first used by Toyota in the production of cars. Lean manufacturing concerns minimising waste in terms of time and materials. Computer modelling of production is an essential part of achieving lean manufacturing.

Simple software such as a spreadsheet can be used to calculate costs of production.

These are split into direct costs such as materials and labour, and indirect costs such as lighting, factory and machine rental and other related costs (see unit 1.13 on enterprise for more information).

More sophisticated computer modelling is available to calculate the costs of production of specific products such as injection mouldings. This software can also calculate the costs of moulds based on material and cycle time for the machine. This would be set against the number of units to be made.

Boeing use computer modelling to assess the feasibility of a design such as the engine for the Boeing 787. An engine is a hugely complex assembly of hundreds of components. Before such an expensive part is put into production, computer modelling is used to test the sequence of how the parts will be assembled and also how they can be disassembled for repair, replacement or recycling (see Unit 1.11).

testing prototypes

An alternative to using computer modelling for testing feasibility is to build a prototype to test with the potential consumers. These could range from simple test rigs for performance through to pre-production prototypes that look and perform exactly like a finished product but may not yet be in mass production (see lessons EX2 and EX3 for further information on prototypes).

A simple prototype like those in the pictures below would allow the function and ergonomics to be tested before it is developed to consider production, finish, graphics, packaging, materials etc.

Summary

• Feasibility studies are used to assess the practicality of a project before investing in materials and manufacturing equipment

• It is a process undertaken by industry rather than in schools or colleges as they have a range of materials and machinery that can be utilised

• Feasibility studies can be used to assess ergonomics, especially of environments or interiors

• Computer modelling can be used to carry out feasibility studies to test projects virtually (see Unit 1.7 for FEA)

• Takt time is the rate at which an item needs to be made to meet customer demands

Revision notes

This is a relatively short unit and is not always directly related to your NEA work, but it is still important that you understand the importance of undertaking feasibility studies before investing in a project in industry.

Similar methods can be done at the beginning of your NEA project to justify the project you plan to undertake.

Revisit FEA from Unit 1.6 and ensure you understand the different types of prototype that can be made and how they could be used for feasibility studies.

Additional lessons EX2 and EX3 elaborate on the different methods of prototyping and should help you to understand how prototyping can be used to test the feasibility of a project before it is developed into a product.