Unit AS 2: Coursework – Product Development
Chapter: Investigation and Analysis of Product
Welcome to your study notes for the opening phase of your AS 2 Coursework portfolio! In this unit, you act as an engineering detective and product designer. Instead of inventing something entirely from scratch, your goal is to find an existing commercial product, pull it apart analytically, figure out where it falls short, and lay the groundwork to redesign it into something better.
Don't worry if this feels like a big task at first. Product investigation is a step-by-step process. Once you know exactly what to look for, you will be able to dissect any product with confidence.
Assessment Snapshot:
• Qualification: CCEA GCE Technology and Design (Code: 8900)
• Unit: AS 2: Coursework – Product Development
• Weighting: Worth 50% of your AS award and 20% of your overall A Level award.
• Time Allocation: Approximately 45 guided learning hours.
• Portfolio Limit: A maximum of 10 single-sided A3 sheets (accompanied by your final physical 3D prototype).
1. Overview of the AS 2 Design Journey
The AS 2 portfolio follows four sequential phases:
1. Investigation and Analysis of Product (The focus of these notes)
2. Redesign Solutions and Development
3. Making / Realisation of Prototype
4. Testing and Evaluation
Analogy: Think of this initial investigation phase as laying the foundations of a house. If your analysis is shaky, weak, or vague, your final redesign will crumble. A rigorous investigation provides the evidence you need for every design decision you make later.
2. Selecting and Justifying an Existing Product
Your first major decision is picking the right product or sub-assembly to develop.
What makes a good product choice?
• Identifiable Flaws: It has clear weaknesses (e.g., poor durability, difficult controls, bad grip, or inefficient assembly).
• Scope for Technical Improvement: It allows you to explore mechanical, electronic, material, or ergonomic redesign.
• Manageable Scale: It must be something you can feasibly develop and prototype within your 45-hour project limit.
• Commercial Viability: It is an actual product used by real consumers, not a vague one-off idea.
Common Pitfall to Avoid: Avoid choosing monolithic, simple objects (like a solid wooden doorstop) because they offer zero technical depth. At the same time, avoid overly complex machinery (like a full petrol lawnmower engine) which is impossible to prototype in the given timeframe. Instead, focus on a manageable product or an identified sub-assembly/mechanism.
Key Takeaway: Always justify why you chose the product. Point out its specific functional faults, ergonomic shortcomings, or environmental weaknesses.
3. Deconstructing the Product: The Core Analysis
When analysing your chosen product, avoid simply describing what it looks like. You must conduct a deep, critical teardown across six essential categories.
Memory Aid – Remember "FAME-SQ":
• F – Function and Performance
• A – Aesthetics and Styling
• M – Materials and Manufacturing Processes
• E – Ergonomics and Anthropometrics
• S – Sustainability and Environmental Lifecycle
• Q – Quality and Safety Standards
A. Function and Performance
• How does the product actually operate?
• What are its primary mechanical, electronic, or structural mechanisms?
• Where does it fail, jam, wear out, or perform poorly under normal operating conditions?
B. Materials and Processing
• Identify the exact materials used (e.g., specific polymers such as ABS or Polypropylene; metals such as mild steel or aluminium alloys; hardwoods/manufactured boards).
• Determine how the components were manufactured (e.g., injection moulding, die casting, CNC machining, stamping, fabrication).
• Critically evaluate: Are these materials appropriate? Did the manufacturer cut costs using brittle plastics where high-impact polymers were needed?
C. Ergonomics and Anthropometrics
Ergonomics is how well the product fits human use. Anthropometrics is the study of human body measurements.
• Percentiles: Products are generally designed to fit the 5th to 95th percentile of the target population.
• 5th percentile: Accommodates smaller users (e.g., lower reach limits, smaller hand grip spans).
• 95th percentile: Accommodates larger users (e.g., maximum clearance dimensions, larger handle diameters).
• Evaluate operational forces (is a switch too stiff?), visual feedback (are symbols clear?), and grip comfort.
D. Aesthetics and Styling
• Evaluate the form, proportion, surface textures, colour palette, and visual appeal.
• Does the aesthetic match the intended consumer market and usage environment?
E. Quality and Safety Standards
• Check for compliance marks such as CE or UKCA markings.
• Identify relevant British, European, and International standards (BS / EN / ISO).
• Identify pinch points, sharp edges, electrical hazards, or components prone to failure under load.
F. Environmental and Lifecycle Factors (Sustainability)
• Design for Disassembly: Can different materials be easily separated for recycling at the end of life, or are they permanently glued/riveted together?
• Obsolescence: Does the product suffer from planned obsolescence (designed to break quickly) or perceived obsolescence (designed to look out of date quickly)?
• Carbon Footprint & Waste: Are the materials recyclable, and is there unnecessary packaging or excessive material volume?
Key Takeaway: Thorough disassembly reveals the hidden compromises made by original manufacturers, giving you direct evidence for your redesign.
4. Target Market and User Needs Analysis
Products are made for real people. You must clearly define who your product serves and collect meaningful data.
1. Define the User Profile:
• Demographic details (age range, physical capabilities, working environment).
• Specific user limitations (e.g., reduced hand strength in older adults, safety needs for children).
2. Gather Real User Feedback:
• Collect both qualitative feedback (written consumer opinions, pain points, complaints from online reviews) and quantitative feedback (percentage ratings, measured hand sizes, recorded failure rates).
• Identify the precise "pain points" users experience during daily operation.
5. Writing the Design Brief and Measurable Specification
All your investigation work leads directly to this final output of the chapter: defining what you are going to design.
The Design Brief
A concise, focused statement outlining the problem and what your new design intends to achieve.
Example: "To redesign the casing and clamping mechanism of a handheld pipe cutter to improve ergonomic grip for 5th–95th percentile users, reduce mechanical jamming, and allow easy disassembly for recycling."
The Measurable Design Specification
Your specification must be detailed and measurable. Vague points will cost you marks!
Good vs. Bad Specification Criteria:
• Bad (Vague): "The handle must feel comfortable."
• Good (Measurable): "The handle diameter must be between \(30\text{ mm}\) and \(38\text{ mm}\) to comfortably fit the 5th–95th percentile adult hand grip."
• Bad (Vague): "Must be made of strong plastic."
• Good (Measurable): "The outer shell must be injection moulded in high-impact ABS to withstand an accidental drop from a height of \(1.5\text{ m}\) without cracking."
• Bad (Vague): "Must be safe."
• Good (Measurable): "The mechanism must incorporate an automatic blade guard complying with relevant BS EN safety guidelines to prevent accidental user contact."
6. Summary of Key Pitfalls to Avoid
• Do not just copy catalogue blurbs: Evaluative research requires your own testing, measurements, and disassembly.
• Avoid disconnect: Every single point in your final specification must link back to an issue discovered during your analysis.
• Watch your page budget: Remember that you have a strict 10 A3 sheet limit for the entire AS 2 portfolio. Allocate your page space wisely so you have sufficient room for design development, manufacturing, and testing sheets later!
Quick Review Checklist:
• Have I justified my choice of existing product?
• Have I evaluated function, materials, ergonomics (5th–95th percentile), aesthetics, standards, and sustainability?
• Have I analysed real target market feedback?
• Is my Design Brief concise?
• Are my Design Specification points quantitative and testable?