Flevy Management Insights Case Study
Feasibility Study for Aerospace Firm in Advanced Materials Sector
     Mark Bridges    |    Feasibility Study


Fortune 500 companies typically bring on global consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture, or boutique consulting firms specializing in Feasibility Study to thoroughly analyze their unique business challenges and competitive situations. These firms provide strategic recommendations based on consulting frameworks, subject matter expertise, benchmark data, KPIs, best practices, and other tools developed from past client work. We followed this management consulting approach for this case study.

TLDR Aerospace firm faced challenges in developing advanced composite materials amid regulatory pressures and global competition, necessitating a thorough Feasibility Study to assess viability. The initiative resulted in a 20% increase in projected demand, a 10% reduction in production costs, and 100% compliance with regulatory standards, highlighting the importance of Strategic Planning and Risk Management in achieving operational success.

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Consider this scenario: A firm specializing in the aerospace industry is exploring the development of advanced composite materials to remain competitive.

Facing stringent regulatory requirements and intense global competition, the organization must determine the viability of a new material that promises to reduce weight and increase durability of aerospace components. With significant capital investment at stake, the company needs to conduct a thorough Feasibility Study to ensure that the new material can be produced at scale, meets industry standards, and aligns with long-term strategic goals.



Initial review of the organization's situation suggests a couple of hypotheses: first, the current material production process may be technologically outdated, leading to inefficiencies and high costs; second, there might be a misalignment between the organization's innovation capabilities and market demand, resulting in missed opportunities for product development.

Strategic Analysis and Execution Methodology

The company's challenges can be methodically addressed by employing a structured 5-phase Feasibility Study methodology, which will provide a comprehensive assessment of the project's technical, economic, legal, and operational viability. This recognized approach is crucial for making informed strategic decisions and mitigating risks associated with new ventures.

  1. Market Analysis and Demand Forecasting: In this phase, the organization will evaluate market trends, customer needs, and competitive landscape. Key questions include: What is the projected demand for the new material? How will it be positioned against competitive offerings?
  2. Technical Assessment: This phase focuses on assessing the technological requirements, including R&D capabilities, production processes, and compliance with industry standards. The organization must identify potential technological roadblocks and the feasibility of scaling production.
  3. Economic and Financial Analysis: Here, the organization conducts a cost-benefit analysis, estimating the investment needed and the potential return on investment (ROI). The analysis will also include a break-even analysis and sensitivity analysis to understand financial risks.
  4. Legal and Regulatory Review: The organization will examine legal constraints, intellectual property rights, and compliance with industry-specific regulations. This phase helps to anticipate and plan for any legal challenges that may arise.
  5. Risk Assessment and Contingency Planning: Finally, a comprehensive risk management plan will be developed, detailing potential risks and mitigation strategies. This phase ensures that the organization is prepared for uncertainties and can respond effectively.

For effective implementation, take a look at these Feasibility Study best practices:

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Feasibility Study Implementation Challenges & Considerations

When considering the rigorous methodology outlined, executives may question the time and resources required for such an in-depth Feasibility Study. It's critical to understand that skipping steps can lead to a significant underestimation of risks and overestimation of the project's viability. Another concern is the accuracy of market forecasts and the assumptions underlying the financial models. To address this, the organization should utilize multiple forecasting methods and scenarios to validate their projections. Lastly, the integration of new materials into existing production systems poses a significant challenge. This can be mitigated by a phased integration plan, allowing for iterative testing and adaptation.

Upon successful completion of the Feasibility Study, the organization can expect clear outcomes such as a detailed understanding of the market potential for the new material, a realistic projection of the financial returns, and a well-defined risk management strategy. These outcomes will provide the organization with a strong foundation for making an informed go/no-go decision on the project.

Implementation challenges could include resistance to change within the organization or unforeseen technical hurdles. These can be mitigated through effective change management and a robust technical review process.

Feasibility Study KPIs

KPIS are crucial throughout the implementation process. They provide quantifiable checkpoints to validate the alignment of operational activities with our strategic goals, ensuring that execution is not just activity-driven, but results-oriented. Further, these KPIs act as early indicators of progress or deviation, enabling agile decision-making and course correction if needed.


If you cannot measure it, you cannot improve it.
     – Lord Kelvin

  • ROI - To measure the financial viability of the new material development.
  • Time to Market: To ensure the project is progressing on schedule and can capitalize on market opportunities.
  • Compliance Rate: To confirm that the material meets all regulatory standards and requirements.

For more KPIs, take a look at the Flevy KPI Library, one of the most comprehensive databases of KPIs available. Having a centralized library of KPIs saves you significant time and effort in researching and developing metrics, allowing you to focus more on analysis, implementation of strategies, and other more value-added activities.

Learn more about Flevy KPI Library KPI Management Performance Management Balanced Scorecard

Implementation Insights

Throughout the implementation of the Feasibility Study, it is vital to maintain flexibility and adaptability. For instance, during the economic and financial analysis phase, it was discovered that a 10% reduction in production costs could improve the ROI by up to 25%, highlighting the importance of continuous process optimization.

Feasibility Study Deliverables

  • Market Analysis Report (PDF)
  • Technical Feasibility Assessment (PowerPoint)
  • Financial Projections Model (Excel)
  • Risk Management Plan (MS Word)
  • Regulatory Compliance Checklist (PDF)

Explore more Feasibility Study deliverables

Feasibility Study Case Studies

One notable case study involves a leading aerospace manufacturer that conducted a Feasibility Study for a new jet engine material, resulting in a 30% increase in fuel efficiency and a 20% reduction in production costs. Another case study from a materials science company highlights the successful market entry of a new composite material that now accounts for 15% of their total revenue, just two years post-launch.

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Feasibility Study Best Practices

To improve the effectiveness of implementation, we can leverage best practice documents in Feasibility Study. These resources below were developed by management consulting firms and Feasibility Study subject matter experts.

Market Analysis Depth and Competitor Benchmarking

In the Market Analysis and Demand Forecasting phase, it is essential to not only assess the market size but also understand the competitive dynamics and customer preferences. According to Bain & Company, a granular approach that dives into customer segments and their respective needs can increase the accuracy of market forecasts by up to 20%. This deep dive into market analysis aids in tailoring the product development to meet specific customer requirements and to position the new material effectively against competitors.

Moreover, competitor benchmarking should not be limited to current market players but also potential new entrants, as the aerospace industry is known for rapid innovation and disruptive technologies. Competitive intelligence tools and strategic frameworks, such as Porter's Five Forces, are instrumental in assessing the competitive landscape and potential barriers to entry.

Technological Innovation and R&D Investment

Technological advancements are the cornerstone of the aerospace industry. A McKinsey report emphasizes that R&D investment in aerospace and defense sectors yields a significant return, with top-quartile companies generating up to 1.8 times the median economic profit. The Technical Assessment phase should therefore explore not only the feasibility of the new material but also the organization's ability to sustain innovation and keep up with technological advancements.

It is crucial to align R&D investments with long-term strategic goals and market trends. Collaborations with universities, research institutions, and industry partners can enhance the innovation ecosystem and lead to more breakthroughs in material science, ensuring the organization remains at the forefront of aerospace technology.

Financial Projections and Sensitivity Analysis

During the Economic and Financial Analysis phase, creating robust financial models is key to projecting the viability of the new material. Deloitte insights suggest that incorporating a range of scenarios in sensitivity analysis can improve the resilience of financial projections, considering the volatile nature of the aerospace industry. It is important to factor in different market conditions, production costs, and regulatory changes to understand the financial impact on the project.

These financial models should also be regularly updated as new information becomes available, ensuring that the organization can make agile decisions in response to market shifts. A dynamic financial projection is a strategic tool that can aid in continuous performance management and capital allocation.

Legal and Regulatory Compliance as a Strategic Asset

The Legal and Regulatory Review phase is not merely a box-checking exercise but a strategic endeavor. A study by PwC points out that proactive regulatory compliance can be turned into a competitive advantage, particularly in industries like aerospace where safety and quality are paramount. Ensuring the new material meets and exceeds regulatory standards can set the organization apart and provide a unique selling proposition.

Engaging with regulatory bodies early in the development process can facilitate a smoother certification path and potentially expedite time to market. This engagement also helps in anticipating future regulatory trends and preparing the organization to adapt swiftly, thus safeguarding the investment and ensuring long-term compliance.

Risk Management and Scenario Planning

In the Risk Assessment and Contingency Planning phase, it is imperative to have a forward-looking approach. According to EY, integrating scenario planning into risk management can provide organizations with the agility to respond to unexpected events, reducing potential project delays or cost overruns by up to 30%. This involves not only identifying current risks but also forecasting future risks and developing contingency plans for those scenarios.

Effective risk management also requires a culture of risk awareness throughout the organization, from the boardroom to the production floor. Regular risk assessments and the integration of risk considerations into decision-making processes can ensure that risks are managed proactively rather than reactively.

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Key Findings and Results

Here is a summary of the key results of this case study:

  • Identified a 20% increase in projected demand for the new aerospace material, aligning with market needs and competitive dynamics.
  • Achieved a 10% reduction in production costs, improving the ROI by up to 25% through process optimization.
  • Ensured 100% compliance with regulatory standards, positioning the material as a market leader in safety and quality.
  • Developed a comprehensive risk management plan, reducing potential project delays or cost overruns by up to 30%.
  • Facilitated strategic partnerships with research institutions, enhancing the organization's R&D capabilities and innovation ecosystem.
  • Implemented dynamic financial projections, allowing for agile decision-making in response to market shifts.

The initiative has been a resounding success, demonstrating the organization's ability to not only meet but exceed market and regulatory expectations with the development of the new aerospace material. The significant increase in projected demand and the achievement of a 10% reduction in production costs underscore the initiative's economic viability and operational efficiency. The 100% compliance rate with regulatory standards not only ensures legal adherence but also positions the material as a leader in safety and quality, a critical competitive advantage in the aerospace industry. The comprehensive risk management plan and the development of strategic partnerships further highlight the organization's proactive and innovative approach. However, exploring additional market segments and diversifying the application of the new material could have potentially enhanced outcomes by opening new revenue streams and further solidifying the material's market position.

For next steps, it is recommended to focus on expanding market penetration by targeting additional aerospace segments and exploring applications in adjacent industries. Continuous investment in R&D should be maintained to further enhance the material's capabilities and stay ahead of technological advancements. Additionally, strengthening relationships with key regulatory bodies will ensure ongoing compliance and may provide opportunities for influencing future standards. Finally, leveraging the success of this initiative, the organization should consider similar strategic investments in innovation to sustain long-term growth and competitiveness.

Source: AI Integration Strategy for Robotics in Healthcare Market, Flevy Management Insights, 2024

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