23-Ind-A4 Production Management · December 2013
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
National Technical Examinations — December 2013 — 98-Ind-A4 Production Management. Three-hour, closed-book exam; Casio or Sharp approved calculators only. Format: seven questions, each worth 20 marks (sub-part weights as tabulated on the front page); only the first five questions appearing in the answer book are marked, so candidates effectively choose 5 of 7. All seven are solved below for completeness. The paper asks for point-form answers wherever possible; the solutions below use full working for clarity.
Reference texts: Nahmias & Olsen, Production and Operations Analysis (7th ed., Waveland/McGraw-Hill) — forecasting, inventory (EOQ) and aggregate planning; Sipper & Bulfin, Production: Planning, Control, and Integration — production-management systems; Hillier & Lieberman, Introduction to Operations Research (11th ed.) — LP formulation and project scheduling (CPM/PERT); Pinedo, Scheduling: Theory, Algorithms, and Systems (5th ed.) — parallel-machine scheduling, makespan and tardiness; Hopp & Spearman, Factory Physics (3rd ed.) — variability and production-system inefficiency; Niebel & Freivalds, Methods, Standards, and Work Design — division of labour and work-design history; ISO 9001:2015 and the Toyota Production System literature — quality management, 5S/lean and TPM.
Question text not reproduced: the examination questions are © Engineers and Geoscientists BC. Open the official past paper (linked at the top of this page) to read the question, then follow the worked solution below.
Given. Ten activities with precedence and durations (days), late completion penalty $\$5,000$/day.
| Activity | Precedes | Duration (days) |
|---|---|---|
| A | B, C, D | 15 |
| B | E | 12 |
| C | E, G | 6 |
| D | H | 5 |
| E | F | 3 |
| F | I | 8 |
| G | F, J | 8 |
| H | J | 9 |
| I | END | 7 |
| J | END | 14 |
Find. (a) The project network and critical path; (b) earliest/latest start times (and slack) of every activity; (c) the effect on finish date if D becomes 35 days, plus at least two recovery strategies.
Approach. Run a forward pass (earliest start/finish) then a backward pass (latest start/finish) through the precedence network to get every activity's slack; the critical path is the chain of zero-slack activities, and its total duration is the project length.
| Activity | ES | EF | LS | LF | Slack |
|---|---|---|---|---|---|
| A | 0 | 15 | 0 | 15 | 0 (critical) |
| B | 15 | 27 | 15 | 27 | 0 (critical) |
| C | 15 | 21 | 16 | 22 | 1 |
| D | 15 | 20 | 17 | 22 | 2 |
| E | 27 | 30 | 27 | 30 | 0 (critical) |
| G | 21 | 29 | 22 | 30 | 1 |
| H | 20 | 29 | 22 | 31 | 2 |
| F | 30 | 38 | 30 | 38 | 0 (critical) |
| J | 29 | 43 | 31 | 45 | 2 |
| I | 38 | 45 | 38 | 45 | 0 (critical) |
| Project duration (original / after D→35d) | 45 d / 73 d (+28 d, +$\$140,000$ penalty risk) | ||||
Recovery strategies (part c, continued). Two genuinely different approaches to pull the finish date back toward 45 days: (1) Crash the new critical path (A–D–H–J). Since D itself is now the bottleneck, negotiate a second subcontractor crew to run in parallel with the strike-affected one (splitting D's scope so two crews attack it concurrently), or authorize overtime/expedited crews on H and J once D finally releases them — buying back days at an added cost that should be compared against the $\$5,000$/day penalty (any crashing move that costs less than $\$5,000$ to save a day is worth it). (2) Fast-track by overlapping activities instead of paying for extra resources. Rather than waiting for D to fully finish before starting H, begin the portions of H that do not depend on D's still-incomplete scope as soon as they are technically able to proceed (and similarly overlap H into J where feasible) — this trades some rework risk for schedule compression at little or no direct cost, and can be combined with strategy (1) rather than used alone.