23-Ind-A4 Production Management · December 2014
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
National Technical Examinations — December 2014 — 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; Womack, Jones & Roos, The Machine That Changed the World — history of mass production and lean; Ford, My Life and Work (1922) and standard histories of the moving assembly line; Juran & Godfrey, Juran's Quality Handbook (5th ed.) — the quality trilogy; Hopp & Spearman, Factory Physics, Ch. 7 — Little's law.
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. Eight months of actual sales, February through September (see table); no other demand drivers (promotions, launch dates, pricing) are supplied.
| Month | Sales (units) |
|---|---|
| February | 450 |
| March | 300 |
| April | 400 |
| May | 740 |
| June | 500 |
| July | 100 |
| August | 1000 |
| September | 800 |
Find. A justified point forecast for October sales, and a discussion of the forecast's reliability and how it could be improved.
Approach. Test the series for a usable linear trend before trusting one, then compare a naive (last-value) forecast against a short moving average to pick the method that best matches the data's actual behaviour, rather than defaulting to whichever method is easiest to compute.
| Method | October forecast |
|---|---|
| Naive (last value) | 800 units |
| Linear trend ($R^2\approx0.23$, unreliable) | 794 units |
| 3-month moving average (selected) | 633 units |
(b) Discussion and improvement. The forecast is weak: eight data points cannot establish seasonality (a real yearly cycle needs at least two full years of data to separate from noise), the near-zero July month (100 units) suggests a stock-out, a discontinued old model, or a lull ahead of a new-model launch rather than organic demand decay, and the August/September rebound (1000, 800) could equally be a one-time launch spike that will not repeat in October. To improve the forecast I would: (1) collect at least 24 months of history to test for a genuine annual seasonal pattern (back-to-school, holiday, or new-model-launch cycles are common for consumer electronics); (2) bring in causal information the retailer already has — Apple's announced launch calendar, planned promotions, and competitor pricing — since a launch-driven spike is a known event, not a random one, and should be modelled explicitly rather than smoothed away; (3) track forecast error (MAD or MSE) month over month and switch to exponential smoothing with a low smoothing constant once enough history exists, so the model adapts without over-reacting to a single outlier month; and (4) disaggregate "iPad sales" into old-model and new-model units, since combining them (as the table does) can hide a simple explanation — e.g. the August spike may be a new-model launch cannibalizing what would otherwise have been steady old-model demand.