23-Ind-A4 Production Management · December 2015
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
National Technical Examinations — December 2015 — 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 15 days because of the accident investigation, plus 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. Then re-run the forward pass with D's new 15-day duration to see whether the critical path itself relocates.
| 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→15d) | 45 d / 53 d (+8 d, +$\$40,000$ penalty risk) | ||||
Recovery strategies (part c, continued). Because the delay is driven by an accident investigation at the subcontractor (a regulatory/safety hold, not simply a resourcing shortfall like a strike), the available strategies are shaped by what can and cannot be rushed: (1) Compress the new critical path downstream of D (A–D–H–J). The investigation itself typically cannot be shortened by throwing money at it (it has to run its course for safety and liability reasons), but once D is released, H and J can be crashed — authorize overtime or a second crew on H and J to buy back days at a 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 H into D's tail end where safe. If the investigation only restricts specific work areas or activities (common in practice), identify which portions of H do not depend on the still-restricted scope and begin them as soon as permitted, rather than waiting for D's full 15 days to elapse; this must be coordinated with whoever is running the investigation to avoid compromising it. (3) Reduce exposure on the non-critical branch as a hedge. Rerunning the backward pass with $T'=53$ gives C and G 9 days of slack each and B, E, F and I 8 days each, so crews can safely be borrowed from those activities for the D–H–J recovery. The limit is the old path A–B–E–F–I (45 days): once H and J have been crashed by a combined 8 days, both paths are critical, and any further crashing has to shorten both paths.