23-Ind-A4 Production Management · May 2015
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
National Technical Examinations — May 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. Seven known months of actual sales, February through September, with April's figure lost when the sales report was misplaced; no other demand drivers (promotions, launch dates, pricing) are supplied.
| Month | Sales (units) |
|---|---|
| February | 450 |
| March | 300 |
| April | missing |
| May | 740 |
| June | 1,000 |
| July | 950 |
| August | 1,000 |
| 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 (part a). Handle the missing April value first (it must not silently become a zero or be guessed as a "typical" month), then fit a linear trend using only the seven genuine observations and test it with $R^2$ before trusting it, comparing against a naive and a short moving-average forecast to pick the best-justified method.
| Method | October forecast |
|---|---|
| Naive (last value) | 800 units |
| 3-month moving average | 916.7 units |
| Linear trend ($R^2\approx0.64$, selected) | ~1,119 units |
(b) Discussion and improvement. The trend forecast is the best-supported of the three candidates, but it still rests on only seven data points and extrapolates beyond the highest month actually observed (1,000 units) — a real risk if the summer plateau (June–August) was driven by a one-time promotion or a new-model launch rather than a sustained ramp, in which case October could just as easily revert toward the 800–950 range. The lost April figure is itself a process problem, not just a forecasting inconvenience: a sales-report-tracking gap that recurs will keep degrading every future forecast's data quality. To improve the forecast I would: (1) fix the reporting process (a shared, backed-up sales log rather than a single misplaceable report) so no future month goes missing; (2) collect at least 24 months of history to test for a genuine annual seasonal pattern (back-to-school and holiday-season cycles are common for consumer electronics, and this series' summer climb could be exactly that); (3) bring in causal information the retailer already has — any manufacturer launch calendar, planned promotions, and competitor pricing — since a launch-driven plateau is a known event, not random noise, and should be modelled explicitly; and (4) track forecast error (MAD or MSE) month over month once more history exists, and switch to exponential smoothing with a moderate smoothing constant so the model adapts to a genuine trend shift without over-reacting to any single month.