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23-Ind-A4 Production Management · May 2015

Question 6 of 7: Construction Project — CPM Network and an Accident-Driven Duration Change

Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)

Notes on this paper

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 6: Construction Project — CPM Network and an Accident-Driven Duration Change (20 marks)

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.

Check — part (c)
In part (c) the delay-causing event is an accident investigation, and D's new duration is stated as 15 days.

Given. Ten activities with precedence and durations (days), late completion penalty $\$5,000$/day.

ActivityPrecedesDuration (days)
AB, C, D15
BE12
CE, G6
DH5
EF3
FI8
GF, J8
HJ9
IEND7
JEND14

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.

A15 dB12 dC6 dD5 dE3 dG8 dH9 dF8 dJ14 dI7 dCritical path (45 d)Arrows = precedence. Boxes not to scale; duration in working days.
Figure 1 — Activity-on-node project network (original durations). Red boxes/arrows mark the original critical path A→B→E→F→I (45 days); part (c) shows this path shifting to A→D→H→J once D lengthens to 15 days.

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.

  1. Forward pass (earliest times). Starting A at day 0 and working through the precedence chain ($ES_i=\max$ of predecessors' $EF$; $EF_i=ES_i+d_i$): $$EF_A=15,\ EF_B=27,\ EF_C=21,\ EF_D=20,\ EF_E=\max(27,21)+3=30,\ EF_G=21+8=29,$$ $$EF_H=20+9=29,\ EF_F=\max(30,29)+8=38,\ EF_J=\max(29,29)+14=43,\ EF_I=38+7=45.$$ The project duration is the later of the two end activities: $\boxed{T=\max(EF_I,EF_J)=\max(45,43)=45\ \text{days}}$.
  2. Backward pass and slack (part b). Setting $LF_I=LF_J=45$ (project length) and working backward ($LF_i=\min$ of successors' $LS$; $LS_i=LF_i-d_i$; slack $=LS_i-ES_i$) gives every activity's latest start and slack, tabulated below. Zero-slack activities are critical.
  3. Critical path (part a). The chain of zero-slack activities is $\boxed{A\to B\to E\to F\to I}$, with $15+12+3+8+7=45$ days, matching the project duration — this is the path shown in red in Figure 1. All other activities (C, D, G, H, J) carry positive slack (1–2 days) and are not critical — note D itself has only 2 days of slack.
  4. Effect of D → 15 days, accident investigation (part c). D is not on the original critical path (2 days of slack), so the first 2 days of its 10-day increase (5→15) are absorbed harmlessly, but the remaining 8 days push its successor chain past the old critical path. Re-running the forward pass with $d_D=15$: $EF_D=15+15=30\Rightarrow EF_H=30+9=39\Rightarrow EF_J=\max(29,39)+14=53$, while the F/I side is unaffected ($EF_I=45$ still, since D does not feed F). The new project duration is $$\boxed{T'=\max(45,53)=53\ \text{days}},$$ a delay of $53-45=\boxed{8\ \text{days}}$ versus the original plan (D's duration increases from 5 to 15 days, a 10-day increase, of which 2 days of slack absorb part, giving a net delay of $10-2=8$ days, confirmed by the recomputation above). The critical path shifts entirely to $A\to D\to H\to J$ (new duration $15+15+9+14=53$ days). At $\$5{,}000$/day, an unmitigated 8-day delay costs $\boxed{8\times\$5{,}000=\$40{,}000}$ in late-completion penalties.
ActivityESEFLSLFSlack
A0150150 (critical)
B152715270 (critical)
C152116221
D152017222
E273027300 (critical)
G212922301
H202922312
F303830380 (critical)
J294331452
I384538450 (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 (an accident investigation 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 — an accident investigation often cordons a specific zone or piece of equipment rather than the entire site), identify which portions of H do not depend on the still-restricted scope and begin them as soon as they are 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. Since G and C both still carry slack under the new schedule (1 day and 1 day respectively, recomputed the same way as Step 2), confirm they are not put at further risk by any resourcing pulled toward the D–H–J recovery effort, so a second problem does not open a second critical path while the first is being managed.