23-Ind-A4 Production Management · December 2017
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
National Technical Examinations — December 2017 — 98-Ind-A4 Production Management. Three-hour, closed-book exam; Casio or Sharp approved calculators only. Format: eight questions, each worth 20 marks (sub-part weights 10/10 as tabulated on the front-page marking scheme); only the first five questions appearing in the answer book are marked, so candidates effectively choose 2 of 3 in Section A and 3 of 5 in Section B. All eight 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/EPQ) and aggregate planning; Sipper & Bulfin, Production: Planning, Control, and Integration — production scheduling, JIT/kanban and shop-floor implementation gaps; 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 and days-off workforce scheduling; Hopp & Spearman, Factory Physics (3rd ed.) — variability, buffering, and production scheduling; Liker, The Toyota Way, and Shingo, A Revolution in Manufacturing: The SMED System — 5S, Five Whys, SMED and lean root-cause analysis.
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.
| Month | Index $t$ | Sales |
|---|---|---|
| February | 1 | 450 |
| March | 2 | 300 |
| April | 3 | Missing |
| May | 4 | 740 |
| June | 5 | 1,000 |
| July | 6 | 950 |
| August | 7 | 1,000 |
| September | 8 | 800 |
Find. October sales forecasts by (a) naïve and exponential smoothing, with an appropriately chosen smoothing constant; (b) the best-justified forecast and how to improve it.
Approach. Treat the missing April observation as genuinely absent rather than interpolated (inventing a value would corrupt every method that touches it): for exponential smoothing, initialize the forecast at the first known observation and carry the forecast forward unchanged across the missing month (no update is possible without an actual to compare against), then apply the standard recursion through the remaining known months.
| Method | MAD | SSE | October forecast |
|---|---|---|---|
| ES, $\alpha=0.3$ | 258.8 | 533,561 | 813.9 |
| ES, $\alpha=0.5$ | 232.8 | 416,725 | 866.1 |
| ES, $\alpha=0.9$ | 190.1 | 335,430 | 819.5 |
| Naïve ($=$ ES with $\alpha=1$) | 191.7 | 328,700 | 800 |
| Method | October forecast |
|---|---|
| Naïve | 800 units |
| Exponential smoothing ($\alpha=0.3$) | 813.9 ≈ 814 units |
| Exponential smoothing ($\alpha=0.9$, lowest MAD) | 819.5 ≈ 820 units |
| Recommended forecast | 800 units (naïve; lowest SSE, tied with $\alpha=0.9$ on MAD) |
Improving the forecast. Recover the true April figure rather than dropping the observation, so exponential smoothing is not forced to carry an un-updated forecast across a gap in the series; extend the history beyond eight months to distinguish a genuine trend or seasonal pattern from short-term volatility; re-fit $\alpha$ as more months arrive (once the ~1,000-unit plateau is established a lower, smoother $\alpha$ may win); track old- and new-model sales separately, since the combined series mixes a declining product with a growing one; and consider a trend-adjusted method (Holt) if growth resumes.