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23-Ind-A4 Production Management: May 2017

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

  1. Question 1 5S and the Five Whys
  2. Question 2 Variability as a Cause of Production Inefficiency
  3. Question 3 Why an Optimal Schedule Is Not Always Implementable
  4. Question 4 EOQ for Plastic Fasteners
  5. Question 5 Li-Ion Battery Production LP Across Three Plants
  6. Question 6 Tablet-Computer Sales Forecast (Naive, Exponential Smoothing)
  7. Question 7 Construction Project — CPM Network and an Accident-Driven Duration Change
  8. Question 8 Rebalancing 14 Jobs Across Three Surface-Mount Machines

Start with Question 1 →

National Technical Examinations — May 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 5 of 8. 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) and aggregate planning; Sipper & Bulfin, Production: Planning, Control, and Integration — production scheduling 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, makespan and tardiness; Hopp & Spearman, Factory Physics (3rd ed.) — variability, buffering, and production scheduling; Liker, The Toyota Way, and the Toyota Production System literature — 5S, Five Whys, and lean root-cause analysis.