23-Ind-A4 Production Management · May 2018
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
National Technical Examinations — May 2018 — 17-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); candidates do two questions from Section A and three from Section B, and only the first five questions appearing in the answer book are marked. 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 moving average, with an appropriately chosen window length; (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 any window that spans it): pick a moving-average window that uses only consecutive KNOWN months, so the gap need not be bridged at all.
| Method | October forecast |
|---|---|
| Naïve | 800 units |
| 4-period moving average (Jun–Sep) | 937.5 ≈ 938 units |
| Recommended forecast | ≈938 units (4-period moving average) |
Improving the forecast. Recover the true April figure rather than dropping the observation, so the moving-average window is not forced to skip over a gap in the series; extend the history beyond eight months to distinguish a genuine trend or seasonal pattern from short-term volatility; and compare a small grid of window lengths ($k=2,3,4$) against in-sample forecast error (MAD or SSE) rather than fixing $k=4$ by judgment alone, since the retailer's own data can indicate whether a shorter (more responsive) or longer (smoother) window fits better.