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23-Ind-A4 Production Management: December 2019

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

  1. Question 1 Just-in-Time Production
  2. Question 2 Lean Terminology — Yo-i-don/Andon, Poka-yoke, SMED, TPM
  3. Question 3 Process Chart for a Custom Computer Manufacturer
  4. Question 4 Seasonal Lawn-Game Production — Dynamic Lot Sizing
  5. Question 5 New-Toy Sales Forecast and Order Quantities
  6. Question 6 Machinery-Upgrade Downtime — CPM Network
  7. Question 7 Circuit-Board Job Scheduling and Minimum Workforce

Start with Question 1 →

National Technical Examinations — December 2019 — 17-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 per 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 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: Liker, The Toyota Way, and Shingo, A Revolution in Manufacturing: The SMED System — JIT, 5S/andon/poka-yoke/SMED/TPM and lean root-cause analysis; Niebel & Freivalds, Methods, Standards, and Work Design — process charting and methods analysis; Nahmias & Olsen, Production and Operations Analysis (7th ed., Waveland/McGraw-Hill) — forecasting, lot sizing (Wagner–Whitin) and aggregate planning; Hillier & Lieberman, Introduction to Operations Research (11th ed.) — project scheduling (CPM/PERT); Pinedo, Scheduling: Theory, Algorithms, and Systems (5th ed.) — parallel-machine scheduling and days-off workforce scheduling.