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23-Ind-A4 Production Management: Undated paper

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

  1. Question 1 The Five Whys and Poka-Yoke
  2. Question 2 The Seven Zeros
  3. Question 3 SMED and Kanban in Just-in-Time Production
  4. Question 4 WX93 Production Line — Setup/Inventory Trade-off (EPQ)
  5. Question 5 Li-Ion Battery Production LP Across Three Plants
  6. Question 6 Cell-Phone Sales Forecast — Naive and 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, and Minimum Workforce

Start with Question 1 →

National Examinations — May 2019 — 17-Ind-A4 Production Management. Three-hour, closed-book exam; Casio or Sharp approved calculators only. Format: eight questions, each worth 20 marks (10/10 sub-part split 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 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, Shingo, A Revolution in Manufacturing: The SMED System, and Shingo, Zero Quality Control: Source Inspection and the Poka-Yoke System — 5S, Five Whys, poka-yoke, SMED and lean root-cause analysis; R.W. Hall, Zero Inventories — the “seven zeros” JIT framework.