23-Ind-A4 Production Management · Undated paper
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
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.
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 | 30 |
| April | — | Missing |
| May | 3 | 740 |
| June | 4 | 1,000 |
| July | 5 | 950 |
| August | 6 | 1,400 |
| September | 7 | 1,800 |
Find. October AND November sales forecasts by (a) naive and exponential smoothing, with an appropriately chosen smoothing constant; (b) the best-justified forecast and how it can be improved.
Approach. Treat the missing April observation as genuinely absent rather than interpolated (inventing a value would corrupt the smoothing recursion); run naive and exponential smoothing over the seven known observations in sequence, skipping April entirely rather than bridging it; check the smoothing constant $\alpha$ by a grid search over $0<\alpha\le1$ minimizing in-sample squared one-step error (the standard way to “choose an appropriate parameter”; note that $\alpha=1$ is the naïve method); and, since neither method carries a trend term, roll each method's one-step-ahead forecast forward unchanged for the second (November) step, since no new actual will exist for October at the time the November forecast is made.
| Method | October forecast | November forecast |
|---|---|---|
| Naïve | 1,800 units | 1,800 units |
| Exponential smoothing ($\alpha=0.8$) | ≈1,702 units | ≈1,702 units |
| Exponential smoothing ($\alpha=0.3$, conventional, for comparison) | ≈1,184 units | — |
| Recommended forecast | 1,800 units (naïve; lowest SSE and MAD, equal to smoothing with the SSE-optimal $\alpha=1$), both months | |
Improving the forecast. Recover the true April figure rather than dropping the observation, so the smoothing recursion is not forced to skip over a gap in the series; extend the history beyond eight months to confirm whether the June–September run is a genuine sustained uptrend (plausible ahead of a fourth-quarter shopping season) or a short-term rebound from March's anomalous dip that will not continue into October and November; investigate what actually caused the March figure (a stockout, a data-entry error, a one-off promotion cannibalizing a competitor month) before treating it as ordinary noise in future forecasts; and, specifically because neither method here carries a trend component, fit a trend-aware model (e.g. double exponential smoothing / Holt's method, or a simple regression against the month index) as a cross-check, since a genuine uptrend would make both naïve and simple exponential smoothing systematically understate October and November once the trend continues past September.