22-Mec-B4 Integrated Manufacturing Systems · December 2013
Question 7 of 7: Forecasting the Demand for a Product
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
Notes on this paper
Paper format. National Exams, December 2013 —
07-Mec-B4, Integrated Manufacturing Systems. Three hours; open book;
any non-communicating calculator permitted. Seven questions are printed and any
five constitute a complete paper, each of equal value (20 marks); only the
first five appearing in the answer book are marked. Several questions call for
an essay answer, where clarity and organisation carry marks. Note 1 of the
paper invites the candidate to state any assumption made where a question is
open to interpretation — that licence is used twice below and each use is
flagged. All seven questions are worked here, so the set can
serve as a complete study resource.
Reference texts. Chase, Jacobs & Aquilano,
Operations and Supply Chain Management (McGraw-Hill) — the source
of this paper's forecasting, line-balancing, cost and quality material;
Groover, Automation, Production Systems, and Computer-Integrated
Manufacturing (Pearson) for process planning, cellular manufacturing,
flexible manufacturing systems and plant networks; Montgomery,
Introduction to Statistical Quality Control (Wiley) for the Shewhart
chart constants and the normal-tail scrap calculations; Nahmias & Olsen,
Production and Operations Analysis (Waveland) for the forecasting
derivations; Kalpakjian & Schmid, Manufacturing Engineering and
Technology (Pearson) for the ring-rolling and tolerance context. Canadian
practice for the quality half of the paper follows CSA / ISO 9001 and
the ISO 7870 series on control charts, which tabulate the same constants
used below.
Question 7: Forecasting the Demand for a Product (20 marks)
Given. Five months of demand history for a single product,
together with a smoothing constant, a starting forecast and a set of moving-average
weights.
Given data
Month
Jan
Feb
Mar
Apr
May
Period t
1
2
3
4
5
Demand (units)
80
100
60
80
90
Smoothing constant α = 0.20 with an assumed January forecast of 70 units;
weighted-moving-average weights 0.30, 0.25, 0.20, 0.15 and 0.10 applied from the
most recent month backwards.
Find. June and July forecasts by four-month moving average;
the exponentially smoothed forecasts for February through June; June, July and
August forecasts by least-squares regression; and June's forecast by weighted
moving average.
Approach. Apply the four standard time-series methods in
turn, each to the same history, and compare what they say — the point of
the question is as much the comparison as the arithmetic.
Figure 7.1 — Demand history with two of the forecasts
overlaid. The exponentially smoothed series climbs steadily from its low
starting value of 70 towards the level of the data, while the least-squares fit
is exactly horizontal at 82 units because the positive and negative deviations
in the five months cancel.
Part (a) — four-month moving average for June. A
four-month moving average forecasts the next period as the mean of the four most
recent actuals:
$$F_{t+1}=\frac{1}{4}\sum_{i=t-3}^{t}A_i$$
For June the four most recent months are February through May, so
$$F_{\mathrm{Jun}}=\frac{100+60+80+90}{4}=\frac{330}{4}
\qquad\Rightarrow\qquad \boxed{\ F_{\mathrm{Jun}}=82.5\ \text{units}\ }$$
January is dropped from the window entirely; a moving average has no memory
beyond its span.
Roll the window forward for July. With June's actual demand
known to be 100, the window becomes March through June:
$$F_{\mathrm{Jul}}=\frac{60+80+90+100}{4}=\frac{330}{4}
\qquad\Rightarrow\qquad \boxed{\ F_{\mathrm{Jul}}=82.5\ \text{units}\ }$$
The forecast is unchanged, which is a useful coincidence to notice rather than
an error: February (100) left the window and June (100) entered it, so the sum
of the window is identical.
Part (b) — set up the exponential smoothing recursion.
Single exponential smoothing updates the previous forecast by a fraction
α of the previous error:
$$F_{t+1}=F_t+\alpha\,(A_t-F_t)=\alpha A_t+(1-\alpha)F_t$$
with $\alpha=0.20$ and the given starting value $F_{\mathrm{Jan}}=70$.
Advance the recursion month by month. Each line uses only
the previous forecast and the actual just observed:
$$F_{\mathrm{Feb}}=70+0.20(80-70)=70+2.00=72.00$$
$$F_{\mathrm{Mar}}=72.00+0.20(100-72.00)=72.00+5.60=77.60$$
$$F_{\mathrm{Apr}}=77.60+0.20(60-77.60)=77.60-3.52=74.08$$
$$F_{\mathrm{May}}=74.08+0.20(80-74.08)=74.08+1.18=75.26$$
$$F_{\mathrm{Jun}}=75.26+0.20(90-75.26)=75.26+2.95=78.21$$
so the smoothed forecasts through June are
$$\boxed{\ 72.00,\ 77.60,\ 74.08,\ 75.26,\ 78.21\ \text{units for Feb, Mar, Apr, May, Jun}\ }$$
The series is still climbing towards the data because the assumed January
forecast of 70 was well below the true level and a smoothing constant of 0.20
corrects only a fifth of the remaining gap each month.
Part (c) — fit a least-squares trend line. Numbering
the months $t=1$ (January) to $t=5$ (May) and fitting
$F_t=a+bt$, the slope and intercept are
$$b=\frac{n\sum tA_t-\left(\sum t\right)\left(\sum A_t\right)}{n\sum t^2-\left(\sum t\right)^2},
\qquad a=\bar{A}-b\,\bar{t}$$
With $n=5$, $\sum t=15$, $\sum A_t=410$, $\sum t^2=55$ and
$\sum tA_t=80+200+180+320+450=1{,}230$,
$$b=\frac{5(1{,}230)-15(410)}{5(55)-15^2}=\frac{6{,}150-6{,}150}{275-225}=\frac{0}{50}=0$$
$$a=\frac{410}{5}-0\times 3=82$$
Project the fitted line forward. Since the slope is exactly
zero, the regression line is the horizontal line
$F_t=82$, and every future period takes the same value:
$$\boxed{\ F_{\mathrm{Jun}}=F_{\mathrm{Jul}}=F_{\mathrm{Aug}}=82\ \text{units}\ }$$
The zero slope is genuine, not a rounding artefact: the deviations of the five
demands from their mean of 82 are $-2$, $+18$, $-22$, $-2$ and $+8$, and weighted
by their period offsets $-2,-1,0,+1,+2$ they sum to
$(-2)(-2)+(18)(-1)+(-22)(0)+(-2)(1)+(8)(2)=4-18+0-2+16=0$. There is no linear
trend in this history at all; the apparent rise from March onwards is exactly
cancelled by the fall from February.
Part (d) — apply the weighted moving average. The five
weights are applied to the five months with the largest weight on the most recent
data:
$$F_{\mathrm{Jun}}=\sum_{i=1}^{5}w_iA_{t+1-i}
=0.30(90)+0.25(80)+0.20(60)+0.15(100)+0.10(80)$$
$$=27.0+20.0+12.0+15.0+8.0
\qquad\Rightarrow\qquad \boxed{\ F_{\mathrm{Jun}}=82.0\ \text{units}\ }$$
The weights sum to 1.00, as they must if the forecast is to be unbiased when
demand is level.
Compare the four answers. The methods give 82.5, 78.21, 82.0
and 82.0 units for June — a spread of only about four units, or five
per cent. Three of the four agree closely because the series has no trend
and no seasonality, so any method that averages it returns something near the
mean of 82. Exponential smoothing is the outlier not because the method is worse
but because it is still recovering from the low assumed starting value; given
several more months it would converge on the same level. For a series like this
one, the weighted moving average or the simple average is the sensible choice,
and the practical conclusion is to plan June around 82 units while watching the
forecast error, since the month-to-month swings of ±20 units dwarf the
differences between the methods.
Final results
Part
Method
Forecast
(a)
Four-month moving average, June
82.5 units
(a)
Four-month moving average, July (June actual = 100)