22-Mec-B4 Integrated Manufacturing Systems · May 2013
Question 3 of 6: Categories of Forecasting Technique, and Method Selection from Data
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
Notes on this paper
Paper format. National Exams, May 2013 — 07-Mec-B4,
Integrated Manufacturing Systems. Three hours; open book; any
non-communicating calculator permitted. Six 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 six 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, scheduling, location and quality material;
Groover, Automation, Production Systems, and Computer-Integrated
Manufacturing (Pearson); Montgomery, Introduction to Statistical
Quality Control (Wiley) for the Shewhart chart constants and operating
characteristics; Nahmias & Olsen, Production and Operations Analysis
(Waveland) for the forecasting derivations; Kalpakjian & Schmid,
Manufacturing Engineering and Technology (Pearson) for the process
context. Canadian practice for the quality half of the paper is
CSA Q / ISO 9001 and the ISO 7870 series on control charts,
which adopt the same constants tabulated below.
Question 3: Categories of Forecasting Technique, and Method Selection from Data (20 marks)
Part (a) — the categories of forecasting technique.
Forecasting methods fall into four families, and they differ in one respect
above all: what they take as evidence.
Qualitative or judgmental techniques take expert opinion as
evidence. Market research, panel consensus, the Delphi method, historical
analogy and the grass-roots build-up of a sales force's own estimates all belong
here. They are subjective and cannot be error-bounded statistically, but they
are the only family available when there is no history to analyse — a new
product, a new market, a technology substitution — and they are the only
family that can anticipate a discontinuity, because a discontinuity is by
construction absent from the data.
Time-series analysis takes the past of the series itself as
evidence, and assumes the future is a continuation of the past. Moving averages,
weighted moving averages, exponential smoothing in its simple, trend-adjusted
and seasonal (Winters) forms, decomposition, and Box-Jenkins ARIMA models are
the members. They are cheap, fully automatable over thousands of stock-keeping
units, and accurate over the short to medium term; they cannot explain
why demand moves, and they cannot see a turning point until after it
has happened.
Causal or associative techniques take other, external variables as
evidence, on the argument that demand is driven by identifiable factors. Simple
and multiple regression, econometric systems, leading-indicator models and
input-output models sit here. They can forecast a turning point, because the
driver turns before the demand does; the price is that the drivers must
themselves be known or forecastable, and that a relationship estimated over one
regime need not hold in the next.
Simulation takes an explicit model of the system's behaviour as
evidence: the demand process, the customers, the competitors, the capacity and
the policies are represented dynamically and run forward, usually stochastically.
It answers questions the other three cannot — what happens under a
capacity constraint, or under a competitor's response, or across a distribution
of outcomes rather than at a point — but it is expensive to build and only
as good as the structural assumptions inside it.
The practical differences follow from the evidence each uses: cost and effort
rise steeply from time series to simulation; data requirements rise the same way;
the useful horizon lengthens from time series (short) to causal and qualitative
(long); and only the causal and qualitative families can call a turning point.
A working operations forecasting system usually runs time-series models for the
routine short-horizon item-level forecasts and overlays judgment and causal
models at the aggregate and long-horizon end.
Given. Twenty-four consecutive monthly demand observations
for a component part, in thousands of units, covering two full years.
Monthly demand for component parts (thousands)
Month
1
2
3
4
5
6
7
8
9
10
11
12
First year
10
8
7
4
5
9
12
19
25
29
19
15
Second year
12
11
11
8
10
17
22
27
32
33
21
19
Find. A plot of the series, a diagnosis of which components
of demand it contains, and a reasoned recommendation of the forecasting method
to use — demonstrated by fitting that method and projecting a third year.
Approach. Plot the data first and read the components off
the plot; then confirm each component numerically — the trend from the two
annual totals, the season from ratio-to-average indices — and let the
diagnosis select the method rather than the other way round.
Sub-part (a) — plot the observations and read them.
The figure above plots all 24 months on one time axis. Three features are
immediate. The series is strongly and regularly seasonal, falling to a minimum
in month 4 and rising to a maximum in month 10 in both years,
with the same shape repeated. The second year lies above the first at almost
every month, so there is an upward trend. And the swing is very large relative
to the mean, which rules out treating the season as noise.
Confirm the trend from the annual totals. Summing each
year,
$$\sum_{\text{year 1}} D = 162, \qquad \sum_{\text{year 2}} D = 223$$
in thousands, so the monthly averages are $162/12 = 13.50$ and
$223/12 = 18.58$ thousand and the year-on-year growth is
$$\frac{223}{162} - 1 = \boxed{0.377 \equiv 37.7\ \text{per cent}}$$
A trend of this size cannot be left to a smoothing model without trend
correction, which would lag the series by roughly $(1-\alpha)/\alpha$ periods
permanently.
Confirm the season with ratio-to-average indices. Dividing
each observation by its own year's monthly average removes the level and the
trend between years, leaving the seasonal factor plus noise; averaging the two
years' ratios for each month gives the index
$$S_m = \tfrac{1}{2}\left(\frac{D_{1,m}}{\bar{D}_1} + \frac{D_{2,m}}{\bar{D}_2}\right)$$
which yields, for months 1 to 12: 0.693, 0.592, 0.555, 0.363, 0.454, 0.791,
1.036, 1.430, 1.787, 1.962, 1.269 and 1.067. They sum to 12.000 as they must, so
no normalisation is needed.
Quantify how strong the season is. The extremes are
$$\boxed{S_{\max} = S_{10} = 1.962, \qquad S_{\min} = S_{4} = 0.363,
\qquad \frac{S_{\max}}{S_{\min}} = 5.40}$$
October demand is more than five times April demand at the same trend level. Any
method that does not carry seasonal indices — a simple moving average,
single exponential smoothing, a plain regression on time — will be wrong
by a factor of two in both directions every year.
Deseasonalise and fit the trend. Dividing each observation
by its month's index and regressing the result on $t = 1,\dots,24$ by least
squares gives
$$\boxed{\hat{D}_t = 11.41 + 0.3775\,t \quad \text{(thousands, deseasonalised)}}$$
with a coefficient of determination of only $R^2 = 0.55$. That modest fit is
worth reporting honestly rather than hiding: with just two seasonal cycles the
ratio-to-yearly-average indices are estimated from two observations per month
and absorb part of the trend, so a good deal of month-to-month scatter survives
deseasonalisation. The direction and slope of the trend are
nonetheless solid, being anchored on two full-year totals rather than on the
noisy monthly values.
Sub-part (b) — recommend the method. The diagnosis is
a series with a clear multiplicative season, a firm upward trend and no visible
cycle, observed monthly and needed monthly. That is exactly the specification of
Winters' triple exponential smoothing, which carries three
updated states — level, trend and a vector of twelve seasonal indices
— with smoothing constants alpha, beta and gamma, and which re-estimates
all three every month as new demand arrives. Initialise it with the level and
trend from the regression above and the seasonal indices just computed, then let
it adapt. The classical decomposition model just fitted (trend
line multiplied by seasonal index) is the correct simpler alternative and the
right way to produce the initial estimates, but it does not update itself; use
it for the annual plan and Winters for the rolling monthly forecast. A tracking
signal should be run alongside, as in Question 1, because the trend estimate
rests on only two years.
Demonstrate the recommendation on a third year. Applying
$\hat{D}_t \times S_m$ for $t = 25$ to 36 gives, in thousands: 14.45, 12.57,
11.99, 7.99, 10.15, 17.98, 23.95, 33.59, 42.65, 47.56, 31.24 and 26.67. The
third-year total is
$$\boxed{\sum \hat{D} = 280.8\ \text{thousand}, \quad \text{26 per cent above year 2}}$$
and the month-10 peak of 47.6 thousand is the number that sizes the capacity and
the inventory build.
Final results — Question 3
Quantity
Value
Categories of forecasting technique
qualitative / time-series / causal / simulation
Year-1 and year-2 totals
162 and 223 thousand
Year-on-year growth
37.7 per cent
Seasonal peak / trough index
1.962 (month 10) / 0.363 (month 4), ratio 5.40
Deseasonalised trend line
11.41 + 0.3775 t thousand per month
Recommended method
Winters' triple exponential smoothing, initialised from the decomposition above