PRODUCTION AND OPERATION MANAGEMENT Part 2 PDF
PRODUCTION AND OPERATION MANAGEMENT Part 2 PDF
PRODUCTION AND OPERATION MANAGEMENT Part 2 PDF
Quantitative Methods
Seasonality: Data exhibit upward and downward swings in a short to intermediate time frame
(most notably during a year).
Cycles: Data exhibit upward and downward swings in over a very long time frame.
Random variations: Erratic and unpredictable variation in the data over time with no
discernable pattern.
ILLUSTRATION OF TIME SERIES DECOMPOSITION
Hypothetical Pattern of Historical Demand
Demand
Time
Time
SEASONAL COMPONENT IN HISTORICAL DEMAND
Demand
Demand
Demand
Time
DATA SET TO DEMONSTRATE FORECASTING METHODS
The following data set represents a set of hypothetical demands that have occurred over several
consecutive years. The data have been collected on a quarterly basis, and these quarterly values
have been amalgamated into yearly totals.
For various illustrations that follow, we may make slightly different assumptions about starting
points to get the process started for different models. In most cases we will assume that each year
a forecast has been made for the subsequent year. Then, after a year has transpired we will have
observed what the actual demand turned out to be (and we will surely see differences between
what we had forecasted and what actually occurred, for, after all, the forecasts are merely
educated guesses).
Finally, to keep the numbers at a manageable size, several zeros have been dropped off the
numbers (i.e., these numbers represent demands in thousands of units).
Naïve method: The forecast for next period (period t+1) will be equal to this period's actual
demand (At).
In this illustration we assume that each year (beginning with year 2) we made a forecast, then
waited to see what demand unfolded during the year. We then made a forecast for the subsequent
year, and so on right through to the forecast for year 7.
Actual
Demand Forecast
Year (At) (Ft) Notes
There was no prior demand data on
1 310 --
which to base a forecast for period 1
3 395 365
4 415 395
5 450 415
6 465 450
7 465
Mean (simple average) method: The forecast for next period (period t+1) will be equal to the
average of all past historical demands.
In this illustration we assume that a simple average method is being used. We will also assume
that, in the absence of data at startup, we made a guess for the year 1 forecast (300). At the end
of year 1 we could start using this forecasting method. In this illustration we assume that each
year (beginning with year 2) we made a forecast, then waited to see what demand unfolded
during the year. We then made a forecast for the subsequent year, and so on right through to the
forecast for year 7.
Actual
Demand Forecast
Year (At) (Ft) Notes
This forecast was a guess at the
1 310 300
beginning.
From this point forward, these forecasts
2 365 310.000 were made on a year-by-year basis
using a simple average approach.
3 395 337.500
4 415 356.667
5 450 371.250
6 465 387.000
7 400.000
Exponential smoothing method: The new forecast for next period (period t) will be calculated
as follows:
New forecast = Last period’s forecast + (Last period’s actual demand – Last period’s forecast)
(this box contains all you need to know to apply exponential smoothing)
Ft = Ft-1 + (At-1 – Ft-1) (equation 1)
The exponential smoothing method only requires that you dig up two pieces of data to apply it
(the most recent actual demand and the most recent forecast).
An attractive feature of this method is that forecasts made with this model will include a portion
of every piece of historical demand. Furthermore, there will be different weights placed on these
historical demand values, with older data receiving lower weights. At first glance this may not be
obvious, however, this property is illustrated on the following page.
DEMONSTRATION: EXPONENTIAL SMOOTHING INCLUDES ALL PAST DATA
Note: the mathematical manipulations in this box are not something you would ever have to do
when applying exponential smoothing. All you need to use is equation 1 on the previous page. This
demonstration is to convince the skeptics that when using equation 1, all historical data will be
included in the forecast, and the older the data, the lower the weight applied to that data.
To make a forecast for next period, we would use the user friendly alternate equation 1:
Ft = At-1 + (1-)Ft-1 (equation 1)
When we made the forecast for the current period (Ft-1), it was made in the following fashion:
Ft-1 = At-2 + (1-)Ft-2 (equation 2)
If we substitute equation 2 into equation 1 we get the following:
Ft = At-1 + (1-)[At-2 + (1-)Ft-2]
Which can be cleaned up to the following:
Ft = At-1 + (1-)At-2 + (1-)2Ft-2 (equation 3)
We could continue to play that game by recognizing that Ft-2 = At-3 + (1-)Ft-3 (equation 4)
If we substitute equation 4 into equation 3 we get the following:
Ft = At-1 + (1-)At-2 + (1-)2[At-3 + (1-)Ft-3]
Which can be cleaned up to the following:
Ft = At-1 + (1-)At-2 + (1-)2At-3 + (1-)3Ft-3
If you keep playing that game, you should recognize that
Ft = At-1 + (1-)At-2 + (1-)2At-3 + (1-)3At-4 + (1-)4At-5 + (1-)5At-6 ……….
As you raise those decimal weights to higher and higher powers, the values get smaller and smaller.
EXPONENTIAL SMOOTHING ILLUSTRATION
In this illustration we assume that, in the absence of data at startup, we made a guess for the year
1 forecast (300). Then, for each subsequent year (beginning with year 2) we made a forecast
using the exponential smoothing model. After the forecast was made, we waited to see what
demand unfolded during the year. We then made a forecast for the subsequent year, and so on
right through to the forecast for year 7.
This set of forecasts was made using an value of .1
Actual
Demand Forecast
Year (A) (F) Notes
This was a guess, since there was no
1 310 300
prior demand data.
From this point forward, these forecasts
2 365 301 were made on a year-by-year basis
using exponential smoothing with =.1
3 395 307.4
4 415 316.16
5 450 326.044
6 465 338.4396
7 351.09564
A SECOND EXPONENTIAL SMOOTHING ILLUSTRATION
In this illustration we assume that, in the absence of data at startup, we made a guess for the year
1 forecast (300). Then, for each subsequent year (beginning with year 2) we made a forecast
using the exponential smoothing model. After the forecast was made, we waited to see what
demand unfolded during the year. We then made a forecast for the subsequent year, and so on
right through to the forecast for year 7.
This set of forecasts was made using an value of .2
Actual
Demand Forecast
Year (A) (F) Notes
This was a guess, since there was no
1 310 300
prior demand data.
From this point forward, these forecasts
2 365 302 were made on a year-by-year basis
using exponential smoothing with =.2
3 395 314.6
4 415 330.68
5 450 347.544
6 465 368.0352
7 387.42816
A THIRD EXPONENTIAL SMOOTHING ILLUSTRATION
In this illustration we assume that, in the absence of data at startup, we made a guess for the year
1 forecast (300). Then, for each subsequent year (beginning with year 2) we made a forecast
using the exponential smoothing model. After the forecast was made, we waited to see what
demand unfolded during the year. We then made a forecast for the subsequent year, and so on
right through to the forecast for year 7.
3 395 328.4
4 415 355.04
5 450 379.024
6 465 407.4144
7 430.44864
TREND PROJECTION
Trend projection method: This method is a version of the linear regression technique. It
attempts to draw a straight line through the historical data points in a fashion that comes as close
to the points as possible. (Technically, the approach attempts to reduce the vertical deviations of
the points from the trend line, and does this by minimizing the squared values of the deviations
of the points from the line). Ultimately, the statistical formulas compute a slope for the trend line
(b) and the point where the line crosses the y-axis (a). This results in the straight line equation
Y = a + bX
Where X represents the values on the horizontal axis (time), and Y represents the values on the
vertical axis (demand).
For the demonstration data, computations for b and a reveal the following (NOTE: I will not
require you to make the statistical calculations for b and a; these would be given to you.
However, you do need to know what to do with these values when given to you.)
b = 30
a = 295
Y = 295 + 30X
This equation can be used to forecast for any year into the future. For example:
All demand forecasting methods vary in the degree to which they emphasize recent demand
changes when making a forecast. Forecasting methods that react very strongly (or quickly) to
demand changes are said to be responsive. Forecasting methods that do not react quickly to
demand changes are said to be stable. One of the critical issues in selecting the appropriate
forecasting method hinges on the question of stability versus responsiveness. How much
stability or how much responsiveness one should employ is a function of how the historical
demand has been fluctuating. If demand has been showing a steady pattern of increase (or
decrease), then more responsiveness is desirable, for we would like to react quickly to those
demand increases (or decreases) when we make our next forecast. On the other hand, if demand
has been fluctuating upward and downward, then more stability is desirable, for we do not want
to “over react” to those up and down fluctuations in demand.
For some of the simple forecasting methods we have examined, the following can be noted:
Moving Average Approach: Using more periods in your moving average forecasts will result in
more stability in the forecasts. Using fewer periods in your moving average forecasts will result
in more responsiveness in the forecasts.
Weighted Moving Average Approach: Using more periods in your weighted moving average
forecasts will result in more stability in the forecasts. Using fewer periods in your weighted
moving average forecasts will result in more responsiveness in the forecasts. Furthermore,
placing lower weights on the more recent demand will result in more stability in the forecasts.
Placing higher weights on the more recent demand will result in more responsiveness in the
forecasts.
Simple Exponential Smoothing Approach: Using a lower alpha (α) value will result in more
stability in the forecasts. Using a higher alpha (α) value will result in more responsiveness in the
forecasts.
SEASONALITY ISSUES IN FORECASTING
Up to this point we have seen several ways to make a forecast for an upcoming year. In many
instances managers may want more detail that just a yearly forecast. They may like to have a
projection for individual time periods within that year (e.g., weeks, months, or quarters). Let’s
assume that our forecasted demand for an upcoming year is 480, but management would like a
forecast for each of the quarters of the year. A simple approach might be to simply divide the
total annual forecast of 480 by 4, yielding 120. We could then project that the demand for each
quarter of the year will be 120. But of course, such forecasts could be expected to be quite
inaccurate, for an examination of our original table of historical data reveals that demand is not
uniform across each quarter of the year. There seem to be distinct peaks and valleys (i.e.,
quarters of higher demand and quarters of lower demand). The graph below of the historical
quarterly demand clearly shows those peaks and valleys during the course of each year.
200
Quarterly Demands Over Six-Year History
150
Demand
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Sequential Quarters Over Six Years
Mechanisms for dealing with seasonality are illustrated over the next several pages.
CALCULATING SEASONAL INDEX VALUES
This is the way you will find seasonal index values calculated in the textbook. Begin by
calculating the average demand in each of the four quarters of the year.
Next, note that the total demand over these six years of history was 2400 (i.e., 310 + 365 + 395 +
415 + 450 + 465), and if this total demand of 2400 had been evenly spread over each of the 24
quarters in this six year period, the average quarterly demand would have been 100 units.
Another way to look at this is the average of the quarterly averages is 100 units, i.e.
(80 + 120 + 142 + 58)/4 = 100 units.
But, the numbers above indicate that the demand wasn’t evenly distributed over each quarter. In
Quarter 1 the average demand was considerably below 100 (it averaged 80 in Quarter 1). In
Quarters 2 and 3 the average demand was considerably above 100 (with averages of 120 and
142, respectively). Finally, in Quarter 4 the average demand was below 100 (it averaged 58 in
Quarter 4). We can calculate a seasonal index for each quarter by dividing the average quarterly
demand by the 100 that would have occurred if all the demand had been evenly distributed
across the quarters.
Year Q1 Q2 Q3 Q4
Seasonal 80/100 = 120/100 = 142/100 = 58/100 =
Index .80 1.20 1.42 .58
A quick check of these alternate seasonal index values reveals that they average out to 1.0 (as
they should). (.80 + 1.20 + 1.42 + .58)/4 = 1.000
USING SEASONAL INDEX VALUES
The following forecasts were made for the next 4 years using the trend projection line approach
(the trend projection formula developed was Y = 295 + 30X, where Y is the forecast and X is the
year number).
Year Forecast
7 505
8 535
9 565
10 595
If these annual forecasts were evenly distributed over each year, the quarterly forecasts would
look like the following:
Annual
Year Q1 Q2 Q3 Q4 Annual/4
Forecast
7 126.25 126.25 126.25 126.25 505 126.25
8 133.75 133.75 133.75 133.75 535 133.75
9 141.25 141.25 141.25 141.25 565 141.25
10 148.75 148.75 148.75 148.75 595 148.75
However, seasonality in the past demand suggests that these forecasts should not be evenly
distributed over each quarter. We must take these even splits and multiply them by the seasonal
index (S.I.) values to get a more reasonable set of quarterly forecasts. The results of these
calculations are shown below.
Annual
Year Q1 Q2 Q3 Q4
Forecast
7 101.000 151.500 179.275 73.225 505
8 107.000 160.500 189.925 77.575 535
9 113.000 169.500 200.575 81.925 565
10 119.000 178.500 211.225 86.275 595
If you check these final splits, you will see that the sum of the quarterly forecasts for a particular
year will equal the total annual forecast for that year (sometimes there might be a slight rounding
discrepancy).
OTHER METHODS FOR MAKING SEASONAL FORECASTS
Let's go back and reexamine the historical data we have for this problem. I have put a little
separation between the columns of each quarter to let you better visualize the fact that we could
look at any one of those vertical strips of data and treat it as a time series. For example, the Q1
column displays the progression of quarter 1 demands over the past six years. One could simply
peel off that strip of data and use it along with any of the forecasting methods we have examined
to forecast the Q1 demand in year 7. We could do the same thing for each of the other three
quarterly data strips.
Year Q1 Q2 Q3 Q4
1 62 94 113 41
2 73 110 130 52
3 79 118 140 58
4 83 124 146 62
5 89 135 161 65
6 94 139 162 70
To illustrate, I have used the linear trend line method on the quarter 1 strip of data, which would
result in the following trend line:
Y = 58.8 + 6.0571X
We could do the same thing with the Q2, Q3, and Q4 strips of data. For each strip we would
compute the trend line equation and use it to project that quarter’s year 7 demand. Those results
are summarized here:
These quarterly forecasts are in the same ballpark as those made with the seasonal index values
earlier. They differ a bit, but we cannot say one is correct and one is incorrect. They are just
slightly different predictions of what is going to happen in the future. They do provide a total
annual forecast that is equal to the trend projection forecast made for year 7. (Don’t expect this to
occur on every occasion, but since it corroborates results obtained with a different method, it
does give us confidence in the forecasts we have made.)