Question 1 (CREW SIZE ) :-

As a maintenance manager, you are required to estimate the minimum number of maintenance department staff to
support the whole company. You know that Malaysian regulation only allows a healthy person to work for a
maximum of eight hours in a day and not more than six days in a week. You also want the staff to feel a bit of work
pressure by making sure that they are always lagging behind in delivering their work result by as mush as two and a
half weeks. On average, every month production department has three machines that need maintenance badly. The
first machine can only be serviced if two maintenance technician work on it at the same time for one twenty one
hours. The second machine can be repaired in three stages, consecutively ( the first stage needs a technician to work
on it for fifteen hours. The second stage needs the machine to be working automatically for forty hours since it has
the intelligence to tune itself for achieving the optimum performance. The third stag need three technicians to work
on three different subsystems at the same time for twelve hours ). The third machine needs four technicians to work
on it simultaneously for eight and a half days.
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Solution:-
Schedled Labor−Hours per Week
crew size= ( Backlog )×( Hours per week )
; 1 month = 4.35 week
From the question:-
Backlog = 2.5 weeks ;
Hours per week = 8 hours × 6 days per week = 48 hours per week
We have three machines …M1, M2 & M3
In the first machine ( M1 ) we have 2 technician work for 21 hours at the same time.
Scheduled labor-hours per week for (M1) = ( 2 worker × 21 hours )/ 4.35 weeks = 9.655

The second machine (M2 ) we have three stages ( S1, S2 & S3 ) :-

In ( S1) we have one technician work for 15 hours.
Scheduled labor-hours per week for ( S1) = ( 1 worker × 15 hours ) / 4.35 weeks = 3.45
In ( S2) needs the machine to be working automatically, no needed for worker.
In ( S3) need 3 workers to work at the same time for 12 hours.
Scheduled labor-hours per week for ( S3) = ( 3 worker × 12 hours ) / 4.35 weeks = 8.276

In the third machine (M3 ) needs 4 workers to work simultaneously for 8.5 days, and each day 8 hours ,
Scheduled labor-hours per week for (M3 ) = ( 4 worker ×8.5 days × 8 hours ) /4.35 weeks = 62.53
(9.655+3.45+8.276+62.53) labor−hours per week
crew size= ( 2.5 weeks)×(48 hours per week )
= 0.699 workers ≈ 1 worker
we need 1 worker to be in maintenance department staff.

But, in the third machine (M3 ) needs 4 workers to work simultaneously.

So, the minimum number of maintenance department is 4 workers to support the whole company.
 Assume that every Worker can do any job .