Question 2 (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 one 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 hundred fifty
hours. The second machine can be repaired in three stages, consecutively ( the first stage needs a technician to work
on it for ninety 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 seventy two hours ). The third machine needs four technicians to
work on it simultaneously for sixty days without violating the Malaysian government regulation.
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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 = 1.5 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 150 hours at the same time.
Scheduled labor-hours per week for (M1) = ( 2 worker × 150 hours )/ 4.25 weeks = 68.96

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

In ( S1) we have one technician work for 90 hours.
Scheduled labor-hours per week for ( S1) = ( 1 worker × 90 hours ) / 4.35 weeks = 20.68
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 72 hours.
Scheduled labor-hours per week for ( S3) = ( 3 worker × 72 hours ) / 4.35 weeks = 49.65

In the third machine (M3 ) needs 4 workers to work simultaneously for 60 days, and each day 8 hours , so we need to
now how many weeks = 60 days / 6 days per week = 10 weeks
Scheduled labor-hours per week for (M3 ) = ( 4 worker ×60 days × 8 hours ) / 10 weeks = 192
(68.96+20.68+49.65+192) labor−hours per week
crew size= ( 1.5 weeks)×(48 hours per week )
= 4.6 workers ≈ 5 workers
we need 5 workers to be in maintenance department staff.

But, we have this situation in our question :-

In the third machine (M3 ) needs 4 workers to work simultaneously for 10 weeks .
In addition we have two assumption for M1 and M2 :-
First one :-
Start maintenance ( M1 ) in the beginning of the month with 2 workers in same time, finish it in day No. 18.
Also maintenance (M2 ) in the same time, ( S3) started in day No. 16 with 3 workers together.
In this case crew size = 2 workers for ( M1 ) + 3 workers for ( M2 ) + 4 workers for ( M3 ) = 9 workers
Second one :-
Start maintenance ( M1 ) in the beginning of the month with 2 workers in same time, finish it in day No. 18.
Start maintenance (M2 ) in in day No. 3, ( S3) started in day No. 19 with 3 workers together.
In this case crew size = 3 workers enough for both (M1 & M2 ) + 4 workers for ( M3 ) = 7 workers
So we choose second assumption with 7 workers the minimum number of maintenance department staff to
support the whole company.
 Assume that every Worker can do any job .