In a machine shop machines are breaking down at a constant rate of one every one hour.

50% of break down

require 2 hours to repair and remaining 2 hours 30 minutes to repair. The machine breakdown leads to a downtime
cost of Rs. 200/hour. The repair mechanics are paid wages at Rs. 4000/month for 200 hours. The mechanics
attend breakdown at FCFS basis. Determine the optimum number of mechanics.

Assume 8 hrs shift and no. of mechanics=2

Repair
Hour Coin RT Start End Waiting
1 1 2.5 1 3.5 0
2 0 2 2 4 0
3 0 2 3.5 5.5 0.5
4 0 2 4 6 0
5 0 2 5.5 7.5 0.5
6 0 2 6 8 0
7 0 2 7.5 9.5 0.5
8 0 2 8 10 0
16.5 1.5
Assume 8 hrs shift and no. of mechanics=3
Repair
Hour Coin RT Start End Waiting
1 1 2.5 1 3.5 0
2 0 2 2 4 0
3 0 2 3 5 0
4 0 2 4 6 0
5 0 2 5 7 0
6 0 2 6 8 0
7 0 2 7 9 0
8 0 2 8 10 0
17 0
Assume 8 hrs shift and no. of mechanics=4
Repair
Hour Coin RT Start End Waiting
1 1 2.5 1 3.5 0
2 0 2 2 4 0
3 0 2 3 5 0
4 0 2 4 6 0
5 0 2 5 7 0
6 0 2 6 8 0
7 0 2 7 9 0
8 0 2 8 10.0 0
16.5 0
DT Hiring
Experiment DT cost Mechanics RT cost Total
1 48 9600 1 16.5 330 9930
2 18 3600 2 16.5 660 4260
3 16.5 3300 3 16.5 990 4290
4 16.5 3300 4 16.5 1320 4620
Consider a machine to which parts arrive at intervals ranging between 1-8 minutes with same probability of
occurrence. The parts spend about 1-6 minutes in the machine with probabilities as given and assume that the
batch size is 100.

Time between Probability Cumulative Range

arrivals Probability
Service time Probability Cumulative Range
1 1/8=0.125 0.125 1-125 Probability
2 0.125 0.25 126-250 1 0.1 0.1 1-10
3 0.125 0.375 251-375 2 0.2 0.3 11-30
4 0.125 0.5 376-500 3 0.3 0.6 31-60
5 0.125 0.625 501-625 4 0.25 0.85 61-85
6 0.125 0.75 625-750 5 0.1 0.95 86-95
7 0.125 0.875 751-875 6 0.05 1 96-100
8 0.125 1 876-1000

Idle
Custo Rand Time in time of
mer om IAT AT Random ST SST SCT WT system server
1 594 0 0 27 2 0 2 0 2 0
2 402 4 4 22 2 4 6 0 2 2
3 183 2 6 87 4 6 10 0 4 0
4 936 8 14 69 4 14 18 0 4 4
5 639 6 20 52 3 20 23 0 3 2
6 356 3 23 90 4 23 27 0 4 0
7 785 7 30 80 4 30 34 0 4 3
8 711 6 36 44 3 36 39 0 3 2
9 214 2 38 98 5 39 44 1 6 0
10 841 7 45 96 4 45 49 0 4 1
Total 430 314 155 469 119
0.274826
Average 4.3 3.14 1.55 4.69 79
Avera Average
Aver ge waiting Average
age servic time of a turn
Arri e custome around Utilizatio
vals time r time n 72.52%
Average
Expe waiting
Expe cted time of
cted servic those
Arri e who 3.369565
vals 4.5 time 3.2 waits 217
Probabil
ity
MoP (wait) 0.46
A milling machine has three different bearings that fail in service. The distribution of life of each bearing is
identical as given. When a bearing fails the mill stops. A repair person is called and new bearing is installed. The
delay time of the repair person follows a distribution as given. Downtime cost for the mill is estimated as $10 per
minute. The direct on-site cost of repair is $30 per hour. It takes 20 minutes for changing one bearing, 30 minutes
for 2 bearings and 40 minutes for 3 bearings. The MoP given by the management is the total cost per 10000
bearing – hours.

Bearing Proba Cumulative Random Digit 1700 0.06 0.90 85-90

bility
life (Hrs) Probability Assignment 1800 0.05 0.95 91-95

1000 0.1 0.1 1-10 1900 0.05 1 96-100

1100 0.13 0.23 11-23 Delay Probab Cum. Random Digit

time ility
1200 0.25 0.48 24-48 Probability Assignment
(Minutes)
1300 0.13 0.61 49-61
5 0.6 0.6 1-6
1400 0.09 0.70 62-70
10 0.3 0.9 7-9
1500 0.12 0.82 71-82
15 0.1 1 9-10
1600 0.02 0.84 83-84