National Textile University Karachi Campus.

BS. Textile Engineering.

Name Fatima Iftikhar

Reg. no. 18-NTU-KC-TE-017

Semester 7th

Course title Garment Production Machinery

Course Code GM- 4041

Date of Submission February 28th, 2022

Assignment Complex Engineering Problem

Submitted to Sir Muzzamil Hussain

 PROBLEM

Determining the Size of Repair Crews and how they interdependent for each type of
maintenance. What parameter will you consider for calculating the total cost of repair?

Sewing machines break down at an average rate of 12 per hour and the average repair time is
0.75 hours. The plant manager at The Shirt Factory has specified that a malfunctioning
machine should be out of production for no more than 2 hours as an average. How many sewing
machine repair specialists should TSF have on duty?

SOLUTION

We use Poisson distribution that can be used to model breakdown occurring within given time
period.

Formula is given as:

𝛌𝒙
P(x) = (𝐞−𝛌 )
𝐱!

λ is shape parameter that shows average no. of events i.e. breakdown in given time interval. It
is 12 machines breakdown/ hr.

Also, we assume that the repair time is exponentially distributed. So, the size of repair crew is
calculated in three steps as follows:

1. Calculating average service rate for entire crew of repair shop

ts = 1/ μ- λ

Here:

o λ: average break down rate = 12/hr.

o μ: average service rate
o ts: maximum allowed out of production time = 2 hr.

Putting values, we get:

2 = 1/ μ- 12

2 μ = 24+1

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μ= 12.5 machines per hour.

2. Calculating implied average service rate per repair specialist:

Machine per hour per specialist = 𝟏⁄𝒉𝒐𝒖𝒓𝒔 𝒑𝒆𝒓 𝒎𝒂𝒄𝒉𝒊𝒏𝒆 𝒑𝒆𝒓 𝒔𝒑𝒆𝒄𝒊𝒂𝒍𝒊𝒔𝒕

=1⁄𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑟𝑒𝑝𝑎𝑖𝑟 𝑡𝑖𝑚𝑒

=1⁄0.75

= 1.333 machines

3. Calculating number of repair specialist

𝛍
No. of specialist = ⁄𝒎𝒂𝒄𝒉𝒊𝒏𝒆𝒔 𝒑𝒆𝒓 𝒉𝒐𝒖𝒓 𝒑𝒆𝒓 𝒔𝒑𝒆𝒄𝒊𝒂𝒍𝒊𝒔𝒕

=12.5⁄1.333

= 9.37

Answer: 10 sewing machine repair specialists should TSF have on duty.

PARAMETERS

Parameters consider for calculating total cost of repairs are:

o Cost of interruptions to production.

o Cost of crews and shops.
o Cost of repair.
o Cost of spare parts and standby machines.

REFERENCES

1. https://www.scribd.com/document/513109736/Microsoft-PowerPoint-
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