UNIT 5 – WORKER – MACHINE RELATIONSHIPS

OVERVIEW
Although the worker and machine process chart can illustrate the number of facilities that can
be assigned to an operator, this can often be computed in much less time through the development of
a mathematical model. This unit will examine the worker and machine relationship and its two types:
(1) synchronous servicing and (2) random (asynchronous) servicing

LEARNING OBJECTIVES
At the end of this unit, the students are expected to:
1. Understand the difference between synchronous and random servicing
2. Determine the number of facilities that can be assigned to an operator through a
mathematical model

DISCUSSION

Synchronous Servicing
Assigning more than one machine to an operator seldom results in the ideal case
where both the worker and the machine are occupied during the whole cycle. Such ideal cases
are referred to as synchronous servicing, and the number of machines to be assigned can be
computed as
l+m
n=
l
where n =number of machines the operator is assigned
l = total operator loading and unloading (servicing) time per machine
m = total machine running time (automatic power feed)
In real life, the operator will be able to service fewer machines because of w = worker
(walk) time. The operator may need to walk between machines or clean and adjust the machines.
This worker time also needs to be accounted for based on the cost of each idle machine and the
hourly rate of the operator. The number of machines that the operator should be assigned under
realistic conditions can be re-estimated by the lowest whole number from the revised equation:

l +m
n1 ≤
l +w
where n1 =lowest whole number
w = total worker time (not directly interacting with the machine, typically walking
time to the next machine)
Using n1 , we can compute the total expected cost (TEC) as follows:

K 1 (l+ m) +n 1 K 2 (l+m)
TEC n 1=
n1

(l+ m ) (K 1 +n 1 K 2 )
¿
n1
 Worker-Machine Relationships

where TEC = total expected cost in dollars per unit of production from one machine
K1 = operator rate, in dollars per unit of time
K2 = cost of machine, in dollars per unit of time

After this cost is computed, a cost should be calculated with n1 + 1 machines assigned to the
operator. In this case, the cycle time is governed by the working cycle of the operator, since there is
some idle machine time. The cycle time is now ( n1 +1)(l + w). Let n2 = n1 + 1. Then the total expected
cost with n2 facilities is

(n¿¿ 2) (l+ w ) + K 2 n2 n2 (l+ w)

TEC n 2=K 1 ¿
n2

¿(l+ w)( K 1+ n2 K 2)

The number of machines assigned depends on whether n1 or n2 gives the lowest total expected
cost per piece.

Example 1 Synchronous Servicing

Consider a walk time of 0.1 minute with l = 1.0 minute and m = 2.0 minutes. Also, the
operator earns PhP50/hr and the machine costs PhP100/hr to run. Determine the optimal
number of machines to be assigned to the operator.
Solution:

l+m 1+ 2
n1 = = =2.7
l+ w 1+ 0.1
Therefore, n1=2 and n2=3

TEC 2=
( l+ m)(K 1 +n1 K 2)
n1 [
= (1+2)min ×
1hr
60 min
× ]
(50+ ( 2 ×100 ) )
2
=Php6.25 /unit

[
TEC 3= (l + w ) ( K 1 +n2 K 2 )= (1+0.1)min ×
1hr
60 min ]
× ( 50+ ( 3 ×100 ) )=Php 6.42/unit

In conclusion, based on the lowest cost, the set up with 2 machines is best. However,
if you can have unlimited sales at a high sales price, you would be better off with 3 machines,
because you can maximize profit.
Example 2 Synchronous Servicing
The analyst in the Red Diamond Electronics Company wishes to assign a number of like
facilities to an operator based on minimizing the cost per unit of output. A detailed study
of the facilities revealed the following:
Loading machine standard time = 0.34 minutes
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Unloading machine standard time = 0.26 minutes

Walk time between two machines = 0.06 minutes
Operator rate = $12.00 per hour
Machine rate (both idle and working) = S18.00 per hour
Power feed time = 1.48 minutes
How many of these machines should be assigned to each operator?
Solution:
l+m 0.34+0.26 +1.48
n1 = = =3.15
l+ w 0.34+0.26+ 0.06
Therefore, n1=3 and n2=4
(l+ m)(K 1 +n1 K 2)
TEC 3= =¿
n1

TEC 4=(l+ w)(K 1 +n2 K 2)=¿=$0.924/pc

Therefore 3 machines are assigned to each operator.

Random (Asynchronous Servicing)
Completely random servicing situations are those cases in which it is not known
when a facility needs to be serviced or how long servicing takes. Mean values
are usually known or can be determined; with these averages, the laws of probability
can provide a useful tool in determining the number of machines to assign a single
operator. The successive terms of the binomial expansion give a useful approximation of
the probability of 0, 1, 2, 3, . . ., n machines down (where n is relatively small), assuming
that each machine is down at random times during the day and that the probability of
downtime is p and the probability of runtime is q = 1 - p. Each term of the binomial
expansion can be expressed as a probability of m (out of n) machines down:

n! m n−m
P ( mof n )= p q
m! ( n−m ) !

Where p = probability of down time

q = probability of uptime= 1-p
The most satisfactory assignment is usually the arrangement showing the least total
expected cost per piece.

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 Worker-Machine Relationships

Example 3 Random (Asynchronous Servicing)

A study revealed that a group of three semiautomatic machines assigned to one
operator operate 70 percent of the time unattended. Operator service time at irregular
intervals averaged 30 percent of the time on these three machines. What would be the
estimated machine hours lost per eight-hour day because of lack of an operator?

Solution:

Machines
Probability Machine hours lost per 8-h day
down m
3! 0 3 0
0 0.3 0.7 =0.343
0 ! 3!
3! 1 2 0
1 0.3 0.7 =0.441
1! 2 !
3! 2 1 0.189*1*8hrs= 1.512 hrs
2 0.3 0.7 =0.189
2! 1 !
3! 3 0 0.027*2*8hrs= 0.432 hrs
3 0.3 0.7 =0.027
3! 0!

A total of 1.512 + 0.432 = 1.944 hours are lost per day because of interference.

Example #2

n = 3, p = 0.1, q = 0.9. Assume the operator is paid Php 30/hr and the machine
costs PhP 100/hr to run, but produces 200 units per hour. What is the total % idle time?
How many operators should be assigned to three machines?

Machines Machine hours lost per 8-h day

Probability With 1 operator With 2 operators With 3 operators
down m
3! 0 3
0 0.1 0.9 =0.729 0 0 0
0 ! 3!
3! 1 2
1 0.1 0.9 =0.243 0 0 0
1! 2 !
3! 2 1
2 0.1 0.9 =0.027 0.027*8=0.216 0 0
2! 1 !
3! 3 0
3 0.1 0.9 =0.001 0.001*8*2=0.016 0.001*8=0.008 0
3! 0!
Total hours lost 0.232 hrs/day 0.008 hrs/day 0

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 Worker-Machine Relationships

For one operator:

Production over 8 hours:

((3 machines*8hours) – 0.232))*200 units/hr = 4,753.6 units

Total cost for 8 hrs:

(PhP30/hr x 1 optr x 8 hrs )+ (PhP100/hr x 8 hrs x 3 mach) = Php 2,640

Unit Cost:
PhP 2,640
=Php 0.56/unit
4 ,753.60 units

For 2 operators:

Production over 8 hours:

((3 machines*8hours) – 0.008))*200 units/hr = 4,798.4 units

Total cost for 8 hrs:

(PhP30/hr x 2 optr x 8 hrs )+ (PhP100/hr x 8 hrs x 3 mach) = Php 2,880

Unit Cost:
PhP 2,880
=Php 0.60/unit
4 ,798.40 units

For 3 operators:
Production over 8 hours:
((3 machines*8hours) – 0))*200 units/hr = 4,800 units

Total cost for 8 hrs:

(PhP30/hr x 3 optr x 8 hrs )+ (PhP100/hr x 8 hrs x 3 mach) = Php 3,120

Unit Cost:
PhP 3,120
=Php 0.65/unit
4 ,800 units

Overall cheapest method: have one operator

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 Worker-Machine Relationships

SUMMARY
Synchronous and random servicing calculations are used to develop more efficient
operations through quantitative methods. Synchronous servicing is where both the worker and
the machine being serviced at regular intervals are occupied the whole cycle. It is an ideal case
which is seldom achieved. Completely random servicing refers to those cases in which it is not
known when a facility will need to be serviced or how long the servicing will take. Quantitative
techniques such as synchronous and random servicing can determine the optimum arrangement
of operators and machines. Analysts should be acquainted with sufficient algebra and probability
theory to develop a mathematical model that provides the best solution to the machine or facility
problem.

PROBLEMS
Solve the following problems. Show your complete solution and use at least 4 decimal
places in solving. Box the final answer.

1. A study reveals that a group of three semiautomatic machines assigned to one

operator operates unattended 80 percent of the time. Operator service time at irregular
intervals averages 20 percent of the time on these three machines. What would be the
estimated machine hours lost per 8-h day because of lack of an operator?

2. The following activities and times (in minutes) were recorded for a mold operator:
■ Removes molded piece from die 0.6
■ Walks 10 ft to a workbench 0.2
■ Boxes widget and places on conveyor 1.0
■ Walks back to molder 0.2
■ Blows out dirt from mold 0.4
■ Sprays oil into mold, pushes “GO” 0.2
■ Mold cycles automatically 3.0
The cycle then repeats itself. The operator is paid $10.00/h, and it costs $15.00/h to run
the molder. What is the optimum number of machines that can be assigned to the operator
to produce the widgets at lowest cost? Draw a worker-machine chart.

3. A (not-so-well-maintained) machine is down roughly 40% of the time. One operator

is assigned to service four identical such machines. Each machine can produce 60
widgets/hr if running (i.e. not completely idle). The operator is paid PhP50/hr and
each machine costs PhP100/hr for power and supplies.
a) What would be the ideal production for an 8-hour shift if all four machines were
running all of the time?
b) What is the actual production for an 8-hour shift given the above conditions?
c)What is the unit cost in part (b)?
d) Since there is so much lost production due to down time, management is
considering hiring another worker to assist the first operator in servicing these four
machines. It has two choices:

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 Worker-Machine Relationships

(i)assign Machine #1 and #2 to the first operator and Machine #3 and #4 to

the second operator.
(ii)or have both operators help each other and service all four machines.
Which choice is best for lowest cost?

REFERENCES

Groover, M. P. (2007). Work Systems and the Methods, Measurement and Management
of Work. Pearson Education International.
Niebel, A. F. (2009). Niebel's Methods, Standards, & Work Design (12 ed.). McGraw
Hill.

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