1st Edition
Spend Analysis and Specification Development Using Failure Interpretation
Considering that the biggest machines that do the most work are made up of smaller machines and components, it becomes obvious that when a large machine breaks, it is normally due to small components acting antagonistically. Detailing a time-tested method for increasing productivity and lowering operational costs, Spend Analysis and Specification Development Using Failure Interpretation explains how to establish performance-based procurement specifications for the components, devices, and items that contribute the most to operational downtime and repair/replacement costs.
The book emphasizes the critical need to perform both spend and failure analysis in order to develop a procurement document, which will ultimately reduce overall costs. Accompanied by downloadable resources with helpful material such as, specification checklists, case study worksheets, form letters, and return on investment (ROI) worksheets that you can customize to your needs, the text discusses how to:
- Identify the products that will cost the most if they fail
- Develop performance-based procurement specifications to reduce direct and indirect costs
- Examine cost analysis as it relates to operations, maintenance, and production
- Determine effective criteria based on properties, test results, and standards for each operation
Written by an industry expert with decades of experience giving seminars, training customers and associates, and authoring numerous papers and articles, the text provides the real-world understanding of the influential components and materials’ physical properties needed to engage in effective failure and spend analysis. It addresses product submission and monitoring and includes helpful tools so you can immediately get started on conducting your own cost-saving analysis.
Buy Bye
Buying to Save—Cost and Value
Concerning Warranties
Defining Operation and Time Costs
Some Recent MRO Recall Items
On the Road to a Profit Return on a Purchase
Costs and Value
Manufacturing Costs
Material Costs
Labor Costs
Manufacturing Overhead
Additional Costs
Cost Behavior Patterns
Examples of "Wasted" Cost Overruns—The $600 Toilet Seat
Cost of Failure
Case Studies—An Effective Way Toward Change
Other Costs Defined
Determining the Return on Investment (ROI) of a Purchase
Applying the ROI Formula
Summary
Tools for the Specification Development Process
Source of Failure
Assessing the Situation
Failure Defined
Taking Advantage of Failure
Sources of Failure: Man, Materials, Methods, Machines
Manmade Failures—Failure of the Employees
Manmade Failures—Failure of Managers
Method Failures—The Failure of Business
Failure of Materials, Failure of Machines
Types of Forces
Strength
Creep (Deformation)
Fatigue (Material)
Rate of Fatigue
Fracture
Brittle Fracture
Ductile Fracture
Wear
Temperature
Thermal Shock Failure
Oxidation—Molecular Transitions and Chemical Influences
Corrosion
Deposit Formation
Factors That Affect Deposit Formation
Concentration and Pressure
Particle Size and Contaminant Type
Summary
Tools for the Specification Development Process
Failure Mode Work Sheet Key
Using the Information Gathered
Fact Finding and Documentation
Physical Properties and Standards
Obtaining Standards from ANSI
Adhesives and Sealants
Paints and Coatings
Coating Failures
Gaskets, Seals, and Belts
Chains
Wire Rope
Pipe
Failure of the Fitting
Joint Failure
Hose
Valves
Fasteners—Screws, Bolts, Nails, Staples
Bearings
Grease
Gears
Gear Oil
Electrical Wire
Lighting
Light-Emitting Diode (LED) Failure Modes
Electric Motors
Summary
Tools for the Specification Development Process
Case Study Work Sheet
Finalizing the Purchasing Specification and Selecting Vendors
Writing the Purchasing Specification
Specification Further Defined
Product Application Requirements
Figures and Tables
Group Terms
General Operational Requirements
Functional Requirements
Performance Requirements
Design Requirements
Terms and Conditions
Price per Units, Payments, Incentives, and Penalties
Contractual Terms and Conditions
Requirements of the Reply
Evaluation Process
Contact Points
Evaluation
Specification Example
The Leon-Maxwell Performance Equation
Application Examples
Excessive Load Example
Excessive or Localized Heat
Contamination
Green Procurement
Conclusion and Summary
Appendix
Bibliography
Biography
Michael Holloway has 25 years of industrial experience. His background includes organic and polymer synthesis as well as laboratory- to pilot-scale material manufacturing for Olin Chemical (Wilmington, Massachusetts), military and aerospace product development of sealants and coatings for Parker-Hannifin (Cleveland, Ohio), product engineering microelectronic photoresists for Rohm & Haas Electronic Chemicals (Midland, Michigan), technical marketing and application engineering for General Electric Plastics (Fairfield, Connecticut), sales and marketing management of automated dispensing systems for Graco (Minneapolis, Minnesota), and most currently as director of reliability and technical development of industrial and heavy equipment lubrication for NCH Corporation (Irving, Texas). Through the course of his career, Holloway has been involved in training customers and associates, giving seminars, as well as authoring numerous papers and articles as well as presenting novel concepts and case studies at national conferences. He has served as a contributing writer for Manufacturing.net, ASSEMBLY magazine, PlantServices magazine, Render magazine, and Lubrication and Fluid Power magazine.
Holloway has been master black belt trained in Six Sigma, served as an adjunct professor at the University of North Texas, and was managing editor for Porsche Club of America’s Slipstream. He holds a BA in philosophy and a BS in chemistry from Salve Regina University, Newport, Rhode Island, and an MS in polymer engineering from the University of Massachusetts.
