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 costsExamine cost analysis as it relates to operations, maintenance, and productionDetermine effective criteria based on properties, test results, and standards for each operationWritten 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 ValueConcerning WarrantiesDefining Operation and Time CostsSome Recent MRO Recall ItemsOn the Road to a Profit Return on a PurchaseCosts and ValueManufacturing CostsMaterial CostsLabor CostsManufacturing OverheadAdditional CostsCost Behavior PatternsExamples of "Wasted" Cost Overruns—The $600 Toilet SeatCost of FailureCase Studies—An Effective Way Toward ChangeOther Costs DefinedDetermining the Return on Investment (ROI) of a Purchase Applying the ROI FormulaSummaryTools for the Specification Development Process Source of FailureAssessing the SituationFailure DefinedTaking Advantage of FailureSources of Failure: Man, Materials, Methods, MachinesManmade Failures—Failure of the EmployeesManmade Failures—Failure of ManagersMethod Failures—The Failure of BusinessFailure of Materials, Failure of Machines Types of Forces StrengthCreep (Deformation)Fatigue (Material) Rate of FatigueFracture Brittle Fracture Ductile FractureWearTemperature Thermal Shock FailureOxidation—Molecular Transitions and Chemical Influences CorrosionDeposit Formation Factors That Affect Deposit Formation Concentration and Pressure Particle Size and Contaminant TypeSummaryTools for the Specification Development ProcessFailure Mode Work Sheet Key Using the Information GatheredFact Finding and DocumentationPhysical Properties and Standards Obtaining Standards from ANSIAdhesives and SealantsPaints and Coatings Coating FailuresGaskets, Seals, and BeltsChainsWire RopePipe Failure of the Fitting Joint FailureHoseValvesFasteners—Screws, Bolts, Nails, StaplesBearingsGreaseGearsGear OilElectrical WireLighting Light-Emitting Diode (LED) Failure ModesElectric MotorsSummaryTools for the Specification Development Process Case Study Work Sheet Finalizing the Purchasing Specification and Selecting VendorsWriting 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 EvaluationSpecification ExampleThe Leon-Maxwell Performance EquationApplication ExamplesExcessive Load ExampleExcessive or Localized HeatContaminationGreen ProcurementConclusion and Summary Appendix Bibliography

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.