Spend Analysis and Specification Development Using Failure Interpretation PDF
Preview Spend Analysis and Specification Development Using Failure Interpretation
Business Management / Facilities Management H o l l Considering that the biggest machines that do the most work are made up o w of smaller machines and components, it becomes obvious that when a large a y 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 S p Failure Interpretation explains how to establish performance-based e procurement specifications for the components, devices, and items that n contribute the most to operational downtime and repair/replacement costs. d A The book emphasizes the critical need to perform both spend and failure n analysis in order to develop a procurement document, which will ultimately a reduce overall costs. Complete with numerous examples, illustrations, and l y case studies, the text discusses how to: s i s • Examine cost analysis as it relates to operations, maintenance, a and production n • Develop performance-based procurement specifications to reduce d direct and indirect costs S • Determine effective criteria based on properties, test results, p and standards for each operation e c • Identify which products will cost the most if they fail i fi c Written by an industry expert with decades of experience giving seminars, a training customers and associates, and authoring numerous papers and t i articles, the text provides the real-world understanding of the influential o n components and materials’ physical properties needed to engage in effective failure and spend analysis. It addresses product submission and monitoring D and includes helpful tools so you can immediately get started on conducting e your own cost-saving analysis. v e l o p m K12333 e ISBN: 978-1-4398-5107-4 n 90000 t www.crcpress.com 9 781439 851074 w w w.c r c p r e s s .co m K12333 cvr mech.indd 1 1/6/11 10:12 AM Spend Analysis and Specification Development Using Failure Interpretation Spend Analysis and Specification Development Using Failure Interpretation Michael D. Holloway CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2011 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20110726 International Standard Book Number-13: 978-1-4398-5108-1 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. 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Contents Foreword.........................................................................................................xi Acknowledgments........................................................................................xvii The.Author....................................................................................................xix 1 Buy.Bye....................................................................................................1 2 Buying.to.Save—Cost.and.Value.............................................................5 Concerning Warranties ..............................................................................11 Defining Operation and Time Costs .........................................................15 Some Recent Maintenance, Repair, and Operations (MRO) Recall Items ........................................................................................22 On the Road to a Profit Return on a Purchase ...........................................23 Costs and Value .........................................................................................26 Manufacturing Costs .................................................................................27 Material Costs ...........................................................................................28 Labor Costs ...............................................................................................29 Manufacturing Overhead ..........................................................................29 Additional Costs ........................................................................................30 Cost Behavior Patterns ...............................................................................30 Examples of “Wasted” Cost Overruns—The $600 Toilet Seat ...................32 Cost of Failure ...........................................................................................35 Case Studies—An Effective Way toward Change .....................................42 Other Costs Defined .................................................................................44 Determining the Return on Investment (ROI) of a Purchase ....................45 Applying the ROI Formula ...............................................................48 Summary ...................................................................................................48 Tools for the Specification Development Process .......................................49 3 Source.of.Failure...................................................................................51 Assessing the Situation ...............................................................................51 Failure Defined ..........................................................................................54 vii viii ◾ Contents Taking Advantage of Failure ......................................................................56 Sources of Failure: Man, Materials, Methods, Machines ...........................57 Manmade Failures—Failure of Employees ................................................58 Manmade Failures—Failure of Managers ..................................................60 Method Failures—Failure of Business .......................................................62 Failure of Materials, Failure of Machines ...................................................65 Types of Forces .................................................................................67 Strength ............................................................................................68 Defining Stress and Strain .......................................................69 Creep (Deformation) .................................................................................71 Fatigue (Material) ......................................................................................74 Rate of Fatigue .................................................................................74 Fracture .....................................................................................................75 Brittle Fracture .................................................................................75 Ductile Fracture ...............................................................................76 Wear ..........................................................................................................78 Temperature ..............................................................................................80 Thermal Shock Failure ......................................................................82 Oxidation—Molecular Transitions and Chemical Influences ....................83 Corrosion ..........................................................................................83 Corrosion in Nonmetals .........................................................84 Galvanic Corrosion .................................................................85 Deposit Formation .....................................................................................85 Factors That Affect Deposit Formation .............................................89 Concentration and Pressure .....................................................89 Particle Size and Contaminant Type ......................................90 Summary ...................................................................................................96 Tools for the Specification Development Process .......................................96 Failure Mode Work Sheet Key ...................................................................99 4 Using.the.Information.Gathered.........................................................101 Fact Finding and Documentation ............................................................103 Physical Properties and Standards ............................................................108 Obtaining Standards from the American National Standards Institute (ANSI) .............................................................................110 Adhesives and Sealants.............................................................................117 Paints and Coatings .................................................................................122 Coating Failures .............................................................................127 Gaskets, Seals, and Belts ..........................................................................130 Chains .....................................................................................................137 Wire Rope ...............................................................................................140 Contents ◾ ix Pipe ..........................................................................................................142 Failure of the Fitting .......................................................................142 Joint Failure ....................................................................................143 Hose ........................................................................................................148 Valves .......................................................................................................150 Fasteners—Screws, Bolts, Nails, Staples ..................................................153 Bearings ...................................................................................................158 Grease ......................................................................................................160 Gears .......................................................................................................162 Gear Oil ..................................................................................................164 Electrical Wire .........................................................................................166 Lighting ...................................................................................................170 Light-Emitting Diode (LED) Failure Modes ..................................171 Electric Motors ........................................................................................172 Summary .................................................................................................187 Tools for the Specification Development Process .....................................187 Case Study Work Sheet ...................................................................188 5 Finalizing.the.Purchasing.Specification.and.Selecting.Vendors.........189 Writing the Purchasing Specification .......................................................189 Specification Further Defined .........................................................198 Product Application Requirements .................................................198 Figures and Tables ..........................................................................199 Group Terms ..................................................................................199 General Operational Requirements ...............................................200 Functional Requirements ...............................................................200 Performance Requirements ............................................................200 Design Requirements ......................................................................201 Terms and Conditions ....................................................................201 Price per Units, Payments, Incentives, and Penalties ..............211 Contractual Terms and Conditions .......................................211 Requirements of the Reply .....................................................211 Evaluation Process .................................................................211 Contact Points .......................................................................211 Evaluation .............................................................................212 Specification Example ..............................................................................212 The Leon–Maxwell Performance Equation ..............................................217 Application Examples ..............................................................................219 Excessive Load Example .........................................................................222 Excessive or Localized Heat .....................................................................225 Contamination ........................................................................................227
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