1st Edition

Spend Analysis and Specification Development Using Failure Interpretation

By Michael D. Holloway Copyright 2011
    367 Pages 25 B/W Illustrations
    by CRC Press

    368 Pages 25 B/W Illustrations
    by CRC Press

    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
    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
    Creep (Deformation)
    Fatigue (Material)
         Rate of Fatigue
         Brittle Fracture
         Ductile Fracture
         Thermal Shock Failure
    Oxidation—Molecular Transitions and Chemical Influences
    Deposit Formation
         Factors That Affect Deposit Formation 
              Concentration and Pressure
              Particle Size and Contaminant Type
    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
    Wire Rope
         Failure of the Fitting
         Joint Failure
    Fasteners—Screws, Bolts, Nails, Staples
    Gear Oil
    Electrical Wire
         Light-Emitting Diode (LED) Failure Modes
    Electric Motors
    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
    Specification Example
    The Leon-Maxwell Performance Equation
    Application Examples
    Excessive Load Example
    Excessive or Localized Heat
    Green Procurement
    Conclusion and Summary




    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.