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Manual for Life Cost Based FMEA

3.1.1. Labor Costs

Labor cost can be derived with the time information input in the cost-based FMEA table using the following equation:

Labor Cost = Occurrence ×{[Detection Time × Labor rate × # of Operators] + [ Fixing Time × Labor rate × # of Operators × Quantity] + [Delay Time × Labor rate × # of Operators]}

A typical Labor rate used for this analysis is $75/hour for the operators.

Assumption: Operators work in pairs when they enter the tunnel to diagnose and to fix the problems.

3.1.2. Material Costs

Component replacement due to failure is considered as material cost. Material cost is obtained using the following equation:

Material Cost = Occurrence × Quantity of parts to replace × Cost of Part

3.1.2.1. Corrector Magnets

Parts cost to replace corrector magnets and their components are shown in Table 6.

Table 6 Parts Cost for Corrector Magnets

Min

Mean

Max

$250

$400

$1000

$200

$750

$2000

$750

$2000

$4000

Part Solid wire Coil Core

Whole Corrector

3.1.2.2. Water cooled Magnets

Parts cost to replace water cooled electromagnets and their components are shown in Table 7. These were typical costs for medium sized magnets in ~2002.

Table 7 Parts Cost for Water Cooled Magnets

Min

Mean

Max

$500

$1500

$4000

$1250

$3500

$20,000

$4000

$11,000

$30,000

Part Hollow Cu Coil Core Whole Magnet

FMEA MANUAL By S. Rhee and C.M. Spencer

12/26

January 2009

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