Lubrication management is far more important than most people realize. Those who get it are implementing innovations that make it much easier to answer “yes” to these basic questions: Is the correct machine lubricant known and available when needed? Is it clean of any contaminants and stored safely in a cool and dry place?
Unfortunately, optimization efforts lag when the role is underappreciated. “I think the industry as a whole has not fully realized how much lubrication can impact the bottom dollar when done correctly,” says Wesley Cash, director of technical services at Noria.
When lubrication is done inconsistently or incorrectly, it negatively affects machine condition and reliability plant-wide, explains Yolanda Diaz, zone technical expert for lubrication at Anheuser-Busch InBev.
USG Interiors, Wells Enterprises, and AB InBev are among the manufacturers utilizing modern tools, services, and strategies in their lubrication programs. Consider their experiences and advice as well as those of industry lubrication experts when working to shape your optimization priorities.
Polished process for building products
Josh Mattson, reliability supervisor at the USG Interiors plant in Cloquet, MN, believes the most valuable component of any lubrication program is the lubrication technician who champions the program. That person must understand the processes, strategies, and benefits of lubrication and receive continuous education on lubrication and oil analysis. Also, he or she must be engaged and empowered to take the lead on monitoring and improving the processes. “This is what our lubrication technician, Dave Mickle, MLT I, brings to our program,” says Mattson.
The Cloquet plant engaged a third party to audit its equipment and lubricants for accuracy and consolidation opportunities. Its oil storage is clean and organized based on 5S standards, and new oil containers are prefiltered before the oil is used. “We filter a new oil barrel 5-7 times before it is put into use,” says Mattson.
For oil analysis, a third-party service has proved cost-effective. Oil changes are based on sampling analysis results rather than on the calendar. Sampling ports are separate from the fill and drain ports to avoid contamination.
Optimization technologies used at USG Interiors in Cloquet include Ultraprobes from UE Systems for ultrasonic monitoring and lubrication; Des-Case desiccant breathers and oil filtration units; vacuum-charged Simplo Jars from RelyAssist for oil sampling in highly contaminated and restrictive areas; quick-connect hookups for filling, draining, filtering, and sampling; and sight tubes/glasses.
Following are Mattson’s recommendations:
- Get a certified Machinery Lubrication Technician Level I (MLT I) in place
- Get management on board with the costs necessary to start the program and strategies to launch and maintain it
- Develop ultrasonic lubrication and monitoring routes, which will work hand-in-hand to strengthen your plant’s reliability strategies
- Encourage ownership and engagement at all levels
Smooth operations for ice-cold environment
Wells Enterprises, best known for its Blue Bunny ice cream brand, audits its lubrication program twice per year to look for improvement opportunities. Don Palmer, reliability analyst at Wells Enterprises, considers the following some of Wells’ most effective lubrication practices:
- An in-house oil analysis laboratory allows for the testing of equipment on regular routes as well as unscheduled testing while troubleshooting equipment problems. Additionally, all new oils are tested to verify cleanliness and to confirm they meet specifications. “Our in-house oil lab tests 1,200 to 1,300 oil samples per year,” says Palmer.
- Oil filtration units, both portable and permanent, are used to remove contamination from gearboxes, hydraulic systems, and compressors. Currently, 75 oil filtration units are used on critical equipment.
- Improved oil sump breathers are used to prevent contamination ingression into the lubricants. “Last year we conducted a contamination study of our active gearboxes and came up with 63 units to implement contamination control upgrades to,” Palmer says.
- Grease analysis testing is used to determine ferrous wear materials in critical bearings. “This was implemented two years ago and has been very successful at a low cost of testing,” explains Palmer. “We currently use the grease testing in three blast freezing locations at -45°F, and we are adding 32 more grease points this year in two additional blast freezing machines.”
Start slow, Palmer advises. “It is very hard to implement a full program and sustain it,” he says. “You need one person to be the program champion and drive towards excellence.” Documentation is important, even if it’s no one’s favorite task. He suggests taking pictures of good and poor lubrication practices and using them as training examples.