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LUBRICATION EXCELLENCE - SURVEY & AUDIT

Audit of Machinery Lubrication Practices
Maintenance is a big business. Approximately one third of the billions of dollars spent on maintenance was found to be unnecessary. Maintenance is one of the areas of company’s expenditure that can be drastically improved upon. According to Dupont “Maintenance is the single largest controllable cost within a plant”. As these maintenance costs are variable in nature, we need structured PM programs, controls and practices to turn these variable costs into fixed costs. PM is a common acronym For Preventive maintenance, predictive maintenance, Planned Maintenance, Proactive Maintenance. As the maintenance costs are paid out of company’s profits the term PM has a new meaning – PM = Profit Maintenance.

All these maintenance strategies are selected for managing the mechanical assets and improving profits. They all Include a strategic lubrication program as an integral part. It is generally accepted within the lubrication community that over 60 % equipment failures relate directly to poor or improper lubrication Practices. In order to improve these practices and Scream profits, survey and audit of Plant’s Lubrication Practices is of utmost importance.

PROGRAM SCHEDULE
Step 1
The program starts with a short meeting between the consultant, the plant manager, the maintenance manager and managers and supervisors from all the department selected Or the program. Then the consultant visits various departments in the site and the rnadhlnes which are short listed Or the survey. The consultant also visits the lubricant storage areas of all the departments concerned. Digital images wherever necessary, will be taken. Existing Machinery lubrication practices will be discussed with employees responsible for operating the plant and those who apply and check the lubrication.

Step 2
The program starts with a short meeting between the consultant, the plant manager, the maintenance manager and managers and supervisors from all the departments selected for the program. Then the consultant visits various departments in the site and the machines which are short listed for the survey. The consultant also visits the lubricant storage areas of all the departments concerned. Digital images wherever necessary, will be taken. Existing Machinery lubrication practices will be discussed with employees responsible for operating the plant and those who apply and check the lubrication.

Step 3
The consultant presents a half-day seminar that is focused on the importance of machinery lubrication, Al analysis, Contamination Control, and the value it can create Or the organization to the plant manager, reliability and maintenance engineers, supervisors, lube technicians etc.,. Each participant (8-10 attendees) receives a courses book. The course content is enhanced by information the consultant gathered during the facility tour earlier in the weep this may include digital images taken onsite.

This becomes a foundation training and helps prepare those who will be present to receive the Audit report. During the next phase, the consultant presents the report to key decision makers For identification of Improvement opportunities and to determine next steps for lubrication management, consolidation, training etc.

Objectives and Goals of Lubrication Audit

  • Identify current practices and suggest best practice alternatives
  • Identify improvement and cost reduction opportunities relating to lubrication management, storage, handling and disposal.
  • Identify opportunities to enhance effectiveness in oil analysis Including sampling methods, tests, target cleanliness levels, data alarms/limits, sampling frequency, etc. and integration with other maintenance technologies.
  • Review contamination control and proactive maintenance practices and propose improvements.
  • Identity opportunities and needs for lubricant consolidation and put basic standards.
  • Suggest needs for training and procedure documentation

BENEFITS

  • Proper Implementation & recommendations suggested in Lubrication audit help to optimize the performance of lubricating fluids and equipment availability, lower overall operating cost and safety risks and increase Profits.
  • Savings in lubrication costs-reducing consumption and cost of high oil Losses / Extend lubricants usable life, which reduces the amount of lubricant requiring disposal
  • Savings in Maintenance repair and Replacement costs
  • Savings in consequential losses due to down time
  • Savings in investment through increased life
  • Reduction in energy consumption