1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf
Lubretec PP 10 Steps UK.pdf
1. 10
Steps to Lubrication Reliability
To enhance Plant & Equipment Reliability and to achieve
World Class Maintenance
A How to guide for Maintenance & Reliability Professionals
2. Lubrication Reliability Best Practice INTRODUCTION
¾ Company : Lubretec bvba
¾ Goal : World Class Maintenance
¾ Strategy : Lubrication Reliability
¾ Tools : Lubrication Best Practices
BEST
Practice
4. 0 10 20 30 40 50
Filter Rating (Particle size, µm, where Beta = 200)
0
2
4
6
8
10
12
14
Millions
of
Cycles
To
Fatigue
Failure
6 25
3 40
1
6.6
3.6
1.3
WHY ? : Bearing life is function of
lubricant Cleanliness
Lubrication Reliability Best Practice INTRODUCTION
5. MEAN TIME BETWEEN FAILURES (hours)
0
5
10
15
20
25
30
ISO
CODE
RESULTS OF DTI SURVEY 1984
>3um
>5um
>15um
WHY ? Failure is related to ISO4406 Code
Lubrication Reliability Best Practice INTRODUCTION
7. Lubrication Reliability Best Practice INTRODUCTION
•Corrugator plant Netherlands
•2006-2008, 24 months survey
•Investigation of all bearing failures
•Total of 2.300 € bearing value
•Total of 150.000 € maintenance cost
WHY ? Recent Case Study
8. Lubrication Reliability Best Practice INTRODUCTION
WHY ? Recent Case Study
• 60% bearing failures = lubrication related :
wrong lubricant, over & under lubrication,
contaminated lubricants
• 15% bearings failures = incorrect fitting &
adjustment, bad mounting, damaged during
fitting
• 5% bearings failures = ignorance & mistakes,
wrong bearing type, wrong clearance or seals
• 20% bearings = no problem, no failures : no
need for change as they were in good condition
9. 1 Lubrication Assessment
2 Organisation & Planning
3 Identification & Inspection
4 Cleanliness Control
5 Lubricant dispensing
6 Grease Lubrication
7 Contamination Control
8 Oil Monitoring
9 Environmental Control
10 Lubrication Training
10 Steps to Lubrication Reliability
10. • Where are we now ?
• What do we do wrong ?
• What do we need to improve ?
Step 1: Assessment & Benchmarking
Best Practice Solution : LubeAssess™
13. Step 4: Cleanliness Control
• Contamination is a major source of failure
• Clean lubricants in operation
• Lubricant Cleanliness Control Centres
• Safe & Clean storage-conditionning-transfer
Best Practice Solution : Lubristation
®
14. • Safe & Clean tools
• Efficient & user friendly
• Adapted to application
• Multi colored identification
• Contamination free
Best Practice Solution : Oil Safe
®
Step 5: Lubricant Dispensing
15. • Best practice tools
• Efficient & practical
• Color-coded, metered
• Automatic
Step 6: Grease Lubrication
Best Practice Solution : Grease Safe™, Mobilube, Elcolube
16. • ISO4406 check
• On line /Off line filtering
• Lubricant protection
Best Practice Solution : Air Sentry
®
, Decolube
Step 7: Contamination Control
17. • ISO 4406 monitoring
• Lubricant life extention (chemistry)
• Cleanliness management
Best Practice Solution : Sampling , CheckFluid
Step 8: Oil Monitoring
18. • Maintenance strategies : 5S
• World Class Manufacturing
• Environmental protection
• Efficiency tools
Best Practice Solution : Absorbents, Spill Control
Step 9: Environmental Control
19. • Reliability Lubrication training
• Reliability Technician
• Lubrication training all aspects
Step 10: Knowledge Management
Best Practice Solution : Lubrication Training
22. Lubrication Reliability : Check List
6 Consolidation of packaging ( centralized storage )
9 Unique type of packaging ( 200 l )
9 Larger type
6 Consolidation of lubricant types ( less is more )
6 Reception control
9 Type check & date
9 Damaged packaging
9 ISO4406 contamination level
6 Proper identification
9 Color coding ( refer to dispensing, avoiding mistakes )
9 Type – brand – internal order code
9 Viscosity
9 Application
9 Date of reception & of first use
23. Lubrication Reliability : Check List
6 Pre-filtering of new oil to required ISO4406 level
9 While transfer to new storage tanks
9 Kidney loop on drum or tank
9 Correct filter rate in function of application
6 Storage in proper environment
9 Clean dedicated lube room, not outside
9 Constant temperature & humidity
9 Organized, safe & efficient
9 Away from dirt causing production environment
9 Use of proper absorbents ( no pellets, no sawdust )
9 Use of regulatory spill-retention equipment
24. Lubrication Reliability : Check List
6 Storage in proper recipients
9 Lube supplier drums, containers ( horizontal/vertical )
9 New plastic tanks - containers ( rust free, translucent )
9 New steel coated tanks ( with oil level )
9 New SS tanks ( oil level )
6 Protection
9 Protect lubes from humidity & dirt with breather-dryers
9 Fully closed containers/tanks, pump-tank connection.
9 Protect grease nipples, quick disconnects with caps & plugs.
6 Transfer and dispensing
9 Closed loop tank-dispensing equipment preferred
9 Use of fully sealable dispensing equipment ( chain of
cleanliness )
9 Filtering during transfer and dispensing
