2. Figure 2 Ref. AIMAN (Italian Association of Maintenance Engineers)
and IRI (International Research Institute) in conjunction with SKF
3. Factors that Enable Lubrication
Excellence
• People Preparedness. People are trained to modern lubrication skill
standards and have certified competencies.
• Machine Preparedness. Machines have the necessary design and
accouterments for quality inspection, lubrication, contamination
control, oil sampling, etc.
• Precision Lubricants. Lubricants are correctly selected across key
physical, chemical and performance properties, including base oil,
viscosity, additives, film strength, oxidation stability, etc.
• Precision Lubrication. Lubrication procedures, frequencies,
amounts, locations, etc., are precisely designed to achieve the
reliability objectives.
• Oil Analysis. This includes optimal selection of the oil analysis lab,
test slate, sampling frequency, alarm limits, troubleshooting
rationale, etc.
4. Advantages of an Audit
Identify duplication of lubricants
Learn about your hidden lubrication costs
Learn of potential safety and environmental issues
Cost out the R.O.I. of automating some of your
critical production equipment
Up-dated manuals as required for your current
automated lubrication system
A customized plan to reduce cost, improve
productivity and safety, listing the opportunities in
priority sequence
5. Equipment Survey Overview
Develop an equipment list
Routine inspection, equipment survey and visual inspection
Identify and label equipments with equipment number and
description
Equipment pictures
Machine criticality assessment and operating parameters
Identify lubricant sections from the OEM manual
Technical data sheet for the selected lubricant for the equipment
Selected lubricant MSDS
Leakage reports
Equipment temperature environment
Oil sampling as required
Lubrication inspection, top offs
Reliability, mean time between failure data on the equipments
Safety and operational hazards
7. Lubricant Survey Overview
Lubricant technical selection practices
Lubricant application practices
Oil analysis program practices
Condition control practices
Lubrication practices standardization (SOPs)
Long term lubricant stability
Lubrication survey and lubricant vendor selection
Consolidate lubricants
Set lubrication preventive maintenance (PM) frequency
Root cause mapping and correction
Program effectiveness reporting
Program management and personal development
8. Lubricant Survey Overview (Cont’d)
Eliminate unnecessary oil changes
Eliminate premature aging of lubricants
Verifying, defining lubrication practices
Verifying, defining re-lubrication activities like volumes,
frequencies, route sequences, machine upgrades etc.
Purchase necessary lubrication equipment and tools
Perform financial analysis review and establish a cost basis
Reduce the number of lubricants in use and thereby reduce the
chances for mis-application and cross contamination
Contamination control practices
Upgrading knowledge level
Develop a lubrication manual
10. Storage and Handling Survey Overview
Lubricant delivery, storage and handling practices should be
followed
Wasteful practices of products, duplication and excess inventory
should be eliminated
Storage room temperature extremes should be avoided
Fluctuating temperatures should be avoided
Containers should not be stored in a humid environment
First in first out (FIFO) system should be maintained such that
stocks are rotated properly
All new drums should be filtered to an appropriate level. Use a
ß3=200 filters for lubricants below 150 cSt @ 40⁰C. Use ß6=100
filters for lubricants above 150 cSt @ 40⁰C
All drums and containers should be labeled and color coded and
filtered drums should be labeled as such with the date of
filtration.
11. Storage and Handling Survey Overview
Filtered drums should be fit with an appropriate air filter to offer
air flow a path of least resistance allowing moisture and solid
particulate to be captured prior to entering the drum.
When new oil is transferred to the top-up container, it should be
transferred through a filter.
Oils should be stored in fluid storage racks
Fluid storage racks should have oil and air filtration
Proper dispensing containers should be used and stored in an
explosion proof cabinet
Drums should be stored horizontally and covered to keep excess
moisture and dirt from settling on them. The openings (bungs)
should be at 3 and 9 o’clock positions to minimize the amount of
breathing in the drums
Drums should be fitted with dispensing taps with covers
15. Safety Survey Overview
MSDS are available and are reviewed
Lock out procedures are followed
Leakage control
Spill response is in place
Handling practices maintain a safe environment
Lubrication equipment use is understood
Sampling procedures are followed
Training to ensure effectiveness and consistency
Proper documentation and reports and manuals
Proper fire hazard precautions are taken
17. Typical Audit
Oil storage and dispensing:-
Oils stored in fluid storage racks
Fluid storage racks have oil filtration
Fluid storage racks have air filtration
Use of proper dispensing containers
Lubricant stocks properly rotated
Bulk oil changes performed using a filter carts
18. Typical Audit
Oil sampling techniques:-
Oil sampling procedures are documented
New oil deliveries are sampled
Oil sampling ports are properly located
Proper oil sampling hardware is installed
Sample ports are properly labeled
Automatic monthly scheduled oil change in place
19. Typical Audit
Contaminant ingression control:-
Proper air breathers are installed on equipment
Additional offline filtration is installed on critical
equipment
Lubrication ports are installed
Off line filter carts are available and employed
regularly
Water stripping equipment is available
Offline filtration and oil filter changes are
performed on condition
20. Typical Audit
Oil analysis program:-
Proper sampling frequencies are defined
Oil analysis test slates are well defined
Proper limits and targets are employed by
machine type
Oil analysis data is effectively communicated
through the company
A process exists for troubleshooting exception
conditions
21. Typical Audit
Program Management:-
Equipment criticality assessed and determined
Regular and condition based PMs in place
Oil changes are based on condition
Qualified and trained technicians dispense
lubricants
PM schedules are tracked in a database
Trend charts showing sample/analysis
performance are publicly displayed