This document outlines 10 steps to achieve lubrication reliability in order to enhance plant and equipment reliability. It begins by explaining why lubrication reliability is important, noting that bearing life depends on lubricant cleanliness and failure rates correlate with lubricant contamination levels. Case studies show 60% of bearing failures were lubrication-related. The 10 steps include conducting a lubrication assessment, organizing planning, implementing cleanliness controls, proper lubricant dispensing and monitoring, environmental controls, and providing lubrication training. Checklists are provided to evaluate lubrication reliability practices and identify areas for improvement.

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

3. WHY ?
BAD
Practice
Lubrication Reliability Best Practice INTRODUCTION

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

6. Lubrication Reliability Best Practice INTRODUCTION
WHY ? Mechanisms of component wear
Result ? Component Failure

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™

11. Step 2: Organisation & Planning
• Lubrication Planning
• Lubrication Management
• Lubrication Management tools
Best Practice Solution : Lube-IT®
software

12. Step 3: Identification & Inspection
• Multiple types lubricants ,avoiding errors
• Complex Chemistry & Compatibility
• TPM, ISO22000, OSHA-EU, IFS, 5S
• Easy inspection & monitoring
Best Practice Solution : Label Safe™, 3-D level

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

20. BAD
Practice
Lubrication Reliability Conclusion

21. Lubrication Reliability Conclusion
BEST
Practice

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

25. Lubrication Reliability : Check List
6 Continuous Lubrication Inspection
9 Oil Levels on machines ( min-max level )
9 Oil quality on machines ( Oil analysis )
9 Lubricant and/or grease leakage
9 Storage inspection ( open drums, dirty connectors, lost
protect caps )
9 Grease level in automatic lubricators
9 Blocked grease lines
9 Filter Saturation indicators
9 Filter content inspection, pictures, samples (FMEA )
9 Breather-dryer inspection for saturation

26. Lubrication Reliability contact & Info
10
Steps to Lubrication Reliability
THANK YOU !
Lubretec bvba
Toon Van Grunderbeeck
toonvg@lubretec.com
+32 476 23 83 78
www.lubretec.com