1.1 Lubrication Management and Organization (LUB) [PDF]

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1.1 Lubrication Management and Organization (LUB)

This module presents the "standard organization" for Lubrication Management and associated roles, responsibilities and skill requirements.

Introduction

Lubrication Management and Organization

Lubrication Roles and Responsibilities

Lubrication Skills

Knowledge Check

Lesson 1 of 5

Introduction

Preventative (periodic/proactive) and Predictive Maintenance schemes have steadily grown in popularity as their long-term bene ts and return on investment (ROI) have been realized over the more traditional Reactive (corrective) Maintenance approach.  Preventative and predictive maintenance  schemes utilize differing concept for nding, identifying and correcting maintenance  issues prior to them becoming major concerns or forcing a costly unplanned shutdown. Whereas, reactive (corrective) maintenance is essentially responding to unplanned events and failures. 

The following graphic re ects these various maintenance schemes and their relationship to maintenance activities.

Maintenance Schemes

What do these maintenance schemes have to do with lubrication management?  The overall objective of the Lubrication Management process is to ensure machine availability.  Part of ensuring machine availability is having in place a well de ned and thoroughly implemented preventative and/or predictive maintenance program. Lubricants are the lifeblood of our equipment and neglecting proper lubrication practices in neither wise, nor a good maintenance practice or plan. Regularly planned, scheduled and executed lubrication routines is not only wise, it is essential.

In this lesson, you will gain a more thorough understanding and familiarization of the following: 

The overarching objective of the lubrication management program and it's organizational components;

The roles and responsibilities required to realize an effective lubrication program;

The various skills, knowledge and abilities  required to properly perform lubrication routines and related tasks and duties.

Lesson 2 of 5

Lubrication Management and Organization

Lubrication Management The objective of lubrication management can be summed up in two very important words: Machine Availability.   When a machine or piece of equipment is down for maintenance, it is not available for its intended or needed purpose.  This effect is further compounded if the machine or equipment breakdown is unexpected and results in more costly unplanned downtime.  

Waiting to perform maintenance after a unit of equipment has failed due to improper lubrication should be unacceptable.  One of the biggest contributors for machine reliability and therefore machine availability is proper lubrication protocols. 

Click on each of the following cards to review the contrast between reactive and preventative maintenance.

Performing costly unplanned machine and Reactive (Corrective) Maintenance Scheme

equipment issues and breakdowns as or after they occur, often resulting in costly and untimely repairs and/or shutdowns.

Utilizing planned and schedule maintenance Preventative (Periodic/Proactive) Maintenance Schemes

activities base on data to minimize unexpected machine and equipment failures and keep production interruptions to a minimum.

Lubrication Program A lubrication program should be a standard part of your preventative maintenance program, which includes oil changes, re lls, sampling, greasing, lter changes, inspections, etc.  Lafargeholcim's organizational lubrication strategy is to centralize the lubrication roles and responsibilities within the Preventative Maintenance Department as illustrated in the following Organizational Chart.

Typical Maintenance Department Organizational Structure Lubrication types , application methods and frequency of servicing must be standardized and utilize best practices to achieve sustained continuous improvement.  Machine criticality, failure history, operating environment and lubricant application will drive decisions regarding your overall lubrication program design. 

The following chart re ects a very general, but relatively accurate snapshot of the percent of equipment failure attributed to poor or improper lubrication practices?  Can you afford these?

Equipment Failure Statistics

Lubrication Organization To accomplish the objective of ensuring machine availability there are six functions of the lubrication management process that must be organized, integrated and synergized. These six functions are: Handle and Storage, Application, Troubleshooting (Root Cause), Oil Analysis, People and KPI's.

The following illustration depicts the six functions: 

Lubrication Management Process

Click on the following six function's terms to discover more about each!

Lubrication

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Proper lubrication is a big contributor to a machines longevity and reliability.  Too much lubricant is just as bad as too little.

Handle and Storage

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The proper handling and storage of lubricants is important to ensuring a lubricant remains free of contaminants, such as moisture and dirt.

Application

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The selection and/or application of a lubricant is vitally important due to speci c needed characteristic, such as viscosity, additives, base oil, speed, load and temperature conditions.

Root Cause - Troubleshooting

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When equipment is running problems may occur.  Understanding the origin and nature of a potential problem assists with identifying its root cause.  There can be many issues in uencing a failure, such as mechanical problems due to improper equipment adjustments.  It is common to mistake mechanical problems as lubrication problems and vice-versa.  For example, if contamination is evident was it caused by a bad seal (mechanical), through improper handling and/or storage or was it the result of an incorrect lubricant (application) being selected.

Oil Analysis

It is important because it allows the oil condition to be known by monitoring and measuring the chemical or physical condition of the lubricant.  Oil Analysis can indicate the life cycle condition of a lubricant or when it should be replaced.

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People

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  Establishing

good communication with suppliers aids in optimizing lubrication application and performance.  Establishing training and new development programs and promoting cooperation ia another component. Likewise good communications with your Maintenance and Production Departments is important for reporting and coordinating abnormal conditions and managing repair times. Regular communications with vibration inspectors facilitates cross check . Similar regular communication with planners aid in the creation of timely work order noti cations and follow-up activities.

KPI's

KPI's such as Oil Consumption Rate (OCR) provides baseline measurements indicating how speci c components of lubrication program is performing, as well as the overall performance of your lubrication program.

Which of the following responses states the most important objective of the  lubrication management process?  

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Effective lubrication 

Machine availability

Meeting KPIs

SUBMIT

True of False: Lafargeholcim's organizational lubrication strategy is to centralize the lubrication roles and responsibilities within the Preventative Maintenance Department. 

True

False

SUBMIT

Match the following activities to their corresponding organizational process component:

Lubricant preservation

Handle and storage

Lubricant selection

Application

Troubleshooting

Root Cause/FLRC

Lubrication sampling

Oil analysis

Communication

People

Lubrication Performance

KPI's

SUBMIT

Lesson 3 of 5

Lubrication Roles and Responsibilities

Lubrication Roles and Responsibilities It is the lubrication professional’s central task to ensure (as it relates to lubrication) that equipment reliability is optimized at the lowest possible operating cost.  

The following graph denotes the many facets that generally comprise an effective lubrication program and the relative importance of each toward ensuring cost effective and proactive maintenance practices.

General Facets of an Effective Lubrication Program

General Roles and Responsibilities  In general, lubrication roles and responsibilities are strategically focused and contribute to improving equipment performance.  A lubricant is a complex combination of chemicals that is formulated to provide speci cally de ned performance properties. The lubricant works by a combination of physical and chemical mechanisms.  Lubrication is more than just applying grease or changing oil. 

It is many diverse activities such as utilizing lubrication plans and regular inspections based on the machine’s maintenance manual,  lubricant suppliers advice, as well as the  lubrication engineer's experience . Additional factors such as operating temperature range, load, viscosity, environment  and design limits must also be factored in as well.  Remember, under the scope of the LH lubrication strategy it is recommended to centralize the lubrication roles and responsibilities in the Preventive Maintenance department.

Simple Lubricant Selection Strategy

Management Roles and Responsibilities The lubrication manager's roles and responsibilities include, the management of oil analysis, lubricant selection, lubrication practices, lubricant handling and storage and contamination control.  There are some strategic administrative activities which focus and contribute to improve equipment performance; these practice require more follow up when the condition of the machine(s) change or some values are out of limits.

Some other general responsibilities include

1

Oversee the selection and application performance speci cations of all lubricants for each machine, assisted by the lubrication engineer, equipment's OEM and lubricant suppliers;

2

Develop and implement Preventive Maintenance Routines (PMRs) and establishes grease and oil sampling and analysis procedures and guidelines;

3

Update routines in management system (work load optimization) and ll out daily lubrication journal (log book);

4

Ensure that selected lubricants are compatible with the machine, process uids and work environments and availability of MSDSs;

5

Establish procedures and guideline to prevent moisture and particle contamination of grease and oil in or out of storage room conditions;

6

Communicate abnormal conditions and ensure proper follow-up.

Sample Example of a Gearbox-Lubricant Checklist

Technician Roles and Responsibilities A Lubrication Technicians roles and responsibilities include, but are not limited to, understanding how to select and apply the proper lubricants to the Plant's machines and equipment. The technician must be

familiar with both the lubricants used and the mechanisms that control friction and wear. An important, but often overlooked technician skill is the knowledge and ability to  both verify and apply proper lubricant levels. Too much lubricant is just as bad as too little! Knowing and applying the correct amount of lubrication is critical to maximizing machine and equipment life.  

Some additional general responsibilities of Lubricant Technicians are:

1

Selecting and applying the correct lubricants for equipment to be greased or oiled;

2

Applying the correct lubrication amounts/levels using  control devices;

3

Selecting and using the correct grease ttings, tags and grease guns;

4

Selecting and using the correct oil port ll locations and dispensing equipment;

5

Selecting and using the correct storage room tools and equipment;

6

Preventing moisture and particle contamination of grease and oil in or out of storage room.

Technician Servicing a Motor Gear Assembly 

Lubrication Storage There are two types of storages to be organized: Warehouse Lubricant Storage and Daily Lubricant Storage.

Warehouse and Daily Lubrication Storage Click on each of the following types of storage cards to further explore each!

Storage of all lubricants still part of the of cial Warehouse Lubricant Storage

warehouse inventory and maintained under the lead and responsibility of warehouse personnel.

Local storage of lubricants for quick, easy access and handling and necessary for Daily Lubricant Storage

daily lubrication tasks. Lubricants stocks in this storage area are already listed as consumed and no longer part of the

Front of card

Back of card

Lubricants and lters must be kept in a clean and organized environment to reduce the potential risk of introducing unwanted contamination.  Lubrication storage locations must be maintained in a safe condition, which also prevents unintended environmental risks such as leaks, spills or other mishaps. Stored oil lters should be kept sealed in their manufacturer’s package to prevent exposure to the elements and potential dirt and moisture contamination.   Failure to do any of these actions can result in the risk of contamination. 

                                                                                              

 Proper Oil Filter Storage Click on each of the following to learn more about lubrication storage conditions!

Inventory

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Always maintain appropriate oil inventory levels in the warehouse and workshop to ensure needed lubricant types and quantities are available when needed and stored in a manner that protects against potential contaminants.

Filters

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Maintain a lter element inventory list and ensure lters are maintained in good condition and protected from potential contamination sources by keeping stored in manufactures packaging until needed.

Identi cation

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Ensure lubrication identi cation labels are af xed and readily viewable and their appropriate MSDS are easily available for personnel to reference.

Cleanliness

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Maintaining the cleanliness of lubrication storage locations is critical to preventing contamination and maintaining an orderly inventory of storaged lubricants and lters.

Envrionmental

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Most lubricants, new or used, pose environmental risks that must be safeguard against and proper storage and labeling are key components of this process. The availability of MSDS help assure proper handling, spill prevention, disposal and rst aid precautions are known.

Technician Performing Lubrication Routine

Lubrication Inspections Are lubrication inspections really needed?  How many lubrication related failures has your facility experienced?  Many companies struggle with addressing foreseeable lubrication related failures, due in part

to a lack of understanding of what a lubrication related issue looks like, why it matters and how to appropriately address it.  Of those failures how many could have been prevented through proper visual  inspections?   Lubrication inspections are part of the standard Lafargeholcim PMRs; they ensure both scheduled systematic inspections and timely servicing of equipment.

Visual lubrication inspection is a basic method for determining the condition of a piece of equipment or a component by simply using your senses. A visual review of a lubricated component might include the collection of basic information, such as asset condition (cleanliness, visible leaks, state of installed modi cations), oil level, oil condition, amount of oil added, lter condition, breather condition, and temperature.

Click on each of the following terms to learn more!

PMRs

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Perform PMRs at the scheduled time and interval.  Always do PMRs in the same order so it becomes a habit and with practice anything wrong can be quickly spotted.

Work Orders

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Follow and understand the job instructions in the work orders, as well as technical information, safety instructions, materials, spare parts, tools, etc

Equipment

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Verify equipment items are in good condition, properly assembled or stowed, properly lubricated and not loose or excessively worn.

Lubricants

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Selection the correct lubricant needed for it's operating characteristics, such as viscosity, additives, base oils, as well as speed, load and temperature conditions.

Technician Performing Visual Inspection Routine When replacing oil and grease, the Lubrication Technician should be remain observant for potential defects and damage that may be

present. In addition to visual inspections equipment components should be checked for proper operating temperature ranges and excessive vibration. A change in sound or increased vibration is an early indication of potential problems and should not be ignored.   For example, performing visual inspections of bearings and gear surfaces for:

1

Changes in color on running surface

2

Spalling, etching or other surface defects like scratches

3

Carbon residues from the lubricant

4

Evidence of corrosion or mositure intrustion

5

Bearing clearance and presence of metal debris

6

Signs of contamination and poor of leaky seal conditions.

Technician Performing Routine Maintenance Activities

1

A lubrication technician routine tasks include performing established PMR routines, visual equipment inspections for oil leaks, temperatures, lubrication pattern and consumption on pinion drives, lubrication, cycle time per centralized systems and cleanness of condition.

2

Relubrication and oil changes when speci ed or required

3

Taking oil samples according PMR and lubrication plan, including analyzing  results and sharing with vibration inspectors..

True or False: In general, lubrication roles and responsibilities are strategically focused and contribute to improving equipment performance.

True

False

SUBMIT

The lubrication management roles and responsibilities include, the management of all lubrication maintenance functions including: (Select all that apply)

Oil analysis

Lubricant selection

Lubrication practices

Lubricant handling and storage

Contamination control

SUBMIT

Match the lubrication storage term in the rst column to its corresponding statement in the second column.

Warehouse Lubricant Storage

Pertains to stored lubricants still within the warehouse inventory.

Daily Lubricant Storage

Pertains to stored lubricants locally available for easy access and handling.

Oil Filter Storage

Kept sealed in their manufacturer's package to prevent exposure to contamination.

SUBMIT

True or False: Lubricants and lters must be kept in a clean and organized environment to reduce the potential risk of introducing unwanted contamination.

True

False

SUBMIT

True or False: Visual lubrication inspection is a basic methodology for determining the condition of a piece of equipments or component by simply using your senses. 

True

False

SUBMIT

Lesson 4 of 5

Lubrication Skills

Lubrication Skills There are four distinct lubrication skills you must apply to ef ciently and effectively manage your lubrication program: Communication, Discipline, Observation and Analysis.

Communications is Key!

Communication Maintaining ongoing communications with your Lubricant Suppliers and Plant Maintenance and Production Departments is the cornerstones to building a strong robust lubrication program!

Click on the following titles to learn more about communication skills!

Communicating with Suppliers

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Regular communication with your suppliers is important to optimizing  lubricant performance, gaining important training and learning of new developments, as well as an external source to discuss oil sampling results.

Communicating with Maintenance and Production Departments

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Strong communication with your maintenance and production departments is critical to keeping everyone informed about abnormal conditions, recent servicing issues and to review and discuss criticalities and/or potential needed interventions.

Communicating with Vibration Inspectors

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Regular and frequent conversations with your Vibration inspector is important to cross check and correlate information as a result of vibration measurements. .

Communicating with Planners

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Regular and frequent conversations with your Maintenance Planners is another critical communication element.  Maintain communications with planners helps ensure timely noti cations and needed follow up actions are initiated and followed up.

Successes Starts with Discipline

Discipline To build a strong lubrication program you must constantly ensure you are adhering to the established lubrication plan and routines.  Being disciplined means performing lubrication routines and PMR's in a timely and consistent manner on a continuous basis!

Click on the following discipline activities to learn more!

Discipline

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Discipline means maintaining, strengthening and implementing lubrication protocols as an established regiment and requires being consistent and disciplined in its application and administration. 

PMRs

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An active PMR program is the backbone of preventative maintenance!  Ensuring regularly planned routines and well de ned and timely PM schedules are an imperative.  

Training

Ensuring all lubrication employees are well trained and informed of basic lubrication routine, as well as receiving regular follow-up and advanced lubrication training is critically important to maintaining a strong, vibrant lubrication team.

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Observing for Leaks and Defects is an Important Lubricant Skill

Observation Being aware of visual cues or listening for unusual sounds or smells or excess vibration are all aspects associated with being observant to surrounding conditions when servicing or inspecting equipment or machines. Who better knows your machines and equipment than your technicians?

Click on each of the following to learn more!

Observation

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Observation is understanding and being aware of potential failure conditions and that is an imperative function of preventable maintenance.  This means being aware and observant of visual indications of leaks, wear and other common damages present during routine inspections, sampling or while performing lubrication servicing.

Visual Inspections

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Regularly conducting visual inspections during sampling or monitoring of lubrication systems, particularly during grease and oil changes.

Employee Training

Employees must be familiar potential defects and failures, as well as trained on how to properly perform visual inspections.  It also means ensuring employees are well trained in other basic lubrication inspection practices.

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Sampling and Analysis are Important Lubricant Skill

Analysis Using the correct process equipment, procedures and  methods for the lubricant sampling and analysis process is imperative to accurately analyzing the lubricant's condition. Not following and adhering to sampling and testing processes can lead to devastating errors! 

Click on each of the following to learn more!

Analysis

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To maintain an effective lubrication program you need access to the correct sampling and testing equipment, be properly trained on those items and possess the ability to accurately perform sample analysis, identify off-spec conditions and contamination.

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Sampling Errors

Improper lubrication sampling analysis and/or using improper sample testing procedures  will likely lead to inaccurate or misleading understanding of the lubricant's condition.  

To be effective, you should maintain ongoing communications with which of the following? (Select all that apply) 

Lubricant suppliers

Maintenance department

Production department

Quality department

SUBMIT

True or False: Being disciplined means performing lubrication routines and PMRs in a timely and consistent manner on a continuous basis

True

False

SUBMIT

Not following and adhering to which of the following processes can lead to devastating errors! 

Sampling and testing

Tracking and tracing

Timely follow-up

SUBMIT

Match the lubrication skill in the rst column to it's corresponding statement in the second column.

Communication

Review and discuss criticalities and/or potential interventions

Discipline

Maintaining your established lubrication protocols

Observation

Being aware of potential failure conditions

Analysis

Using proper lubrication sampling testing procedures

SUBMIT

Lesson 5 of 5

Knowledge Check

Please complete the following quiz which contains ten questions,  a score of 80% or greater is required.

Question

01/10

Complete this sentence: LafargeHolcim’s organizational lubrication strategy is to centralize lubrication roles and responsibilities within the 

Production department.

Preventive maintenance department.

Warehouse and storage unit.

Question

02/10

Complete this sentence: The overall objective of the Lubrication Management Process is to ensure  

Machine availability.

Only best lubricants are used.

Lubrication technicians are always available.

Only best lubrication practices are used.

Question

03/10

Which of the following is a key organizational process components? 

Handle and Storage

Application

Troubleshooting (Root Cause)

Oil Analysis

People

KPI's

All the above.

Question

04/10

Fill in the Blanks: Lubrication roles and responsibilities contain activities that are ____________________ and ________________ to improving equipment performance.

Tactically focused, contribute

Well developed, contribute

Strategically focused, contribute

Well de ned, geared

Question

05/10

Fill in the Blanks: Lubricants lubricate machines through a combination of _______________and ______________ actions. 

Physical, chemical

Chemical, lubrication

Physical, lubrication

None of the above

Question

06/10

What are two types of organized storages:  Select all that apply.

Equipment Lubricant Storage

Warehouse Lubricant Storage

Daily Lubricant Storage

Central Lubricant Storage

Question

07/10

Lubricants and lters must be kept in a clean and organized environment to reduce the potential risk of introducing .  Select all that apply.

Dust and dirt particles.

Moisture.

Other unwanted contamination.

Question

08/10

Which of the following are lubrication skills you must apply to ef ciently and effectively manage your lubrication program? Select all that apply.

Communication

Discipline

Observation

Analysis

Question

09/10

Which of the following is not generally associated with maintaining good communications with your lubricant Suppliers:

Optimizing the performance of lubricants

Training and new developments

Discussing oil sampling results

Gas ow or similar

Question

10/10

Being aware of leaks, wear and other common damages present during routine inspections, sampling or performing lubrication activities are examples of

Being observant of visual indications.

Understanding your role and responsibilities.

Conducting  PMRs.

Closely following work task checklists.