A steel plant in Nagtahan, Pasig was struggling with the drawbacks of manual lubrication: frequent component failures, unplanned shutdowns, and high maintenance and production costs. The machinery required weekly manual lubrication, necessitating operational halts. Difficult and hazardous access to the machines further complicated proper lubrication, posing significant health, environmental, and safety risks.
To counter the issues, the plant has been facing, Le Price installed an Automatic Centralized Lubrication System. A single-port lubricator, complex dual-line, reversing unit, and lube timers have been installed to help with the automatic lubrication. A world-class lube storage will keep the lubricants clean and fresh. Lubrication accessories were also installed, and a preventive maintenance service contract was employed to further strengthen the maintenance program.
Lastly, the team conducted training and seminar to hone the skills of the plant’s personnel.
After deploying the action plan, the plant was able to reduce maintenance costs and waste. The fresh and clean lubricant has also been automatically distributed at the right point and time. An accurate amount of lubricant is also being dispensed. The operating temperature decreased from 60 deg c to 40-45 def c. Lastly, Le Price's maintenance program reduced the maintenance costs for equipment and eliminated the safety and health risks.
The plant is reported to have reduced bearings and parts failure which extended the machine service life. The plant also saved up to 60% of procurement and maintenance costs.The plant’s personnel gained enhanced technical productivity and equipment maintenance processes skills to ensure machine performance and safety. All the safety issues were properly addressed by Le Price Maintenance Service.