The potential for a significant financial gain via lubrication excellence is huge that most plants and industries in the Philippines have yet to realize. Reduced downtime as a result of avoiding breakdowns is the most prevalent financial advantage. In today's budgeting cycle and supply chain challenges, it pays to have better reliability and dependability. When you embark on your journey towards lubrication excellence, here are some useful tips to bear in mind to be able to capitalize on your programs.

maintenance cost reduction

Maintenance cost reduction

Implementing change requires cost but the advantages to be gained outweigh the overall cost of investing in lubrication best practices. Of course, before you start investing, it is important to determine what your end goal is. What are the prudent and tried-and-true maintenance techniques to use to accomplish this goal? What is the minimum amount that must be invested? 

 

Avoiding Overspending

Some businesses fail to see low-hanging fruits right in front of them. Poor energy management strategies, such as those found in many older plants, are an excellent example. With minimal expense used in addressing these low-hanging fruits, you have so much to gain. Here are some of the potential savings outside of the maintenance budget:

  • Operator inactivity as a result of unavoidable scheduled or unplanned downtime (intangible)

  • Production has been lost or hindered (tangible)

  • Costs of energy/fuel use (tangible)

  • Defects in the product/spoilage (tangible)

  • Costs of leakage, waste, and disposal (tangible)

  • Overtime charges and other unanticipated labor/contractor costs (tangible)

  • Parts that aren't in the budget (tangible)

  • Shipping charges for over-budget "rush" parts (tangible)

  • Purchases are being disrupted (intangible)

  • Storeroom disruption (intangible)

  • The morale of the employees is harmed (intangible)

  • Customer dissatisfaction (intangible)

  • Consequences for safety (tangible and intangible)

  • Environmental ramifications (tangible and intangible)

 

fuel and energy control

1. Getting Your Fuel and Energy Bill Under Control

Even little variations in lubricant selection and application can have a significant influence on energy usage. Most users are unaware of this information; it is thus frequently overlooked. 

Ways to Achieve:

  • Consistency of Grease - Just like any other lubricant, the consistency of grease can affect energy usage. The consistency and chemistry of a lubricant have an impact on the energy required to move grease in frictional zones and nearby cavities of moving machine parts.
  • Properties of Grease-Channeling - A grease with strong channeling properties keeps the bulk lubricant away out of moving parts, thereby reducing churning and drag losses
  • Overgreasing - It is well known that over-greasing of bearings increases friction and raises the bearing temperature. The same may be said for under-lubricated bearings due to the lack of separation between two metal surfaces. A half-inch change in oil level can raise the temperature by more than 10 degrees C for bath-lubricated bearings and splash-lubricated gears. This means more energy use, shorter oil life, and more wear.
  • Energy is lost as a result of wear. Wear not only causes machine failure but also reduces performance in the interim between repairs or overhauls. Due to sluggish or irregular machine performance, as well as higher energy consumption, production is frequently compromised. Hydraulic pumps and actuators, for example, lose volumetric efficiency as they age. This slows down work and increases energy consumption. As a result of wear, gears and bearings require more energy. Due to wear in the valve train, bottom-end bearings, and combustion chambers, even diesel engines have lower combustion efficiency. As a result, there is an increase in fuel usage.
  • Viscosity with high precision - The viscosity of a lubricant has a direct impact on the oil film it produces. In engines, gears, bearings, and hydraulics, extremely high viscosity produces churning losses (internal oil friction) and heat generation. It can also lead to lubricant starvation.

 

lubricant spending reduction

2. Saving Money on Lubricants

The purchase of lubricants is not the most expensive item in a regular maintenance budget. It is, nonetheless, seen as a genuine, concrete expense that is usually targeted for cost savings. Of course, pretending to save money by "purchasing cheap" is a bad idea.

Ways to Achieve:

  • Optimizing Lubricant Selection for Longer Life - "Optimum" refers to the highest level of performance for a machine. Don't go overboard with your spending, yet don't skimp on it either. Choosing a long-life lubricant can cut oil usage by more than half in many circumstances. It's risky to try to save money by buying economy-formulated lubricants for inappropriate applications. Don't be seduced by the false promise of forgiveness, either. Attempting to correct poor lubrication habits by purchasing pricey premium lubricants is also risky. Small variations in lubrication performance can result in significant changes in machine reliability and lubricant expense. Small discrepancies should be avoided in choosing the best lubricant for a machine application.
  • Increase the Lifespan of Your lubricant - Lubricants age in a linear pattern when used according to specifications. They eventually perish as a result of cumulative depletion or other factors. However, life expectancy is affected not just by the lubricant's quality, but also by the type and severity of stressful exposures. Contaminants such as heat, air, and moisture are the most significant contributors to lubricant degradation.
  • Re-lube Interval Optimization - Many machines should not be subjected to oil changes based on time. Instead, their lubricants should be replaced "on-demand" and only when absolutely necessary. Grease lubrication can also be adjusted in terms of re-lube frequency and volume in particular applications.
  • Leakage Reduction - Don't ignore leaks; deal with them as soon as possible. The quality and cleanliness of lubricants have a significant impact on safety and dependability.

 

contamination control cost reduction

3. Contamination Control Cost Reduction

The expense of operating major facilities and fleets in dusty regions can be significant. Where strict contamination control is required, you still have a few alternatives for getting the most cleanliness for the least amount of money.

Ways to Achieve:

Select the Affordable Filtration option - Filter size, media type, dirt-holding capacity, and other factors all have significant roles in the cost of filters. Getting sound and balanced counsel on this can be a financial boon.

 

quality preventive

4. Quality Preventive Maintenance Program

Recalibrating PMs will help you optimize your program. Optimization entails removing unproductive activities and creating new ones to fill in the gaps. Most essential, make sure your plan is foolproof to guarantee there are no high-risk failure modes without a PM countermeasure.

Ways to Achieve:

Keep track of compliance and the backlog - Maintain a tight grip on route compliance. Keep a close eye on the backlog of work orders and the total maintenance debt. Many firms, however, fall behind on proactive maintenance PMs because they are too preoccupied with the backlog of urgent repairs. Everything gets out of hand when we let small things deteriorate. Bear in mind that nothing is "prevented" through breakdown maintenance. 

 

inspection and condition monitoring

5. Inspection and Condition Monitoring in One

Condition monitoring necessitates a deliberate and effective alignment. Understanding machine criticality and failure mechanisms and establishing targets are the first steps. Many non-critical parameters may only require basic onsite oil analysis examinations rather than having costly, in-lab testing. Patch testing, viscosity comparator, crackling test, clear and brilliant, and manual ferrous density are quite useful. Frequently performed inspections on the machine are often far more effective.

Alignment aids in the efficient deployment of activities and expenditures, reducing waste and redundancy. The term "unification" refers to the integration of all condition monitoring activities into a single, intentional program. Unification and alignment are engineering processes that have the potential to yield huge benefits in reducing current condition monitoring costs as well as optimizing the state of machine reliability.