Maintenance Technology September 2016 - 37

LUBRICATION STRATEGIES Sample Gearbox-Lubrication Checklist Task Sequence Lubrication Instruction 1 Lubricate red grease points numbered 1, 3, and 7 each with 2 cc (2 full grease gun shots) of ABC EP1 grease in the red-sleeved grease gun. 2 Lubricate red grease points numbered 2 and 4 each with 4 cc (4 full grease gun shots) of ABC EP1 grease in the red-sleeved grease gun. 3 Lubricate blue grease points numbered 5 and 6 each with 2 cc (2 full grease gun shots) of XYZ 505 grease in the blue-sleeved grease gun. Check: 4 Is gearbox #12 reservoir oil level between the Hi and Lo level marker? If Yes, move on to next task. If below the Lo marker level, fill reservoir to Hi marker level with ABC ISO 220 gear oil. If above Hi marker level, note on work order and report condition to supervisor. Designed correctly and written in a concise manner, similar to those used in the aviation and medical fields, lubrication checklists can overcome ignorance and ineptitude and promote low risk through a high degree of consistency. Quick Tips for Successful Checklists As I wrote in a March 2013 "Don't Procrastinate, Innovate" column for Maintenance Technology, Dr. Atul Gawande's 2009 book The Checklist Manifesto-How to Get Things Right, was, and still is, an intriguing read. It offers some invaluable insight for those in the reliability and maintenance field. In his book, Gawande details how he pioneered the "Safe Surgical Checklist," based on a model that the aviation industry adopted following the infamous World War II Boeing 299 crash. That checklist has certainly stood the test of time. According to Daniel Boorman of Boeing (Seattle)-the person charged with developing aviation checklist manuals for all of the company's planes for 20+ years-the secret of a good one is how it's written, starting with using simple and precise language familiar to users in the profession. Among Boorman's other tips: ■ A checklist doesn't have to be too comprehensive to be effective (usually between five and nine items). ■ Well-designed checklists fit the flow of the specific work, encourage users to read each point out loud, and help them detect potential failures before they occur. ■ A successful checklist ideally fits on one page, is free of unnecessary color and clutter, and uses upper and lower case in a sans-serif font such as Helvetica. Objective instruction and interaction Instructing an operator to "lubricate as necessary" will only guarantee a subjective decision about which lubricant is to be used, as well as how much and how often. Subjectivity, in turn, invokes inconsistent behavior leading to lubricant cross contamination, over or under filling reservoirs, bearing-seal breaching, or starving bearings. These situations all reflect SEPTEMBER 2016 high-risk behavior that can easily result in premature, yet preventable, machine failure and downtime. They don't have to be a problem in your plant. In Dr. Atul Gawande's 2009 bestselling book, The Checklist Manifesto: How to Get Things Right (Metropolitan Books, New York), he described the first military test flight, more than 75 years earlier, of the Boeing B17 bomber that had been introduced in the late 1930s. Ending in a crash due to a simple oversight by the most experienced pilot in the U.S. Army at the time, this flight led to the aviation industry pioneering operational and maintenance checklists. Designed to overcome human ineptitude, attitude, and ignorance, the aviation checklist, written in simple and exact language familiar to the profession, was instituted to ensure that each and every pilot, from that point on, followed a consistent, set procedure prior to takeoff and landing. As head of the World Health Organization's "Safe Surgery Saves Lives" program, Dr. Gawande successfully adapted that checklist into a simple, innovative tool for the medical field-and subsequently credited its use for a dramatic reduction in hospital and surgical deaths, regardless of hospital conditions. There's a significant takeaway from this story for those of us who have an interest in the health and well being of industrial equipment and processes. Lubrication checklists that don't challenge or insult maintainers or operators (but are designed correctly and written in a concise manner similar to those used in the aviation and medical fields) can overcome ignorance and ineptitude and promote low risk through a high degree of consistency. Take, for example, the sample checklist in the table at the top of this page. Written in objective language, it points to minor, required steps for making modifications to the lubrication-system components of a gearbox. It specifically references Hi-Lo-fill indicators on the lubricant-reservoir sight gauge that help personnel make simple, yet accurate, Go/No-Go decisions when checking the reservoir, and a number and color identification of the grease nipple and grease gun that's used to visually identify the correct lubricant amount and type for each bearing. Color, though, is just one aspect of identification called out on the checklist. It also references the exact grease point and reservoir number, the MAINTENANCETECHNOLOGY.COM | 37 http://www.MAINTENANCETECHNOLOGY.COM

Table of Contents for the Digital Edition of Maintenance Technology September 2016

Editorial
Uptime
On The Floor
Old-School Approach To New-World Technology
Art Meets Reliability Science
Commit To Safety
Robot-Human Interaction Getting Safer
Sanitary, Stainless Conveyors Not The Same
Reduce Hidden Process-Safety Costs
Pace Your Reliability Program
Win The War With 'Lubrication By Design'
SAP Tips And Tricks
Understand Pump Vibration
Select The Right Relay
Bearing Care
Clear Up HOA Confusion
Potato Waste Becomes Clean Water, Energy
Products
Showcase
Ad Index
Final Thought
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - Cover1
Maintenance Technology September 2016 - Cover2
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - 2
Maintenance Technology September 2016 - 3
Maintenance Technology September 2016 - Editorial
Maintenance Technology September 2016 - 5
Maintenance Technology September 2016 - Uptime
Maintenance Technology September 2016 - 7
Maintenance Technology September 2016 - On The Floor
Maintenance Technology September 2016 - 9
Maintenance Technology September 2016 - Old-School Approach To New-World Technology
Maintenance Technology September 2016 - 11
Maintenance Technology September 2016 - 12
Maintenance Technology September 2016 - 13
Maintenance Technology September 2016 - 14
Maintenance Technology September 2016 - 15
Maintenance Technology September 2016 - Art Meets Reliability Science
Maintenance Technology September 2016 - 17
Maintenance Technology September 2016 - 18
Maintenance Technology September 2016 - 19
Maintenance Technology September 2016 - Commit To Safety
Maintenance Technology September 2016 - 21
Maintenance Technology September 2016 - 22
Maintenance Technology September 2016 - 23
Maintenance Technology September 2016 - Robot-Human Interaction Getting Safer
Maintenance Technology September 2016 - 25
Maintenance Technology September 2016 - Sanitary, Stainless Conveyors Not The Same
Maintenance Technology September 2016 - 27
Maintenance Technology September 2016 - 28
Maintenance Technology September 2016 - Reduce Hidden Process-Safety Costs
Maintenance Technology September 2016 - 30
Maintenance Technology September 2016 - Pace Your Reliability Program
Maintenance Technology September 2016 - 32
Maintenance Technology September 2016 - 33
Maintenance Technology September 2016 - 34
Maintenance Technology September 2016 - 35
Maintenance Technology September 2016 - Win The War With 'Lubrication By Design'
Maintenance Technology September 2016 - 37
Maintenance Technology September 2016 - 38
Maintenance Technology September 2016 - SAP Tips And Tricks
Maintenance Technology September 2016 - Understand Pump Vibration
Maintenance Technology September 2016 - Select The Right Relay
Maintenance Technology September 2016 - Bearing Care
Maintenance Technology September 2016 - 43
Maintenance Technology September 2016 - Clear Up HOA Confusion
Maintenance Technology September 2016 - Potato Waste Becomes Clean Water, Energy
Maintenance Technology September 2016 - 46
Maintenance Technology September 2016 - 47
Maintenance Technology September 2016 - 48
Maintenance Technology September 2016 - 49
Maintenance Technology September 2016 - 50
Maintenance Technology September 2016 - 51
Maintenance Technology September 2016 - 52
Maintenance Technology September 2016 - Showcase
Maintenance Technology September 2016 - Ad Index
Maintenance Technology September 2016 - 55
Maintenance Technology September 2016 - Final Thought
Maintenance Technology September 2016 - Cover3
Maintenance Technology September 2016 - Cover4
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