Uptime Magazine - October/November 2008 - (Page 29)

made with minor intrusion into the program. At a minimum, a detailed lubrication manual should include the following: • • • • • Equipment number and Description Equipment Picture Lubricant section from the OEM manual Selected lubricant technical data sheet Selected lubricant Material Safety Data Sheet (MSDS) Is All Equipment in CMMS? NO YES Enter Equipment into CMMS Are PM Task Codes in CMMS? NO YES Enter PM Task and Frequency Create Lubrication & Equipment Inspections Review Exception Reports for Consistency & Clarity Set Inspection Schedule Enter PM Task Codes into CMMS Purchase Necessary Lubrication Equipment – When purchasing the necessary equipment for your lubrication program, we must remember one of the 5R’s mentioned earlier. That is, we want our lubricant in the right condition. Properly lubricating equipment involves the use of equipment to both store and apply lubricants at set intervals and as needed. In storing lubricants, we want to ensure that the lubricants are used in a First In, First Out manner. Remember all lubricants have a shelf life. When applying lubricants the following equipment is recommended (but not limited to): • Storage racks • Sealed plastic heavy duty oil dispensing containers • Grease Guns • Bulk lubricant storage containers • Filter carts Set Lubrication Preventive Maintenance (PM) Frequency – Before entering the lubrication task into the Computerized Maintenance Management System (CMMS) or Enterprise Asset Management System (EAM), it is necessary to determine the frequency at which the lubrication tasks will be repeated. This information, along with the other data collected, will be input into the system and used to generate the service schedule. Services to be performed should include but not be limited to: • • • • Lubrication Inspection and Top-off Equipment visual inspection Equipment Temperature Readings Oil Sampling (as required) Figure 1 - Lubrication Implementation Flow Chart set, create the lube routes. Review the routes for clarity and consistency. If any changes need to be made, ensure they are made and then set the inspection schedule (Figure 1). Another key factor in implementing a program is to have your safety practices developed and in place. When it comes to lubrication safety, there are a number of unique aspects regarding the use and handling of lubricants. Because they are designed to minimize friction in machines, lubricants are slippery When lubricant is accidentally spilled or leaks onto the operating floor or any other undesirable location, it can lead to a high-risk situation that must be immediately attended to in order to prevent personal injury. In addition, because they are for the most part a hydrocarbon derivative, lubricants are flammable. The proper fire-hazard precautions should be taken. Finally, some lubricants can cause personnel health problems when the lubricant comes into contact with the skin. Items for consideration for your safety practices include, but are not limited to, the following: • MSDS (Material Safety Data Sheets) are available and are reviewed. • Lock out procedures are followed • Leaks are under control • Spill response in place • Handling practices maintain a safe environment • Lubrication Equipment use is understood • Sampling procedures are in place and followed the lubrication program are in place and documented. If these documents exist, they must be reviewed and evaluated. When reviewing these documents and procedures, we must ensure that they support the maintenance strategy, address the purpose of the task and give clear guidance and direction to complete all tasks in a safe, effective and efficient manner. Managing Lubrication Program Phase Managing your lubrication program is the third phase in this journey. Large amounts of maintenance dollars and resources are often budgeted to develop and implement an initiative such as a lubrication program. Once the program is in place, however, insufficient attention might be provided to ensure that full benefit is continually received from the initial expenditure. Programs put in place to meet a requirement or management expectation, without established ownership and a guiding vision, can decay into a low value day-to-day chore. As work requests and work orders are written, we must ensure there is clarity in what work needs to be performed. All too often there is a lack of information delivered from the floor, which can lead to poor planning & scheduling efforts. Once the work has been identified, scheduled for work and then executed, most important portion of this entire process, documenting the work performed, comes into play. Work history is one of the greatest struggles faced daily in the manufacturing world. In most facilities there are “pockets of excellence” within the organization. There may be multiple software programs being utilized, but the problem arises when the information collected does not get back to the main software system. All work information needs to be documented and available for review in the main CMMS or Implementing Lubrication Program Phase The second phase in building a lubrication program is the implementation phase. Once all the data has been collected and gathered in the development phase it must go somewhere. If the information isn’t already in the plant’s Computerized Maintenance Management System (CMMS) or Enterprise Asset Management (EAM) system, it must be input into it. Once in the CMMS or EAM, we must ensure that the Preventive Maintenance (PM) and task frequencies are set. Once the frequencies have been www.uptimemagazine.com The final piece to implementing a lubrication program lies in training the individuals that will be performing the tasks at hand. All persons performing lubrication related work must be properly trained to ensure the effectiveness and the Receive Plan consistency of the Document Perform Work Order and program. Also, we Schedule Work /Work Tasks Work Request must ensure that procedures for all major tasks and Figure 2 - Basic Work Flow Process functions within Close Work Order 29 http://www.uptimemagazine.com

Table of Contents Feed for the Digital Edition of Uptime Magazine - October/November 2008

Uptime Magazine - October/November 2008 Contents Upfront Upclose: An Asset Management Oasis in the Desert Information Technology: Streamlining Through Simplicity Lubrication: Phases for Framing a Solid Foundation Infrared: Do Your Homework Before You Buy Maintenance Management: Get It Together by Getting Together Motor Testing: Key Elements in Motor Decision Making Precision Maintenance: Shedding Some Light on Tolerances Reliability: RCM & the Mortgage Meltdown Ultrasound: A Multidimensional Tool Vibration: The Whirling Pump Mystery, Solved with ODS Upgrade: Are You Looking in the Right Place for Your Wear Debris?

Uptime Magazine - October/November 2008

For optimal viewing of this digital publication, please enable JavaScript and then refresh the page. If you would like to try to load the digital publication without using Flash Player detection, please click here.