Efficient Plant April 2019 - 25

feature | lubrication strategies

information regarding its performance. The
data should be used to evaluate whether the
organization's policy and objectives are being
achieved, as well as identifying corrective
actions and areas for improvement.

KEY PERFORMANCE INDICATORS
Key Performance Indicators (KPIs) allow us
to set an end-goal target, or objective, based
on multiple business needs, or objectives, and
track whether we are successful in meeting or
surpassing them. KPIs also allow us to analyze
and understand, in a laser-like fashion, where
we need to focus improvement efforts.
Managing with performance measurement
means that reliable data must be collected
on a regular basis. The obvious maintenance
conduit for tracking performance is the
work-management system in which assets,
type of work performed, and failure types
are tracked simultaneously and reported.
Lubrication work management can be tracked
in a dedicated lubrication-management system
(LMS), or can be tracked as a work type within
a maintenance-management system such as
a computerized maintenance-management
software system (CMMS), enterprise asset
management (EAM) system, or an information management system (IMS).
KPIs rely on system reports pertaining to
labor, work type, occurrence events, and
factors such as cycle, time, cost, inventory, and
trend alarms, to populate the KPI data requirement. In addition to program performance,
KPIs also test how well a software system is
implemented and used by the quality and
accuracy of data extracted.
Once the management system is able to
produce the data required by the KPI calculation(s), reporting routines can be set up in the
system to provide updates on a regular basis.
Where no dedicated lubrication-management-software system is used to singularly
track lubrication-related work, identifying
lubrication-related work is simply a matter of

APRIL 2019

capturing and classifying all lubrication work
orders as a specific lubrication work-order
type. For example, many maintenance systems
typically sort their work orders prior to release
into lubrication (work specific to activities such
as lubrication-system maintenance and servicing, filling of reservoirs, and filter changes),
mechanical, electrical, facility, and general/
service maintenance-related work.
Failure occurrences are tracked based on
the same classifications and, in addition, are
tracked upon completion as to whether they
are maintenance-caused or related issues
(issues over which maintenance/lubrication
technicians exercise full control), or non-maintenance-caused or related issues (issues that
maintenance and the lubrication technician
cannot prevent but must manage as part of
their mandate. Examples include graffiti,
operator damage, and denied access to an
asset.) In addition, consequence of failure can
also be simply tracked by categorizing the
result of any breakdown or corrective work
performed as no loss of service, minor service
loss (as long as one shift), and major service
loss (more than one shift).
To understand and report on the effectiveness of a lubrication program, the cost of all
production downtime loss and the reactive
cost of all corrective, repair, and breakdown
work related to bearing and bearing-surface
components (seals, pistons, valves, ways)
failure/loss must be compared to the cost
and effort of the proactive work related to the
filling, cleaning, and maintenance of lubrication-delivery systems, hydraulic-fluid systems,
and management of lubricants. Almost all
maintenance related-failures are preventable.
KPIs allow a department or corporation to
turn simple data collected on a work order into
meaningful management information. This
is often referred to as "data-driven decision
making." KPIs are primarily used to assess
risk, performance, and cost. They are further
categorized into strategic/long-term, tactical/

mid-term, and operational/immediate.

CALCULATING KPIs
The following represent the most commonly
used lubrication KPI calculations. KPIs can be
expressed in terms of a single equipment piece
or rolled up hierarchically to represent the line,
area, product, or plant:
KPI 1: Asset(s) (machine/line) availability
(based on lubrication-related failures)
Total # lubrication hours from date A to B -
(Total minor + major service loss hours from
same date A to B) x 100
Total # lubrication hours from Date A to B
KPI 2: Lubrication-related maintenance cost
as a percentage of total maintenance cost

Note: Can be calculated for just LPM work
or all lubrication-related work
Cost of all lubrication-related maintenance
work (parts and labor) from date A to B x 100
Total cost of all maintenance work (parts and
labor) from date A to B
KPI 3: Lubrication-related maintenance cost
as a percentage of total operating cost
Cost of all lubrication-related maintenance
work (parts and labor) from date A to B x 100
Total department or corporate operating cost
from date A to B
KPI 4: Mean time between lubrication
failure (MTBLF)
Total operational time (shift/day/hours/
minutes) from date A to B
Total number of lubrication-related failures
from date A to B
KPI 5: Lubrication PM (LPM) work-order
compliance (can also be used with other
lubrication work-order types

continued on p. 26

EFFICIENTPLANTMAG.COM |

25


http://www.EFFICIENTPLANTMAG.COM

Efficient Plant April 2019

Table of Contents for the Digital Edition of Efficient Plant April 2019

Efficient Plant April 2019 - 1
Efficient Plant April 2019 - Cover1
Efficient Plant April 2019 - Cover2
Efficient Plant April 2019 - 1
Efficient Plant April 2019 - 2
Efficient Plant April 2019 - 3
Efficient Plant April 2019 - 4
Efficient Plant April 2019 - 5
Efficient Plant April 2019 - 6
Efficient Plant April 2019 - 7
Efficient Plant April 2019 - 8
Efficient Plant April 2019 - 9
Efficient Plant April 2019 - 10
Efficient Plant April 2019 - 11
Efficient Plant April 2019 - 12
Efficient Plant April 2019 - 13
Efficient Plant April 2019 - 14
Efficient Plant April 2019 - 15
Efficient Plant April 2019 - 16
Efficient Plant April 2019 - 17
Efficient Plant April 2019 - 18
Efficient Plant April 2019 - 19
Efficient Plant April 2019 - 20
Efficient Plant April 2019 - 21
Efficient Plant April 2019 - 22
Efficient Plant April 2019 - 23
Efficient Plant April 2019 - 24
Efficient Plant April 2019 - 25
Efficient Plant April 2019 - 26
Efficient Plant April 2019 - 27
Efficient Plant April 2019 - 28
Efficient Plant April 2019 - 29
Efficient Plant April 2019 - 30
Efficient Plant April 2019 - 31
Efficient Plant April 2019 - 32
Efficient Plant April 2019 - 33
Efficient Plant April 2019 - 34
Efficient Plant April 2019 - 35
Efficient Plant April 2019 - 36
Efficient Plant April 2019 - 37
Efficient Plant April 2019 - 38
Efficient Plant April 2019 - 39
Efficient Plant April 2019 - 40
Efficient Plant April 2019 - Cover3
Efficient Plant April 2019 - Cover4
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-june-2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanfeb2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjulyaug2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epfeb2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjan2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovdec2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptoct2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptember2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epaugust2018
https://www.nxtbook.com/atp/MaintenanceTechnology/0818schneider
https://www.nxtbook.com/atp/MaintenanceTechnology/epjuly2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtsept2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJune2015
https://www.nxtbook.com/atp/MaintenanceTechnology/M
https://www.nxtbook.com/atp/MaintenanceTechnology/0415endress
https://www.nxtbook.com/atp/MaintenanceTechnology/MTApril2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTMarch2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTFebruary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJanuary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTDecember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTNovember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTOctober2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTSeptember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2014
https://www.nxtbookmedia.com