Maintenance Technology January 2016 - (Page 27)
LUBRICATION STRATEGIES
WINSTON CHURCHILL WROTE, "Responsibility is the price of
greatness." These words have special meaning for those of us in the
lubrication field.
In organizations that seek to become great, all personnel must
understand the negative upstream and/or downstream impact
that their individual actions could have should they neglect to
effectively and efficiently fulfill their roles. This is especially true
of lubrication team members, who, through daily interaction
with machinery and moving parts, are directly responsible for the
successful lubrication of equipment in their charge-as well as for
any consequences resulting from their activities. Their failures will
manifest directly in the loss of equipment availability, reliability,
and life-cycle longevity, and indirectly through production yield
and quality losses.
A case in point
My look into the oil and grease purchasing patterns of a major
North American automotive-assembly manufacturer during a
lubrication-operations effectiveness review (LOER) was a real eye
opener. I was astounded by the many tens of thousands of dollars
per month the corporation was spending on just one type of chainlubricant oil.
This automatic-chain-lubricator oil was a name brand, premiumquality, molybdenum disulphide, high-temperature formulation.
Designed specifically to lubricate power- and free-conveyor chain
pins and bearings passing through the types of high-temperature
paint-bake ovens found in automobile assembly lines, it was an
ideal match for the application. So, given those facts, why was
the facility using so much of the product for just four conveyorlubricator systems? Moreover, why had the lubrication staff or the
lubricant supplier neither noticed nor brought to management's
attention the systems' dramatic (more than 10-fold) increase in
lubricant consumption over the past two years?
Further investigation revealed that the chain-oil consumption
increase had coincided with the hiring of a new lubrication technician. The PM (preventive maintenance) job plan and frequency for
checking and filling the automated lubricator reservoirs, though,
had remained unchanged-from the time the devices were installed
and commissioned more than three years prior. This discovery
prompted a physical investigation of the four lubricators themselves. The findings were more than surprising!
The four lubricators were a popular, highly reliable brand. Lowtech in design, they used a pneumatic pump-to-point-style pump
connected to dynamic injectors that would "volley" or "shoot" a
small fixed amount of oil into either the unshielded trolley rollingelement bearings or the chain-link pins that connected the trolleys.
All of the devices were in excellent condition-and still located
where they had been originally installed-complete with reservoirs
full of oil. Curiously, though, all had been shut off electrically at the
breaker and their pneumatic air supplies had been shut off at the
feed-line valves. As a result, all of these units were totally useless.
Investigators subsequently learned that the four original
lubricators had been "replaced" further down the conveyor line
JANUARY 2016
Several
Hands
Responsible
For This Oil
Debacle
The actions of personnel can either
lead to great success in lubrication
programs or, as this case study
shows, to costly calamity.
Ken Bannister
MEch Eng (UK), CMRP, MLE
Contributing Editor
Lubrication team members must understand how their
actions can have negative upstream and/or downstream
impact should they neglect to effectively and efficiently
fulfill their roles.
MAINTENANCETECHNOLOGY.COM | 27
http://www.MAINTENANCETECHNOLOGY.COM
Table of Contents for the Digital Edition of Maintenance Technology January 2016
My Take
Uptime
On The Floor
Keeping Old Machines Running Like New
Operational Excellence Is A Competitive Necessity
Sell Reliability to Management
Several Hands Responsible For This Oil Debacle
Infrared Detects Leaks
Mobile CMMS Benefits
Gear Pitting Issues
Manage Energy Processes
Products
Ad Index
Showcase
Final Thought
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