Elevate Your Bottom Line with World‑Class Industrial Lubrication

Ineffective lubrication erodes profit margins. In one automotive case, a scheduled gearbox replacement was postponed because oil‑analysis data were ignored, leading to a catastrophic failure six months later and a 12‑hour plant shutdown that cost $15 million.

Lubrigard Ltd. (a division of WearCheck Canada Inc.) hosted the “Blueprint to World‑Class Lubrication” workshop in Burlington, ON. The session—attended by 25 reliability professionals—delivered concrete, on‑site training and real‑world examples of production losses caused by poor lubrication. Lubrigard plans to run six to eight free workshops in 2013.

Participants were guided through a systematic assessment that benchmarks a plant’s lubrication program against industry best practices, builds a compelling business case, and produces a customized action plan to elevate lubrication management.

Discussion covered lubricant storage, handling and dispensing; application procedures; equipment maintainability; contamination control; oil sampling and analysis; and training.

At the workshop’s conclusion, each group received detailed, plant‑specific action lists and an estimate of the annual financial drain caused by subpar lubrication. A one‑hour follow‑up session with the instructor was offered to review the plan with key team members.

A 2013 study in Machinery Lubrication magazine surveyed 350 maintenance professionals. Ninety‑nine percent said lubrication is critical or very important for equipment reliability, yet only 32 percent felt their programs approached world‑class levels.

The survey identified three main barriers: limited knowledge, insufficient executive support, and maintenance staff overwhelmed by reactive tasks.

The one‑day workshops tackle these hurdles by equipping attendees with practical tools and a clear roadmap. Proper lubrication eliminates failures and boosts uptime, while poor practice can erode up to 30 % of a plant’s maintenance budget.

Successful oil‑analysis programs start with a commitment to peak performance—setting targets, defining responsibilities, selecting equipment, establishing sampling points, gathering data, choosing a lab, performing accurate tests, and acting decisively. Building a business case is essential.

Oil analysis and basic inspections detect abnormal wear, determine optimal oil‑change intervals, and reveal environmental or process contamination.

Evaluating filtration upgrades, lubricant brands, and reliability gains ensures the program remains effective. Root‑cause analysis confirms maintenance actions and blocks the failure cycle.

Maintenance leaders focus on the financial impact of poor lubrication. Estimating yearly losses and closing the gap on common failure causes is the first step toward savings.

Next, calculate upfront and ongoing costs, then compute a five‑year NPV and IRR to quantify total improvement returns.

Paul Dumont, Lubrigard’s OMA‑certified business development manager, stresses the minuscule size of destructive particles that damage lubricated equipment. He advises monitoring wear, proper oil‑change timing, and contamination control.

Proactive maintenance must prevent oil contamination during circulation. If equipment behaves like the 95 % of North American lubricated machines, oil degrades rapidly.

Ingression control—preventing dirt and water from entering the lubricant—is vital. Proper air breathers with 3, 5, or 10‑micron filtration block dust and keep oil clean.

Implementing a lubrication management program that includes oil analysis delivers high ROI. Oil analysis is a predictive tool that refines reliability decisions and empowers tradespeople, steering the organization toward world‑class maintenance.

Robert Robertson is a contributing editor at Machinery & Equipment MRO and a Mississauga, ON‑based freelance writer.

Find the original article on the MRO website.