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Eliminate unexpected lubrication-related failures

Effective equipment lubrication should be the goal for all maintenance, reliability and operational teams. It improves production performance and, ultimately, an organisation’s bottom-line profitability.

Many lubricant OEM’s, such as The Molykote brand, encourage plants to consider the 6 “R’s” when selecting a lubricant team to accomplish maintenance and lubrication goals – right people, right time, right quantity, right product, right method, right track.

Challenging the status quo is often the biggest obstacle for companies seeking an effective lubrication strategy. By assessing their current lubrication practices, plant managers can quickly identify improvement areas and make cost-effective decisions to reduce unplanned downtime and enhance machinery life.

maximum operational efficiency

Optimise lubrication practices

Minimize downtime

Improve operator safety

Plant lubrication review

Lubrication Survey

During a lubrication review, our experienced engineers will conduct a thorough assessment of your plant’s current lubrication practices. The ultimate goal of a lubrication review is to ensure every piece of equipment is receiving the correct lubricant, in the correct quantities, at the correct frequency to prevent any lubrication related failures.

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Lubrication strategy

Plant Study

A lubrication survey at a steel production plant identified high levels of vibrations caused by shot blasting – a method used to clean, strengthen (peen) or polish metal. The high levels of vibration were traveling to a fixed racking containing spare assets in close proximity. This was causing false brinelling and resulting in costly premature bearing failures.

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Is it time to review your existing lubrication strategy?

If your lubrication tasks are delivered or assigned to the least-qualified/trained individuals in your organisation, with no set schedule or means of monitoring, then it is probably time to review your current lubrication procedures.

Our lubrication surveys follow several key stages to identify any shortfalls and we work with appointed site champions to develop the correct foundations to build a successful site lubrication programme. This is split into three phases.

Plant Lubrication Review

In phase 1, we work with you to:

  • Determine equipment list – This is a list of equipment that requires a lubrication schedule, derived from a        company’s asset register.
  • Determine lubrication tasks – An assessment of what is required to lubricate the assets, oil, grease, auto lubricators, (good for remote or inaccessible areas), handheld grease gun, etc.
  • Determine lubrication frequency –  The frequency (and amount) is calculated using software.
  • Validate with CMMS – Raise a Planned Maintenance Operation or update current CMMS work schedule with as much information as possible.

In phase 2, the work done in phase 1 is road-tested and refined.

  • Create Work Order – To carry out the work, this order as a minimum will indicate lubricant type, frequency, amount and any safety considerations
  • Plan Work Schedule – Routine lubrication is generally carried out in work groups, i.e. many assets lubricated together.
  • Conduct Work and Review – Carry out the work and note any discrepancies/issues, i.e. Leaks, access to equipment issues, improvements. All of this must be documented and actioned as required.

In phase 3, based on equipment history being obtained in phase 2 a reiterative process is put in place to ensure continual improvement.

  • Review Equipment History – Using CMMS is ideal if it is up to date or by memory.
  • Schedule Annual Review – Assessment of lubrication schedules, and improvements as required.
  • Implement Solutions and Evaluate – Strive to continuously improve lubrication processes.
  • Conduct RCA / RCM – Use these tools to identify failure modes and to improve site equipment maintenance activities.

More information

At PCMS Engineering, we have a strong history in helping companies prevent lubrication related failures across site by reviewing and improving their current lubrication practices to identify shortfalls and develop the correct foundations to build a successful site lubrication programme.

Call us
+44(0)1709 876712
Our headquarters
Unit 3a, Adwick Park, Manvers, Rotherham S63 5AB
Email us
info@pcmseng.co.uk