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Lubrication – Getting it Right
Nick Thomas
North Sea & Caspian Sales Manager
11 February 2004 at 1500
Agenda
• Lubrication – Getting it Right– Cultural Change can be the answer
• Individual Elements– Product Selection– Contaminant Exclusion & Removal – Oil Condition Monitoring– Storage & Handling– Awareness, Education, Training & Skills Management– Evaluation of Programme
Lubrication – Getting it Right
• The Prize of imbedding best in class lubrication practices– Increased Reliability
– Reduced Downtime
– Maximise Value
– Increased Profits
Critical Steps to Success
• Identify Opportunities for improvement• Action Plan developed
– Implement changes identified– Culture transformation
• Action Plan implemented (12,24,36 months or more)• Plan for continuous improvement
Plan, Design & Implement (outline)
• Phase 1 - Plan– Training a critical component
• Awareness Training for all stakeholders– What, why & when
– Open forum discussion groups• Discuss specific roles of group, departments
– Educating management• Supervision of implementation (team leaders) • Upper management (financial support)
– Assess Maintenance Management system• New programme needs to complement
Plan, Design & Implement (outline)
• Phase 2 – Design– Design
• Lubrication PMs, Contamination Control, Oil Analysis, Lube-Handling, Lubrication Selection
– Installation• Hardware, equipment modifications
– Documentation• Incorporate best practice in parallel with installation• Baseline for continuous improvement
– Training/Coaching• Ideas at awareness become embedded• Team members start to take ownership
Plan, Design & Roll Out (outline)
• Phase 3 – Roll Out– New procedures within MMS completed and tested– Formal & on-the-job training for new procedures– Evaluation
Lubrication PMs
• Audit of lubrication PMs– Missing– Not Required– Changed to reflect best practice
Contamination Control
• Contamination affects machine wear and lubrication degradation rates– Build in reliability– Extended life
• Contamination Control Programme– Optimise targets– Method to suit application
Oil Analysis & Inspection Systems (OCM)
• Provides– Check that contamination control & lubrication
management efforts are effective– Advance warning enabling targeted response to
conditions that compromise reliability
• Are you Maximising value?
Handling & Storage
• Consider lubricants as a working component in mechanical systems just like a bearing, valves.
• Lubricant Packaging– Know consumption Rates– Maintain Safety stock– How much space available– Condition of storage facility
• Recommended Storage Life– Factors that impact
Handling & Storage
• Lubricant Storage– Outdoor Storage– Opened Containers– Proper Labelling– Lubrication Identification Equipment– Re-suspending additives
• New Oil Cleanliness• The Storeroom
Lubrication Selection
• OEM Specification • Identified Lubrication Solution • Rationalisation
Value of Effective training
• Cost of an Untrained Workforce– Expensive & Wasteful Oil Analysis– Undetected Faults & Failures– High Cost of Lubrication – Poorly specified Equipment parts– High labour costs– High Cost of Reactive Maintenance– Costly Mistakes that lead to Premature Failure– High Machine Energy Consumption
Summarise
• Investing Time & Capital in Best in Class Lubricants Management will improve reliability & reduce downtime medium to longer term.
• No quick fix• Cohesive Plan needed for a change in long term
approach
Questions & Answers