Potential Pitfalls
Whether a Lubrication Program is already in place, or in the planning stage, be aware of some pitfalls that could potentially compromise an effective program.
Over-lubrication increases fluid friction, generating excessive heat that can cause seal damage, leaks, and contamination ingress, resulting in higher costs and waste of resources. On the other hand, under-lubrication increases machinery wear and tear due to overheating and makes equipment components more susceptible to rust and corrosion.
Selecting the incorrect lubricant for temperature or load conditions can impact performance by not providing adequate protection and shortening the life of the lubricant, thus requiring more frequent changes and increasing costs.
Cross-contamination from mixing different lubricants can cause chemical reactions that reduce effectiveness and increase wear. The metal particles from wear and tear then circulate in the lubricant, causing further damage.
Poor lubrication practices stemming from inadequate application techniques, ignoring manufacturer recommendations, or a lack of training can potentially introduce errors into the lubrication process.
Neglecting regular maintenance, such as a failure to regularly monitor lubricant condition, replace filters when necessary, or the prolonged use of degraded lubricants, can lead to significant machinery damage.
Environmental factors can cause harm, including temperature variations that alter lubricant viscosity, humidity and moisture that cause lubricant emulsification and corrosion, and dust and particulates in harsh environments that contaminate the lubricant.
Economic constraints can also lead to setbacks and poor outcomes. For example, cost-cutting may dictate the use of lower-quality lubricants or longer lubrication intervals, as well as postponing the purchase/use of advanced monitoring tools (such as U.E., thermography, vibration, or oil analysis kits).
Finally, Lubrication Programs can face technological limitations, e.g. outdated systems that do not provide consistent or adequate lubrication, and legacy monitoring methods that do not provide real-time data on lubricant condition and machinery performance.
Culture Change: Overcoming Resistance
For a Lubrication Program to succeed, organizations need to create a culture that values and prioritizes proper lubrication practices at all levels. A shift in mindset based on the following principles will help overcome the usual resistance to such a widespread culture change:
Leadership commitment – management leading by example, committed to the Lubrication Program by actively participating and promoting best practices, along with a clear vision and goals.
Effective communication – awareness campaigns to highlight the value of lubrication and feedback channels for employees to make suggestions in a collaborative environment.
Education & training – programs for all relevant personnel, e.g. maintenance staff, operators, and engineers, focusing on lubrication best practices, the importance of proper lubrication, and the consequences of neglect.
Standardization & documentation – lubrication procedures and schedules tailored to each piece of equipment, supported by checklists and detailed recordkeeping to track compliance and identify areas of improvement.
Monitoring & metrics – defined KPIs (for equipment uptime, maintenance costs, and lubricant consumption), as well as regular audits and inspections to ensure Lubrication Program effectiveness.
Advanced technologies & tools – software solutions to manage and track lubrication activities, as well as condition monitoring tools (e.g. oil and vibration analysis) to assess the health of lubricants and machinery in real time.
Incentives & accountability – assignment of roles and responsibilities for lubrication tasks, as well as recognition and reward of employees who follow best practices and contribute to the success of the program.
Continuous improvement – periodic reviews and updates of lubrication procedures to reflect feedback, audit results, and technological advancements, as well as root cause analysis to investigate lubrication failures or issues so they do not recur.
Benchmarking & consulting with experts – stay competitive and innovative by comparing lubrication practices with industry standards and best practices, as well as leveraging the knowledge and perspectives of external lubrication expertise.
Incorporating these cultural changes into the company’s core values and operational philosophy will bring machinery lubrication to the same level of concern as safety and quality standards.
