1. ©
Lubrication Reliability Practices for Improved
Equipment Reliability
Ian Knight
Enluse BV
The Netherlands
Organized by On behalf of
© DOTS © EFNMS vzw
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2. Who Are We!
©
 Ian Knight, Australian living and working in Europe, based In The
Netherlands.
 Mechanical trade background, however sales, service and
marketing are my key qualifications.
 35 years with SKF in Sales, Service and Marketing.
 Extensive experience in Condition Monitoring, Lubrication and
Equipment Reliability.
 Started Enluse BV in 2003.
 European importer for Fluid Defense lubrication equipment line.
 Supply all Lube related equipment from the lube room to the
machine.
 Consult on implementing Lubrication Reliability strategies.
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3. ©
Over 2 years over 100 replaced
bearings were examined
€2,300 of Bearing Costs!
but €150,000 Maintenance Costs ©

4. ©
The Conclusions
Over 60% were due to
lubrication issues.
15% were due to poor
maintenance issues.
5% were due to
ignorance issues.
15% The balance
(approx.) were in good
condition??
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5. ©
The Conclusions
Bearings are the rotating core of
all equipment .
Reduced bearing consumption, is
increased equipment reliability.
Lubrication accounts for most
failures and damage.
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6. The Key Conclusion ©
A better lubrication strategy, will
reduce bearing consumption and
increased equipment reliability .
So we should make Bearing
Consumption Reduction, a
Reliability KPI.
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7. ©
The Reliability KPI’s
Down Time Up Time
However, detailed
Bearing reliability improvements Lube
Consumption Consumption
should have a package of
supporting KPI’s.
Inventory Overall
Levels Lube
Maintenance
Cleanliness
costs to
production
levels
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8. ©
Lubrication Reliability ???
We know lubrication
It’s part of our is important.
reliability
metrics.
It’s so important it
should be a stand
alone Reliability
activity.
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9. ©
Lubrication Reliability
An effective Lubrication program
must consider many points.
Can we claim for every machine?
 We are using the right lube?
 We add lube at the right time?
 In the right quantities?
 In the right condition?
 We are maintaining our lube
condition?
If so – then you have a reliable
Lubrication Program.
If not – then we will have
problems.
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10. ©
Lubrication Reliability
All activities to Processes & tools to
improve reliability reduce equipment
wear and damage
Lubrication Contamination
Strategy Control
Lubrication
Knowledge Data Base
and Management
The people and Application and Reporting Administration of
their commitment the work to be
to the work done
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11. Lubrication Reliability
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Activity Maturity Level
Lubrication
Strategy Asset
Efficiency
Culture
Cleanliness and
Contamination Proactive
Control Lubrication
Management
Data Base
Management Lubrication
and Reporting Processes
Lubrication Basic
Knowledge and Requirement
Application
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12. Lubrication Reliability
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Cleanliness & Data Base Lubrication
Lubrication
Contamination Management Knowledge &
Strategy
Control and Reporting Application
Lube Room Cost verses
Basic Dedicated Standards in Data Base
Requirement Resources Existence Investment in
Place Uptime
Instructions for Procedures for Maintenance Trained Staff
Lubrication Reducing Planning
Processes the Work on Lubrication
Contamination Controls
Proactive RCFA on all Integrated in
Lubrication Oil Analysis and Dedicated Lube Reliability
failed Parts Evaluation Software
Management Program
Asset KPI’s on Lube Overall Plant Integrated and Measurement of
Efficiency Effect to Cleanliness Seamless to Activity
Culture Reliability Measurements CMMS Effectiveness
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13. Lubrication Assessments
©
 Where are we now ?
 What do we do wrong ?
 What do we need to do better ?
Best Practice Solution : Lube Assess .
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14. ©
Lubrication Assessments
Coal Fired Power Station Assessment Result
Maintenance Lubrication Cleanliness & Data Base Lubrication
Environmental Supply
Culture & Strategy Contamination Management Knowledge
Practice Control & Reporting
Asset
Efficiency Not Not
Applicable Sure
Culture
Proactive
Not
Lubrication
Applicable
Managemen
t
Lubrication Do Not
Processes Know
Basic Maintenance
Experience
requirement
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15. ©
10
Steps to Lubrication Reliability
To enhance Plant & Equipment Reliability and to achieve
World Class Maintenance
15
A How to guide for Maintenance & Reliability Professionals
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16. ©
1. Assessment / Benchmarking
• Where are we now ?
• What do we do wrong ?
• What do we need to do better ?
Best Practice Solution : Lube Assess .
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17. ©
2. Organization and Planning
• Lubrication Planning
• Lubrication Management
• Lubrication Management tools
Best Practice Solution : Mafuta.
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18. ©
3. Identification
• Multiple types lubricants
• Complex Chemistry & Compatibility
• Avoiding errors
• TPM, ISO22000, OSHA, IFS
Best Practice Solution : LABEL SAFE .
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19. ©
4. CLEANLINESS CONTROL
• Contamination is a major source of failure
• Clean lubricants in operation
• Lubricant Cleanliness Control Centres
• Safe & Clean storage-conditioning / transfer
Best Practice Solution : Lubristation Luberooms .
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20. ©
5. LUBRICANT DISPENSING
Dispensing equipment needs to be :
• Safe & Clean & Closed
• Efficient & user friendly
• Adapted to application
• Multi colored identification
• Rust free
Best Practice Solution : Oil Safe .
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21. ©
6. GREASE LUBRICATION
• Best practice tools
• Efficient & practical
• Color-coded
Best Practice Solution : Grease Safe, Mobilube .
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22. ©
7. CONTAMINATION CONTROL
• ISO4406 check
• On line /Off line filtering
• Lubricant protection
Best Practice Solution : Air Sentry, Magnum, Decolube
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23. ©
8. OIL ANALYSIS
• ISO 4406 monitoring
• Lubricant life extention (chemistry)
• Cleanliness management
Best Practice Solution : Oil Analysis services, sampling tools
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24. ©
RELIABILITY/CLEANLINESS LEVEL
30
RESULTS OF DTI SURVEY 1984
25
20
ISO CODE
15 >3um
>5um
10
5 >15um
0
MEAN TIME BETWEEN FAILURES (hours)
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25. ©
BEARING LIFE
Ref Dr. D.P. MacPhearson of Westland Helicopters Ltd.
14
6.6
To Fatigue Failure
12
Millions of Cycles
10
8
3.6
6
4 1.3
1
2
0
0 3 6 10 20 25 30 40 50
Filter Rating (Particle size, µm, where Beta = 200)
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26. ©
9. ENVIRONMENTAL CONTROL
• Maintenance strategies : 5S
• World Class Manufacturing
• Environmental protection
• Efficiency tools
Best Practice Solution : Fluid Defense Absorbents
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27. ©
10. KNOWLEDGE MANAGEMENT
• Reliability Lubrication training
• Reliability Technician
• Custom in-plant training, all levels
Vision Interactive style Feedback
Fun Blogs
Motivating Forums
Meaningful E Mails
Recognizable Cartoons
Transfer Cartoon Strips
Engaging
Cartoon characters
Best Practice Solution : Reliability Institute bv
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28. LUBRICATION RELIABILITY ©
BAD
Practice
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29. ©
LUBRICATION RELIABILITY
BEST
Practice
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30. ©
The Reliability Institute
Change Management Requirements To Achieve
World Class Maintenance
Stephen Thomas
22 module online learning program
with dialogue / interaction to Stephen.
7 ©

31. ©
Lubrication Reliability
10 steps to Improved Production Reliability and World Class Maintenance
THANK YOU - QUESTIONS
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