Technical Topic

Technical Topic
Lubrication Program Management
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A Key to Success Lubrication Management Program Goals

Regardless of industry type, maintaining a safe work place, To properly define the goals of your lubrication management
complying with applicable laws and producing profitable products program, choose from the following list (depending on what best
with maximum quality are all sound objectives for world-class meets your company’s needs):
company. But, what does it take to accomplish these objectives?
To be successful, manufacturers like yourself positively, absolutely, • Reduce lubricant related failures
require maximum equipment availability. • Use the fewest correct lubricants and minimize waste
• Apply the lubricant in the correct manner, at the proper
To make that happens, you need a disciplined, world-class time and in the correct amounts
lubrication program. This can be achieved by establishing some • Integrate the plant’s preventive and predictive maintenance
guiding principles that include: goals into the lubrication program
• Continually investigate and implement methods to improve
Setting the Implementing the and achieve the above goals
Defining the
importance of tools required to
lubrication
a lubrication achieve lubrication
management Once you’ve defined the goals of your lubrication management
management management
program goals
program program goals program, you need to be sure you have the proper tools that will
enable you to achieve these goals. No matter what method you
The Importance of a Lubrication Management Program implement, to ensure success, you should use the following tools.
Most people believe that by just maintaining or adding lubricant
to the rotating equipment provides effective lubrication. However,
by not implementing the lubrication management program, the
opportunity to optimize equipment reliability and maximize the
return on your investment may be lost. Disciplined lubrication
management is the foundation of a world-class lubrication
program. The following chart illustrates the difference made in
a plant’s total cost of ownership once you’ve taken that step.
DESCRIPTION BEFORE AFTER

Annual Lubrication Cost including Labor,
$1,055,000 $845,000
Lubricant Costs and Supply Costs
Total Annual Maintenance Budget $24,000,000 $22,000,000
Percent Annual Lubrication Costs Versus Total

4.4% 3.8%
Maintenance Budget
Lost Annual Availability Due to Scheduled and
6% 2%
Unscheduled Maintenance
Estimated Annual Profit Lost Due to Lost
$3,500,000 $1,200,000
Equipment Reliability
Annual Maintenance Department Overtime 22% 14%
Annual Number of Equipment Failures Due to

18 2
Poor Lubrication
Annual Volume of Lubricant Consumed (gallons) 62,000 15,000
Chart shows example numbers for demonstration purpose only.

Lubrication Program Management
Basic Tools Required for an Effective Program

Leadership Lubrication needs to be a priority for maintenance managers. Be sure to nominate a program
champion — someone who will assume the responsibility, accountability and control for the
program.
Standard Operating Procedures SOPs can help guarantee repeatability and quality work. SOPs also assist in the training of
(SOP’s) lubricators and enable you to track and communicate equipment condition.
Teamwork & Communication A world-class lubrication program must have a team that works and communicates with all
members of the manufacturing group-operations, maintenance, purchasing, planning and
engineering.
Lubrication Scheduling, To handle the quantity of data encountered (even for a small plant), an effective computerized
Planning, and Tracking system should be employed. Without it, important equipment trends may be missed and/or
Management Systems documentation of the lubrication program may be lacking.
Training To continually improve, both program leader and lubricators must continually learn best
lubrication practices, as well as learn new techniques in their specific discipline.
Metrics Knowing the past performance and understanding the effects of program efforts enable
you to evaluate lubrication program-related decisions. Some useful metrics are: 1. Total
maintenance costs and percentage spent on lubrication
2. Percentage of equipment scheduled and unscheduled downtime
3. Number of lubricant related failures
4. Percentage of maintenance overtime labor
5. Lubricant consumption
6. Safety incidents
Audits In order to improve, you need to validate or audit your lubrication program. Whether
performed internally or by a third party, the effort to benchmark and evaluate your lubrication
program against other “best in class” operations will supply tremendous dividends.
Conclusion
Safety, compliance, and maximum quality manufacturing are sound
objectives for a world-class company. A disciplined lubrication
management program is what’s needed to achieve these objectives.
And, when you set goals that help you succeed, you are well on
your way to establishing a world-class lubrication program.
Refs: “Lubrication Management: A Key to Success” By Tom Schiff
The Engineered Difference — Winter 2001
© 2019 Exxon Mobil Corporation. All rights reserved.All trademarks used herein are trademarks or registered
trademarks of Exxon Mobil Corporation or one of its affiliates unless otherwise noted. mobil.com/industrial

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Lubrication Program Management

Energy lives here™

A Key to Success Lubrication Management Program Goals

DESCRIPTION BEFORE AFTER

Total Annual Maintenance Budget $24,000,000 $22,000,000

Percent Annual Lubrication Costs Versus Total

Annual Maintenance Department Overtime 22% 14%

Annual Number of Equipment Failures Due to

Annual Volume of Lubricant Consumed (gallons) 62,000 15,000

Chart shows example numbers for demonstration purpose only.

Basic Tools Required for an Effective Program

Refs: “Lubrication Management: A Key to Success” By Tom Schiff

The Engineered Difference — Winter 2001

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