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