Lubrication science
Building a lubrication reliability programme: elements, steps and measures
Quick answer
The six parts of a lubrication programme, a six-step roadmap, the measures to track and who is responsible for what.
What it is
A lubrication reliability programme makes sure the right lubricant, in the right condition, reaches the right place at the right time. It turns good intentions into a routine with owners, checks and numbers.
Six elements
| Element | What it covers |
|---|---|
| Lubricant standardisation | One right lubricant for each application, and fewer products overall. |
| Cleanliness and contamination control | Targets, filters, seals, breathers and clean handling. |
| Condition monitoring | Oil analysis and inspection routes. |
| Handling and storage | Labelled containers, dedicated equipment, first in first out, clean storage. |
| Training and ownership | Skills and clear responsibility for lubrication. |
| Continuous improvement | Review results and improve procedures. |
Six-step roadmap
| Step | Actions |
|---|---|
| 1. Assess | Review the current state. Find gaps and opportunities. |
| 2. Plan | Set goals and scope. Develop strategies, standards and procedures. |
| 3. Implement | Roll out standards, tools and training. Make sure it is done. |
| 4. Monitor | Collect data, analyse trends and track the measures. |
| 5. Improve | Take corrective action and optimise the process. |
| 6. Sustain | Keep the standards and the culture in place over time. |
Measures to track
| Measure | Direction |
|---|---|
| Unplanned downtime, hours | Down |
| Lubricant-related failures | Down |
| Oil analysis compliance, % | Up |
| Oil cleanliness (ISO code) | Cleaner |
| Lubricant life, hours | Up |
| Maintenance cost | Down |
| Energy use | Down |
| Safety incidents | Down |
Who does what (example)
| Activity | Responsible | Accountable | Consulted | Informed |
|---|---|---|---|---|
| Lubricant selection | Lubrication engineer | Reliability manager | Maintenance, equipment maker | Operations |
| Oil analysis and monitoring | Reliability engineer | Reliability manager | Laboratory, maintenance | Operations |
| Contamination control | Maintenance team | Maintenance manager | Lubrication engineer | Operations |
| Storage and handling | Store-in-charge | Maintenance manager | Lubrication engineer | All users |
| Training and awareness | Lubrication engineer | HR or reliability manager | All departments | All users |
Common reasons programmes fail
- Lack of awareness and training.
- Too many lubricants, chosen by habit.
- Poor storage and handling.
- Irregular monitoring, with no trends.
- Nothing measured, so nothing improves.
- No owner, or resistance to change.
Best practices
- Visible management support.
- Clear roles and responsibilities.
- Standardised lubricants and specifications.
- Oil analysis and trend monitoring, with alarm limits.
- Cleanliness targets.
- Training and recognition.
- Regular review.
Takeaway. A lubrication programme works when it has owners, standards, measures and a review. Start with the machines that matter most and grow from there.
Put it to work in the tool