Discover the essentials of lubrication management for machinery and equipment to improve uptime and reduce wear.
Lubrication management involves the systematic planning, application, monitoring, and control of lubricants to minimize wear and tear, reduce equipment downtime, and extend asset life. A critical pillar of asset reliability and maintenance, the program includes selecting appropriate lubricants, ensuring proper storage and handling, and preventing contamination to support overall plant reliability and efficiency.
Proper lubrication, a practice that dates back thousands of years, is fundamental for machine reliability. This measure of equipment maintenance has evolved from basic manual greasing to sophisticated, data-driven programs that involve scheduled maintenance, contamination control, and automated systems, all aimed at maximizing dependability and efficiency.
Implementing modern lubrication management systems delivers measurable advantages, including the following:
Reduced downtimes – Most mechanical failures and damages that lead to equipment shutdowns are attributed to poor lubrication practices. Consistent and proper lubrication increases uptime and productivity.
Higher cost savings – Constant repairs and part replacements are expensive. Well-lubricated machines also require less energy to run, thereby reducing electricity bills.
Enhanced workplace safety – Excessive machine friction causes overheating, which manifests in various ways that pose a risk of accidents and injuries. This form of proactive maintenance significantly reduces equipment malfunctions, directly protecting frontliners from harm.
Implementing a lubrication management program goes beyond greasing a machine’s wheels and cogs. To boost equipment efficiency, reliability, and lifespan, consistently following these core principles is crucial:
Key Principles for Effective Lubrication Management
Machine components operate under unique conditions. Consider temperature, pressure, speed, and exposure to contaminants when choosing the right lubricant to prevent increased wear, corrosion, overheating, or total equipment failure.
These are the different types of lubricants and their most appropriate applications:
Oil is ideal for high-speed machinery and parts due to its excellent flow and heat dissipation.
Grease is a semi-solid lubricant suitable for components that require long-lasting lubrication and protection against contaminants. This is used where liquid oils may leak or drain away.
Penetrating lubricants are used to clean or loosen rusty or seized parts.
Dry lubricants, such as molybdenum disulfide and graphite, are great for high-temperature or dusty environments where liquids would attract dust or dirt.
Synthetic lubricants provide superior performance under extreme conditions, offering thermal stability, oxidation resistance, and longer service intervals.
Under or over-lubrication can be just as damaging to a piece of equipment as using the wrong lubricant. Standardizing the lubrication management system ensures consistent and accurate application at the right points, in the correct amounts, and at proper intervals.
Consider the following elements when developing a lubrication management program:
Element | Definition | Considerations |
Lubrication Point | This pertains to the specific location where the lubricant must be applied to the equipment. | Examples of lubrication points: - Bearings - Gears - Chains - Joints - Sliding surfaces |
Type of Lubricant | The lubricant should be matched to equipment specifications. | - Equipment manufacturer’s maintenance instructions - Equipment model, type, or version |
Amount of Lubricant | Aside from following the manufacturer’s guidelines, relubrication amounts can be calculated based on surface areas and operational conditions. | - Component size - Speed - Type |
Frequency and Interval | Maintenance managers should be fully aware of lubrication schedules, particularly when and how often this is conducted. | - Manufacturer recommendations - Equipment usage - Operational environment - Type of lubricant |
Method of Application | This ensures even distribution with little to no contamination. | The most common methods: - Manual application with grease guns or oil cans - Automatic lubrication systems - Drip feed - Splash - Mist lubrication - Centralized systems |
Constant monitoring ensures lubricants are still performing their intended function. This also detects early signs of contamination, degradation, or mechanical problems. Operators should be able to independently identify issues and address them, preventing costly machine complications and damages.
Here are some effective ways to monitor the effectiveness of the lubrication management system:
Visual inspection checks for signs of leakage, discoloration, or dirt buildup.
Oil analysis tests for viscosity, contamination, and wear particles.
Ultrasound or acoustic monitoring detects friction and lubrication failures.
Infrared thermography identifies abnormal heat patterns.
Vibration analysis pinpoints changes in machine behavior.
Even the best lubrication program fails if personnel aren’t adequately trained to carry it out correctly. Minimize human error by delivering the following training programs:
Lubrication basics and functions
Identifying and selecting lubricants
Safe handling and storage
Proper application techniques
Reading and interpreting lubrication charts and schedules
Use of lubrication tools and monitoring devices
Maintaining detailed records of all lubrication activities ensures accountability. This also tracks lubricant performance, supports preventive maintenance goals, and helps with audit readiness. The following should be included in the documentation:
Date and time of lubrication
The lubricant used (type, brand, specification)
Application point and machine ID
The amount applied and the method used
Personnel who performed the task
Observations or anomalies during the task
The next scheduled lubrication date
Equipment lubrication is important universally, but it has become indispensable in manufacturing. It ensures the reliable and continuous performance of diverse and intricate machinery operating under demanding conditions. The following should be considered to address the unique challenges in this sector:
High equipment utilization – There’s an increased risk of wear in the industry because machines run for extended hours. Optimizing lubrication schedules maintains continuous operation without failure.
Diverse machinery types – Different machines require different lubricants and schedules to suit specific motions, loads, and speeds. Developing an efficient lubrication program for each equipment type is non-negotiable.
Environmental factors – Dust, moisture, and temperature extremes affect lubricant performance and contamination. These conditions require careful selection and stringent management.
Regulatory compliance – The food, beverage, and pharmaceutical sectors require stringent lubricant standards to meet safety and hygiene regulations. Thoroughly review relevant regulations to ensure compliance.
Integration with maintenance systems – Leverage technology (e.g., Computerized Maintenance Management System or CMMS) to ensure timely and accurate lubrication aligned with the company’s overall preventive maintenance goals.
Thermosash was able to achieve ISO certification in six months using the Mitti Platform by centralizing workflows, boosting visibility, enhancing accountability, and streamlining quality control through QA checks and automatic corrective action alerts.
Mitti (by SafetyCulture) is a mobile-first operations platform adopted across industries such as manufacturing, mining, construction, retail, and hospitality. It’s designed to equip leaders and working teams with the knowledge and tools to do their best work—to the safest and highest standard.
Implement consistent lubrication management by utilizing digital checklists, real-time monitoring, and centralized documentation. Ensure lubrication tasks are performed correctly and on schedule, improving equipment reliability and safety through a unified platform.
✓ Save time and reduce costs ✓ Stay on top of risks and incidents ✓ Boost productivity and efficiency ✓ Enhance communication and collaboration ✓ Discover improvement opportunities ✓ Make data-driven business decisions
