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Thursday, 1 November 2012

Practical tips to cut industrial lubrication costs

How do you cut lubrication costs without sacrificing reliability?

To many, cutting industrial lubrication costs means sacrificing performance and reliability. This need not be the case – by using the correct products and systems we may just be able to have our cake and eat it too!

You can cut industrial lubrication costs by implementing the correct systems.

Correct Filtration can drastically reduce industrial lubrication costs.

New oil can be expensive as is the labour cost involved in the oil change. Deploying strategic filtration retrofits such as off-line filtration systems (kidney loop) can significantly reduce the cost of replacing your oil as well as enhance
capture efficiency. Combining a clean oil strategy with good filtration economy is the central objective.

Smart Oil Analysis is crucial if you want to cut industrial lubrication costs.

Passive oil analysis is nearly always a waste of time and money if you’re trying to cut industrial lubrication costs. Too many organizations are merely going through the motions. Companies need to educate their staff in oil analysis and make strategic investments in the correct application of this technology.

 The correct implementation of this system entails:
  • Taking active control of the oil analysis program. 
  • Improving on-site analysis activities 
  • Tuning alarms and limits to work effectively 
  • Investing in modern sampling hardware 
  • Managing test slate selection 
  • Rigorous training of maintenance staff. 
Closed loop practices.

Precision maintenance is a pipe dream unless you have programmatic feedback processes in place. When things go wrong:
  • Analyse the causes. 
  • Identify the root causes. 
  • Repairs, rebuilds and teardown inspections require feedback to close the loop. 
Armed with this information, consider how you’re going to adjust maintenance and operating conditions to avoid recurrence.

You have to train Lube-savvy Workforce if you’re to cut industrial lubrication costs.

Organizations that pinch pennies by cutting training budgets and hiring the incompetent, in order to reduce industrial lubrication costs, generally get what they deserve.

Top-tier firms, however, are learning to up-skill their technicians and qualify them before they get assigned to routine lube maintenance or related tasks.

Training and skill development can consume more than 10 percent of annual work hours, yet still earn attractive yields to employers.

Optimized Oil Changes. 

The concept of optimized oil changes has two facets:

  • One is accomplishing all steps reasonable to prolong the oil's service life. 
  • The second is, as best possible, to change the lubricant when its remaining useful life is nearly spent; not sooner and not later. 
Inspection Mantras.

Never underestimate the value of the daily, one-minute inspection in reducing industrial lubrication costs.. Of course there are inspections and then there are real inspections (conducted by motivated and trained technicians).

These inspection-artists know when, where and how to perform their craft. Skill and vigilance are key. Best-in-class companies seem to be receiving amazing rewards from this strategy.

These strategies are application-dependent, but for many organizations, they can earn sizable annual savings.

Quality-formulated Lubricants play an equally important role in cutting industrial lubrication costs.

There are thousands of cheap lubricants on the market, and many of them have no business in your machines. There are also scores of premium synthetic oils specifically formulated for quality and performance.

They cost more but fill an important niche in the market. Figuring out how to put the right lube in the right machines is a tall order for most organizations. Navigating this maze requires training and occasional expert advice if you want to cut industrial lubrication costs.

Habot Synthetic Lubricants have both the skills and quality products to help you cutting industrial lubrication costs, so give us a call.