wayne dearness auditing your lube mgt system

8/13/2019 Wayne Dearness Auditing Your Lube Mgt System

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Lubrication

Education &

Consulting

to Industry

OilToil

Ref: Dearness 201117-18/10/2011 Copyright 2011 Oil & Toil Pty Ltd

Auditing Your Lube

Management System

An Oil & Toil Pty Ltd Presentation

Presented by: Wayne Dearness

SIRF Condition Monitoring & Lubrication Forum

Bankstown Sports Club, Sydney 18/10/2011


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Copyright 2011 Oil & Toil Pty Ltd 2

Auditing your Lube Management System - (Sustainable Improvements)

Strong industry growth and developmentin Australia's mining resource and energy sectors

has seen the investment of millions of ($s) into new and refurbished plant; a significant issue

for companies struggling to identify and employ asset life-cycle management tools effectively

auditing of Lubrication Management Systems being one of these tools, often poorly used!

Lubrication Audits employedby many companies fail to deliverthe sustainable long-term

benefits envisaged. Recommendations provided fail to address any more than immediate,

narrow and visible issuesnot those interlinked with management objectives, production

forecasts, logistics, asset life-cycle costing, etc. Such areas form the basis of the audit and

buy-in from management to drive and own the processEssential audit elements!

Do not simply throw budget ($s)at lubrication management system audit recommendations by

purchasing the latest lubricant storage and dispensing equipment, etc. Seek independent

assistance from vendor neutral professionals to provide direction and support in planning and

implementing a sustainable lubrication management audit program.

Ref: Dearness 2011


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Auditing your Lube Management System - (Sustainable Improvements)

The Audit processgenerally includes the following points in one form or another, within the

audit terms of reference:

Inspection to document the as issituation - (Assessor experience and plant knowledge is

essentialwhat the as is is for one person is not for another)

Identification of gap elements(When is a gap, a gap? How do I measure?)

Provision of recommendations(How do I fix gaps and to what level?)

The following presentationseeks to highlight (2)basic audit methods, audit criteria andpractices involved in auditing:

Major plant & machinery baseline or benchmark audit(1-3 yearly)

Performance tracking audit(wkly, mthly, 3 mthly); often referred to as a tick & flick audit

The presentationalso highlights a number of plant gapissues and industry best practice

recommendations.

Understandingthe toolsand architecturerequired before embarking on an audit program is

paramount! It is the deciding factor between long term success or costly failure, and a less

than fruitful asset life-cycle management program. The knowledge invested in the assessor is

also critical to the success of the program.

Ref: Dearness 2011


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Management - Adopt a Methodology to Achieve Sustainable Lubrication

Mgt

Ref: Dearness 2008 & 2011

1. Documentthe AS IS 2. Plan &Consolidate 5. Optimise &Re-Plan3. EmployResources 4. Manage &Review

6. Revise & Control

BenchmarkStarting Point!

Conduct a Lube Audit

Enhanced Supply Management

Educate StaffAlign Staff & Mgt

Job DescriptionsLube TechEstablish LPIT

LPIT Champion

Employ Proactive Lube Practices

Dispensing & Store Rationalise

QA & Suppliers

Contamination Goals Set

Select Sampling

Onsite OA & Test

Select OA Lab

Write Procedures - Document

Plan Mini - Projects

Lube Software

RCM & CM Tools


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1st- Understand & Implement ~ The Proactive Maintenance Philosophy!

Ref: J Fitch 2004; Dearness 2004

3

2

1

W

rong

Oil

Dust

Misaligned Process

Chemicals

Imbalance

Cold

Water

Air

Heat

Bearing

Pitting

Noisy

Bearing

Abrasive

Wear

Oil

Oxidised

Oil Thermal

Breakdown

Gas

Entrainment

Burnt

Smell

Overheating High

Vibration

Wear

Debris

Cavitation

Branch Dies

Control

These

Problem

Disappears

Proactive Maintenance

(Remove the Root Causes)

Keep it Clean

Keep it Dry

Keep it Cool

Keep it Aligned & Balanced

Keep it Well Oiled

The Tree Does Not Shoot

Again or it Simply Dies Back !!

General Maintenance(We Cut the Tree Down)

Repair Machine

Replace Old Parts

Rebuild Machines

Remove Old Parts

The Tree Re-Grows and We Doit Again & Again &


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2nd- Maximise Benefits ~ Employ Proactive Lubrication Management!

Ref: ECF; Dearness 2003

FLUID PROPERTIES (extended drain-extended lube life) CONTAMINATION PROPERTIES (extended machine life)

0

500

1000

1500

2000

2500

Competitor Oil (A) Competitor Oil (B)

Oil Hours

Transmission Oil Hours - Oil A & B

Lubricant Life Extension + Machine Life Extension = ($) MAXIMUM BENEFIT

The 80/20 Rule ~ Paretos Principle

Particles Moisture & Fluids Degraded or

Wrong Lubricant

Misaligned &

Imbalance

Heat & Cold

Root Cause Failure Modes & Mechanisms

Paretos Principle The(80/20 Rule):

Aggressively Control

those areas that producethe Greatest BenefitsVital few and TrivialMany


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3rd- Develop & Employ Sectional (LPIT) Teams ~ A Reliability Strategy!

Ref: Dearness 2004

Rule of ThumbDo Not Use (PIT) Team Technicians for General Maintenance, Production & Operation Tasks

Maintenance ~ Reliability Department

(LPIT) Team Champion or Owner

Reliability Engineer(Solutions, Re-Design, Projects, ROI, CBA, etc)

Lubrication Technicians

Planner / CM Interpreter(Control Hub, CM Interpreting, Work Orders, etc)

Vibration Technicians Other (CM) Technicians


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(1) ~ Benchmark AuditPresentation of Results & Structure!

The Audit Report outcome- As with any lubrication Audit or assessment, qualitative data

is best converted to a subjective form of quantitative data, providing a current as is

benchmark and measure against future surveys; supporting program growth. Withoutsuch a lubrication management scorecard, areas of high performance and those requiring

improvements - can be overlooked. Efforts of improvement can be ill directed and

ineffective, a costly waste of valuable resources - both financial and human.

Qualitative data collected during a Customer Plant Audit is expressed in a semi-

quantitative manner, scored from (0 to 10); zero being the lowest level and industry bestpracticeat ten. Such scores are presented via some (72) basic Lubrication

Assessment Observationsthat are grouped into (13)individual Lubrication

Assessment Parameters, each reflective of the (6) Key Repor t Criter ia Areasoutlined

earlier.

A multidimensional scale Spider Graphis used to illustrate the current as islubricationAudit Assessment results, relative to industry best practices for each of the

assessment parameters described. Also noted is a reasonable target for a customer to

aim for through the development of improved lubrication management practices. This

rating system is pseudo-quantitative and should be used as a relative indicator only. The

scaling system makes no attempt to scale the importance of criteria, all assessment

parameters are weighted evenly for overall comparison only.



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(1) ~ Benchmark Audit - Spider Chart Result of (13) Assessment

Parameters


0

2

4

6

8

10

Lubricant Selection

Grease Application

Oil Application

Contaminant Exclusion

Contaminant Removal

Oil Analysis Sampling

Oil Analysis TestingOil Analysis Targets & Settings

Visual Lube & Machine

Inspections

Lube and Parts Storage &

Handling

Program Performance

Education, Training & People

Reliability Program

Current "AS IS" Status

Interim Estimated Goal

Industry Best Practice


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(1) ~ Benchmark Audit(6) Key Criteria Areas & (72) Assessment Points!



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(1) ~ Benchmark AuditTypical Content of an Annual Audit



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(1) ~ Benchmark Audit(6) Key Criteria Areas for Practical Focus!

Benchmark Auditsare focused upon (6) key cr iteria areas, investigating themany aspects of lubrication concerned with the operation and maintenance of

plant machinery. The (6) key areas provide a platform for discussion of on-siteobservations, industry best practice and an action plan to achieveindustry best practice; thereby ensuring that any lubrication managementchanges are serviceable and sustainable. The (6) key areas include:

1. People(e.g. ownership, pro-active training program, motivation, processculture, maintenance and production culture, oil analysis skills and knowledge,oil laboratory awareness, continuous improvement culture, competencyassessment)

2. Lubr icat ion & Machinery Pract ices(e.g. skills-training, industry focus, plantlubrication and production knowledge, breather/filters, dirt, water, dutyload/cycle, greasing, lubricating routes, plant equipment and sampling, samplingequipment and methods, ownership, oil lab sample requirements,housekeeping, company and statutory standards, environment and waste)

3. Storage, Handl ing & Dispens ing Equipment(e.g. skills-training, purchasingawareness, warehouse, housekeeping, ownership, hazard control andemergency equipment, solvents and cleaning equipment, ventilation,consumables, equipment maintenance and servicing, waste methods,dispensing pumps and filters, oil cans, grease guns, hoses and bulk systems)



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(1) ~ Benchmark Audit(6) Key Criteria Areas for Practical Focus!

4. Supp l ier Management(e.g. skills-training, continuous product knowledge

and support, oil analysis sampling equipment, pro-active techniques, ownership,

purchasing, pack sizes, rationalization, mutual KPI`s, waste disposal)

5. Lub r icant Analys is(e.g. skills-training, testing knowledge and education

standards, information technology, lube software, pro-active, predictive and

preventative control and limits, trending, alarms, interpretation/solutions,

ownership, recording and use of results short and long term, technology storagemedium-graphics etc, alarm notification and response, relationship and

understanding of onsite lab services and requirements)

6. Lub r icat ion Procedures(e.g. skills-training, safety & documentation, tool-

box awareness and information transfer, training documentation, hazard trainingand documentation, emergency procedures, oil sampling and test procedure

documentation, service and maintenance management, production, ownership,

environment and waste management, record keeping and ordering, third party

testing, compliance to statutory regulation, standards and licenses, continuous

improvement-self audit, use of KPIs)



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(1) ~ Benchmark AuditAnnual Audit Overlays to Highlight Gap Areas!

The annual Audit findingsand benchmarking of current customer practices is an invaluable tool for planning future lubrication

management programs and their implementation. Annual Audit results are overlaid on the spider graph to highlight areas

of program growth and those requiring action; identifying gaps, excesses, direction, costs, benefits, wins and culture.



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Employ Resources ~ Tool-up & Apply Best Practice Knowledge!

Ref: EHM 2007; Dearness 2008 & 2010

1. Documentthe AS IS 2. Plan &Consolidate 5. Optimise &Re-Plan3. EmployResources 4. Manage &Review

6. Revise & Control

Champion the LPIT Process

Foster LPIT Ownership

Tap WorkforceStaff Benefits

Toolbox Meetings - Culture

Use Proactive Target Goals

Maintain Goals & Trend - Software

Rationalise Lube & Equipment

Install Breathers, Filters, Vents etc

Dispensing & Storage Equip

Use QA Supply

Install Sampling

Do Onsite Tests & Visit OA Lab

OA Interpretation

Use Procedures & Lube Practices

Do Mini-Projects

Refresh TrainingReinforce Input


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Identify & Correct Gaps ~ Audit the AS IS - Lubricant Supply Chain

Ref: Dearness 2004

Supplier Bulk Storage

Supplier Transport Storage

On-site Storage

Working Lubricants

Dispensed Lubricants

Waste Lubricant Storage Farm

Re-claimed Lubricants

Re-cycled Lubricants

Re-conditioned Lubricants

Focus on the Proactive Elements of Lubrication

Management (Contamination, Water, Degraded or WrongOil, Misalignment & Imbalance, Air, Heat or Cold)and

Identify Shortfalls in Your Processes


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Bulk Oil Storage ~ Before & After Lubrication Improvements!


Before After


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Oil Drum Storage ~ Before & After Lube Upgrade!


Before After


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Oil Drum Dispensing ~ Before & After Lube Dispensing Upgrade!


Before

After


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Closed System Oil Dispensing ~ Best Practice Lube Contamination Mgt!

Ref: Randy Hall, Temple Island 2009; Dearness 2009 & 2010

(4) Seal Reservoirs

Fit ALL MachineryReservoirs with Breather /Fill / Drain / Oil SampleManifolds fitted with Snap-

on Dry Break Couplings

Use the Oil Safe 10LContainer & PumpFittedwith Snap-on Dry BreakCouplings to Dispense Oilto the Completely SealedUnit

(1) Workshop 205L Oil DrumFiltration & DispensingStation

Oil is circulated via a pumpthrough the filter and back tothe drumKidney LoopFiltration cleaning the oil

(2) Workshop 205L Oil DrumDispensing Station

Filtered oil is pumped viaflexible hose into the Oil Safe 10Lcontainer

Oil Safe 10L container lid isfitted with Snap-on Dry BreakCoupling to allow fillingSealedClean Oil System Best Practice

(3) Modified Oil Safe Container

Oil Safe 10L Container & PumpLidFitted with Snap-on Dry BreakCouplings to Fill & Dispense Oil tomachineryNo Contamination

Use colour coded Snap-on DryBreak Couplings of different sizesfor each type of oil used in theplantensuring that any cross-contamination of oils is avoided

Colour code all oilsStorage,

Dispensing & Machinery

Fit Snap-onDry BreakCoupling


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(1,000L) Bulk Oil Storage & Dispensing ~ Before & After Lube Upgrade!


Before After


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(1) ~ Criteria for Practical Focus - Conducting a Benchmark Audit



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Question Time!

Ref: Dearness 2011

Any Questions?

Company: Oil & Toil Pty Ltd

Author: Wayne DearnessMechanical Engineer

Offer: Lubrication & Asset Mgt Planning

Hands-on Lubrication & Machinery Education

Lubrication & Machinery Auditing

Consulting & Program Technical Support

Contact: [email protected] M: 0434 003 627
mailto:[email protected]:[email protected]

wayne dearness auditing your lube mgt system

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