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SIRF Condition Monitoring & Lubrication Forum Bankstown Sports Club, Sydney 18/10/2011
17-18/10/2011
Lubrication Audits employed by many companies fail to deliver the sustainable long-term benefits envisaged. Recommendations provided fail to address any more than immediate,
narrow and visible issues not 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 process Essential 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.
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Dearness 2011 2
Overheating
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Branch Dies
Oil Hours
Particles
Reliability Engineer
(Solutions, Re-Design, Projects, ROI, CBA, etc)
Planner / CM Interpreter
(Control Hub, CM Interpreting, Work Orders, etc)
Lubrication Technicians
Vibration Technicians
Rule of Thumb Do Not Use (PIT) Team Technicians for General Maintenance, Production & Operation Tasks
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Dearness 2004 7
Qualitative data collected during a Customer Plant Audit is expressed in a semiquantitative manner, scored from (0 to 10); zero being the lowest level and industry best practice at ten. Such scores are presented via some (72) basic Lubrication Assessment Observations that are grouped into (13) individual Lubrication Assessment Parameters, each reflective of the (6) Key Report Criteria Areas outlined earlier.
A multidimensional scale Spider Graph is used to illustrate the current as is lubrication Audit 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.
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Dearness 2004 & 2011 8
Lube and Parts Storage & Handling Visual Lube & Machine Inspections Oil Analysis Targets & Settings
Current "AS IS" Status Interim Estim ated Goal Industry Best Practice
(1) ~ Benchmark Audit (6) Key Criteria Areas & (72) Assessment Points!
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(1) ~ Benchmark Audit (6) Key Criteria Areas for Practical Focus!
Benchmark Audits are focused upon (6) key criteria areas, investigating the many aspects of lubrication concerned with the operation and maintenance of plant machinery. The (6) key areas provide a platform for discussion of on-site observations, industry best practice and an action plan to achieve industry best practice; thereby ensuring that any lubrication management changes are serviceable and sustainable. The (6) key areas include:
1.
People (e.g. ownership, pro-active training program, motivation, process culture, maintenance and production culture, oil analysis skills and knowledge, oil laboratory awareness, continuous improvement culture, competency assessment) Lubrication & Machinery Practices (e.g. skills-training, industry focus, plant lubrication and production knowledge, breather/filters, dirt, water, duty load/cycle, greasing, lubricating routes, plant equipment and sampling, sampling equipment and methods, ownership, oil lab sample requirements, housekeeping, company and statutory standards, environment and waste) Storage, Handling & Dispensing Equipment (e.g. skills-training, purchasing awareness, warehouse, housekeeping, ownership, hazard control and emergency 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)
2.
3.
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(1) ~ Benchmark Audit (6) Key Criteria Areas for Practical Focus!
4.
Supplier 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) Lubricant Analysis (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 storage medium-graphics etc, alarm notification and response, relationship and understanding of onsite lab services and requirements) Lubrication Procedures (e.g. skills-training, safety & documentation, toolbox awareness and information transfer, training documentation, hazard training and 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)
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Dearness 2004 & 2011 13
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The annual Audit findings and 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.
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Dearness 2004 & 2011 14
Champion the LPIT Process Foster LPIT Ownership Tap Workforce Staff 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 Training Reinforce Input
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: EHM 2007; Dearness 2008 & 2010 15
On-site Storage
Dispensed Lubricants
Working Lubricants
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After
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Use colour coded Snap-on Dry Break Couplings of different sizes for each type of oil used in the plant ensuring that any crosscontamination of oils is avoided
(1,000L) Bulk Oil Storage & Dispensing ~ Before & After Lube Upgrade!
Before After
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Question Time!
Any Questions?
Contact:
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Dearness 2011
Oil & Toil Pty Ltd Wayne Dearness Mechanical Engineer Lubrication & Asset Mgt Planning Hands-on Lubrication & Machinery Education Lubrication & Machinery Auditing Consulting & Program Technical Support wayne@oilandtoil.com or M: 0434 003 627
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