Oil & Toil

Lubrication Education & Consulting to Industry

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

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2011

17-18/10/2011

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Auditing your Lube Management System - (Sustainable Improvements)

Strong industry growth and development in 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 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

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Auditing your Lube Management System - (Sustainable Improvements)

The Audit process generally includes the following points in one form or another, within the audit terms of reference: Inspection to document the as is situation - (Assessor experience and plant knowledge is essential what 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 presentation seeks to highlight (2) basic audit methods, audit criteria and practices 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 presentation also highlights a number of plant gap issues and industry best practice recommendations. Understanding the tools and architecture required 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.
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Dearness 2011 3

Management - Adopt a Methodology to Achieve Sustainable Lubrication Mgt

6. Revise & Control 1. Document the AS IS 2. Plan & Consolidate 3. Employ Resources 4. Manage & Review

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5. Optimise & Re-Plan

Benchmark Starting Point!

Conduct a Lube Audit

Enhanced Supply Management Educate Staff Align Staff & Mgt Job Descriptions Lube Tech Establish 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
Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Dearness 2008 & 2011 4

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

Gas Entrainment Abrasive Wear Problem Disappears High Vibration Noisy Bearing Bearing Pitting Cavitation

General Maintenance (We Cut the Tree Down)

Repair Machine Replace Old Parts Rebuild Machines Remove Old Parts

Overheating

Oil Thermal Breakdown Burnt Smell

Wear Debris Oil Oxidised

The Tree Re-Grows and We Do it Again & Again &

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Branch Dies

Proactive Maintenance (Remove the Root Causes)

Keep it Clean $ Keep it Dry Keep it Cool Keep it Aligned & Balanced Keep it Well Oiled Cold Wrong Oil Imbalance Misaligned Process Chemicals Heat Control These
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Dust Water Air

The Tree Does Not Shoot Again or it Simply Dies Back !!

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: J Fitch 2004; Dearness 2004

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2nd - Maximise Benefits ~ Employ Proactive Lubrication Management!

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

The 80/20 Rule ~ Paretos Principle

2500 2000 1500 1000 500 0

Competitor Oil (A) Competitor Oil (B)
Transmission Oil Hours - Oil A & B Paretos Principle The (80/20 Rule): Aggressively Control those areas that produce the Greatest Benefits Vital few and Trivial Many

Oil Hours

Particles

Moisture & Fluids

Degraded or Wrong Lubricant

Misaligned & Imbalance

Heat & Cold

Root Cause Failure Modes & Mechanisms

Lubricant Life Extension

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Machine Life Extension

Ref: ECF; Dearness 2003

= ($) MAXIMUM BENEFIT

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

Maintenance ~ Reliability Department

(LPIT) Team Champion or Owner

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

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

Lubrication Technicians

Vibration Technicians

Other (CM) 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

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(1) ~ Benchmark Audit Presentation 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. Without such 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 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

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

Lubricant Selection 10 Reliability Program 8 Education, Training & People 6 4 Program Perform ance 2 0 Contam inant Exclusion Oil Application Grease Application

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Lube and Parts Storage & Handling Visual Lube & Machine Inspections Oil Analysis Targets & Settings

Contam inant Rem oval

Oil Analysis Sam pling Oil Analysis Testing

Current "AS IS" Status Interim Estim ated Goal Industry Best Practice

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2011

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

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2011

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(1) ~ Benchmark Audit Typical Content of an Annual Audit

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2011

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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.

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2011

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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

5.

6.

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

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

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

6. Revise & Control 1. Document the AS IS 2. Plan & Consolidate 3. Employ Resources 4. Manage & Review 5. Optimise & Re-Plan

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

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

Focus on the Proactive Elements of Lubrication Management (Contamination, Water, Degraded or Wrong Oil, Misalignment & Imbalance, Air, Heat or Cold) and Identify Shortfalls in Your Processes

Supplier Bulk Storage

Supplier Transport Storage

On-site Storage

Dispensed Lubricants
Working Lubricants

Waste Lubricant Storage Farm

Re-cycled Lubricants Re-claimed Lubricants Re-conditioned Lubricants

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004

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Bulk Oil Storage ~ Before & After Lubrication Improvements!

Before After

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2010

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Oil Drum Storage ~ Before & After Lube Upgrade!

Before After

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2010

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Oil Drum Dispensing ~ Before & After Lube Dispensing Upgrade!

Before

After

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2010

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Closed System Oil Dispensing ~ Best Practice Lube Contamination Mgt!

(1) Workshop 205L Oil Drum Filtration & Dispensing Station
Oil is circulated via a pump
through the filter and back to the drum Kidney Loop Filtration cleaning the oil

(2) Workshop 205L Oil Drum Dispensing Station

Filtered oil is pumped via
flexible hose into the Oil Safe 10L container Oil Safe 10L container lid is fitted with Snap-on Dry Break Coupling to allow filling Sealed Clean Oil System Best Practice

(3) Modified Oil Safe Container

Oil Safe 10L Container & Pump
Lid Fitted with Snap-on Dry Break Couplings to Fill & Dispense Oil to machinery No Contamination

(4) Seal Reservoirs

Fit ALL Machinery Reservoirs with Breather / Fill / Drain / Oil Sample Manifolds fitted with Snapon Dry Break Couplings Use the Oil Safe 10L Container & Pump Fitted with Snap-on Dry Break Couplings to Dispense Oil to the Completely Sealed Unit

Fit Snap-on Dry Break Coupling

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

Colour code all oils Storage, Dispensing & Machinery

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11> Ref: Randy Hall, Temple Island 2009; Dearness 2009 & 2010 20

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

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2010

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

Copyright 2011 Oil & Toil Pty Ltd <SIRF RT CM&L-18/10/11>

Ref: Dearness 2004 & 2011

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Question Time!

Any Questions?

Company: Author: Offer:

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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