Is your
lubrication program really as good as you think it is?
Is it good enough?
Does it enhance
or degrade your reliability effort?
How do you know?
After more than 21 years of experience dealing with client
lubrication programs this author has concluded that there is a
common trait that exists between nearly all companies with
respect to their lubrication programs. That trait is
'confidence'.
Sounds good, right? No one would argue that there is a benefit
to having a high level of confidence in the ability to
accomplish a task. Confidence leads to definitive action, but
does confidence lead to the correct action?
Lets put this into perspective a bit. Consider the growing
confidence of a teenage boy. A good measure of confidence is
necessary for him to become his own person, but confidence
without knowledge leads to foolishness. Most teenage boys think
they are effective automobile drivers, but would you put your
son, or nephew, in a high-power automobile on a racetrack, and
tell him to 'open’er up and see what you can do'.
Not likely! Your collective experience reminds you that
confidence is not enough to get the maximum performance from the
automobile. But, once that teenage boy is subjected to precise
instruction under properly controlled conditions, the confidence
and proper type of experience combined may enable him to take
full advantage of the power on the racetrack.
Grading
Lubrication Practices
Once again, is your lubrication program any good? Is your
confidence rooted in your own impressions, or is it rooted in a
comparison to some objective standard? Wouldn’t you like to know
if your confidence is justified or misplaced?
Over the next 10 months Reliability Web and AMRRI will provide
an opportunity for you to grade your lubrication practices from
a purely objective point of view. Each month an article
explaining a portion of the 10-part benchmark process will be
accompanied by a web-based benchmark form that you may use to
grade your own practices.
The grading process will be presented in the form of a survey.
The survey will have nine distinct segments as follows:
1 Vendor Selection Process
2 Lubricant Delivery, Storage and In-plant Handling Process
3 Lubricant Technical Selection Practices
4 Lubricant Application Practices
5 Oil Analysis Program Practices
6 Condition Control Practices
7 Lubrication Program Management and Personnel Development
8 Standardization (SOP's) Machine Lubrication Practices
9 Safety, Health and Environmental Practices
The nine segments represent aspects of both effective (precise)
machine lubrication, and effective organizational management.
Toward the end of the process we will add a place where you can
‘factor’ your survey with a priority rating for each of the nine
segments, which will be based on your sites priorities. Each
segment will have an average of about 30 condition statements
that require responses. The condition statements are statements
of fact reflecting conditions that represent a 'best practice'
based on the author’s research, personal experience and past
benchmarking activities.
Each statement should include only one factual criterion, and
each statement should be acknowledgeable with a Yes or No,
marked as either a 1 (yes) or a 0 (no) on the worksheet or
on the online benchmarking tool. The scoring scale is listed
below:
Obj. Score
(Objective Score)
0 = The statement is FALSE
1 = The statement is TRUE
If you would
like a more comprehensive assessment methodology: For the
statements that receive a Yes response, the criterion is then
graded subjectively by providing a quality score between 1 and 5
(1 is poor quality/no consistency and 5 is superior
quality/absolute consistency). The subjective/qualitative rating
allows the inspector to influence the results if the inspector’s
opinion is warranted.
These two scores are multiplied together and then multiplied by
two to put the results on a 10 point scale. (You may ask, why
put this on a 5-point scale to start with?.... We will address
this later!) If the subjective score category is left empty,
then the score defaults to the objective score. The
comprehensive rating
system is displayed below for your review.
Quality Score - The quality with which the item(s) is/are
completed:
1 = Poorly done
2 = Done sporadically or without concern for technical accuracy
3 = Done with care but limited skill or capability to improve
the quality
4 = Done with attention to detail, but limited skill or
knowledge
5 = Done with careful attention to detail and quality, and with
a high degree of skill
At the end of the series Reliability Web and AMRRI will present
a summary of all the surveys that have been conducted on-line,
against which you can compare your specific results. The
process, and accompanying user data, will be summarized and
presented again as a half-day course at the
International
Maintenance Conference in
December, 2007.
So, please, read along and participate by grading your plant
practices over the course of the next 10 months.
The following article introduces the first step of the survey for your
consideration.
Step 1. Selecting a Vendor
Step 2. Lubricant Storage,
Delivery and In-plant Handling Process
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