INDUSTRY 4.0/IIOT/AI
AN UNSUNG HERO IN MAINTENANCE
Rob Webster, head of onsite condition monitoring and asset management at RS UK & Ireland, underlines the importance of lubrication good practice in condition monitoring
n the quest to achieve solid asset maintenance programmes that help minimise risk of unscheduled downtime, and associated costs, many industrial operators are urged to focus on digital transformation. While Industry 4.0 and the Industrial Internet of Things (IIoT) are undoubtedly help in this quest, building a solid foundation comprising maintenance activities in the condition monitoring toolkit is vital. One unsung hero of condition monitoring is lubrication. Infrequent lubrication, or use of the wrong product, could lead to premature asset degradation or even failure. In our experience, many industrial operators don’t have adequate or scheduled lubrication programmes in place to help avoid this. With much of the equipment used in industrial plants having components that require lubrication, it’s hard to fathom the side-lining of this key activity. Bearings, valves, gears and rotating parts in machinery will require lubrication, but not all are created equal. With so many different applications, it can often require some expert knowledge to select the right ones. A food processing plant will need to select the appropriate food grade lubricant for the avoidance of product contamination and ensure protection during rigorous wash down procedures. A plant running busy or continuous production lines might have to opt for heavy duty lubricants, or use more frequently. It’s not just a case of grease up and go!
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The role of lubricant in machine health is key: poor lubrication was cited as a primary cause of 70 per cent of industrial equipment wear and failure cases in Ken Bannister’s 2014 State of the Lubrication Nation report. So as a major cause of machine issues or failure, it’s certainly not an area to be ignored. There can be a general lack of awareness of good lubrication practices, but the situation is exacerbated by knowledge gaps and engineer resource availability. It is increasingly
26 MAY 2025 | PROCESS & CONTROL
the case that engineers are spread more thinly, so while they might be firm believers in oil condition monitoring, they simply lack the time or resource to act on it. This is because engineering budgets are tight and production time expectations are at an all-time high. As a result, lubrication can fall by the wayside in maintenance strategies. Another key issue is a lack of collaborative working in some organisations which can lead to counter-productive activities. One job role might be to wash-down equipment regardless of the impact of washing away the vital grease, simply because of a lack of knowledge. Similarly, if multiple engineers are responsible for lubrication, under or over greasing can occur. Both can be equally detrimental to asset health. When job roles work collaboratively and have an understanding of the preceding and subsequent activity processes, a better outcome can be achieved. There is also significant value in human sensory abilities when it comes to good lubrication. Having bodies on the factory floor using hearing and sense of smell to identify anomalies is invaluable. But as resources become more scant, this isn’t always achievable. Sensors are key in condition monitoring, but can’t always replace or replicate the function of humans. This is another contributory factor to lubrication issues that can cause asset downtime. There are many specialists offering lubrication services or even training so that good practice can be enhanced or established in-house.
Some offer auditing and then help with building or optimising existing lubrication programmes; and there are usually options to have a tailored lubrication strategy executed as a service, giving peace of mind that the
correct product is being used for the specific application and at the right times. It’s also important to consider how lubricants are transported or stored, as this can help eliminate contamination which can lead to lubrication failure. Specialists can help with this. The return on investment for a well- implemented program can yield a savings potential of several hundred per cent to more than 1000 per cent. This is based on factors like reduced wear and tear on machinery, extended equipment lifespan, and improved energy efficiency.
Implementing metrics or key performance indicators (KPIs) to measure lubrication programmes – or any maintenance programme – will help any organisation achieve significant savings. A metric we work to at RS is that customers should be able to save £8 for every £1 spent.
There is also the cost saving potential to consider in getting lubrication frequency right: many firms change lubricant more frequently than they need to, just because of lack of proper testing knowledge or equipment. Specialist solutions providers can help in this area, as well as with analysis of oils, greases and coolants, ensuring they conform to ASTM and ISO standards.
An average hourly cost of downtime of £5,471.95 was revealed in RS’ Performance in Focus report into the state of maintenance engineering. In challenging and competitive times no organisation wants to miss out on opportunities to reduce risk of downtime, and create efficiencies and cost savings. This highlights the importance of a holistic approach to maintenance and not missing out any activities, including lubrication, as a vital part of the condition monitoring mix.
RS UK & Ireland
uk.rs-online.com
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