How to tackle lubrication problems in industrial manufacturing
Lubrication is a vital part of industrial manufacturing. No matter the type of machinery or manufacturing process, lubrication lies at the heart of each assembly and process. Experts in industrial production know that manufacturing industries with a longer uptime and higher machine life yield more profitable returns. However, there are several areas for improvement regarding how machines and processes in manufacturing industries are lubricated. There have been high losses in essential resources like energy and machine wear and tear caused by inappropriate lubrication standards. This blog explains how to tackle lubrication problems in industrial manufacturing.
Importance of effective lubrication in industrial manufacturing
Lubrication can be defined as a process where a layer of liquid or solid is applied to a surface to reduce friction between two surfaces that are moving relative to each other. Without proper lubrication, the manufacturing plant’s equipment would quickly grind to a halt.
Lubricants serve several purposes depending on their application, but their primary purpose is to:
- Increase the life span of machinery and equipment by reducing friction and wear and tear
- Improve productivity and profitability by keeping machines running at peak efficiency
- Reduce downtime for repairs and maintenance
- Reduce energy consumption by lowering generated heat
Types of lubrication systems
The manufacturing industry utilises several lubrication systems due to their complex requirements. Some even use customised lubrication systems to maximise efficiency. Here are a few common lubrication systems:
1. Pressure lubrication
This method uses an oil pump that applies pressure to push oil through a tube into a small hole at the end of the shaft, where it lubricates the bearings. The pressure ensures adequate lubrication to all moving parts, even those functioning at high speed.
2. Drip feed
This method uses a drip feed system that constantly drips oil onto moving parts, so they don't rub together. Some dripper systems use gravity, while others use pumps or compressed air to push the oil out of their tanks and onto your machinery's moving parts.
3. Manual lubrication
Manual lubrication is the traditional method of applying lubricants to machinery. This method requires a person to apply the lubricant to the machinery manually. It is effective, but it can be inconvenient and time-consuming. Additionally, manual lubrication can lead to the over-application of lubricant. This can cause a buildup of machinery parts and contribute to increased downtime
How to maintain a lubrication system
In the industrial sector, there are a few common lubrication problems. These tips will assist you in understanding and resolving these issues.
1. Creating an SOP
Creating a standard operating procedure is a vital step to ensuring the proper maintenance and lubrication of machinery in industrial manufacturing. By creating a standard operating procedure, you can ensure that all employees are on the same page regarding lubricants, machinery, and other factors that affect machinery performance.
An SOP will include information such as:
- The type of oil needed for each machine
- The frequency with which the oil must be changed
- How often should the machine be inspected for damage or wear
- Who has authority over which machines at any given time
In addition to creating an SOP for lubrication, you may also want to look into other ways of improving your industrial machine maintenance processes. For example, consider implementing an industrial machine maintenance software solution that helps you track each piece of equipment and its current condition.
2. Ineffective sampling points
Several manufacturing companies fail to realise the full benefits of their lubricants because they fail to check their lubrication systems adequately. The most common reason is that they do not have proper point sampling points or hardware to check their lubrication systems.
Inadequate point sampling points or hardware can lead to several problems, including:
- Incorrect test results
A lack of sample points will make it difficult to determine how effective your applicators are. This could result in incorrect test results, leading to issues with your lubrication programme. - Inadequate monitoring
A lack of sample points or hardware can make monitoring applicators difficult for managers and operators. Therefore, they will be less likely to take action if problems arise with the applicators or other equipment.
Ensure ample primary and secondary sampling points to monitor the lubrication system performance constantly.
3. Improper labelling for oil and grease containers
Proper labelling is essential for lubrication. The label should include the brand name, product description, recommended applications and other relevant information. It can also include the manufacturer's name and address and a bar code for easy identification. Labelling provides safety information and helps workers use the correct oil or grease for their application. This can dramatically reduce maintenance costs and downtime.
Final thoughts:
Effective lubrication is a catalyst for achieving maximum operating efficiency and profitability. However, using top-grade, industry-specific lubricants is equally essential as they are formulated while considering industrial requirements. Castrol is among the leading liquid engineering companies in the world and provides highly effective industrial lubricants for the manufacturing industry. You can browse our comprehensive range of high-quality industrial manufacturing lubricants to improve your lubrication management systems.