Empowering

Reliability
through
Lubrication Program
Development ( LPD )
Roadmap to Lubrication Excellence
 VAS Tribology Solutions : Introduction

Indias only comprehensive lubrication services company

(www.tribologysolutions.com)

Licensed partners of Noria Corporation,USA ( www.noria.com).

The World Leader in Machinery Lubrication,Oil Analysis and Consulting.

Education & Training
Consulting
Magazine & Newsletters
Conferences
Online Resources
Vendor Neutral

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VAS Tribology Solutions Customers

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 Introduction

Exclusive partners : Noria Corporation, USA

VAS TRIBOLOGY SOLUTIONS

Publication Education &

Training
Lube &
Coolant Consulting
Management
 Our Verticals

Total Fluid Publication Lubrication

Management (TFM)
Training Program
Inventory Development (LPD)
management Regions only
Public Training magazine on:
Handling & Dispensing
In house Training Highly detail plan to
Condition Monitoring Reliability
achieve lubrication
Filtration/Renewal Online Training Lubrication excellence resulting
Sump/Tank Cleaning Lubricants in improved
Reliability
Robust reporting
system & data analysis
Environmental safe
disposal
LPD : Lubrication Enabled Reliability

NORIA
LUBRICATION-
LUBRICATION-
LUBRICATION
The Right
ENABLED
PROGRAM
Lubricant
RELIABILTY
DEVELOPMENT

Keep it Cool
 The Economics of Maintenance & Lubrication

Sample study of manufacturing plant with effect of Lubrication Program Development(LPD)

Lubricants & Lubrication Lubricants and Lubrication

3% - INR 90 lakhs 2.5% - 75 lakhs

17.7%
12%
Annual
Misc
Profit
INR 3.6 Cr
INR 5.3 5Cr

45% 37%
10 %
Replacement Parts Replacement Parts
Misc
INR 13.5 Cr INR 9.8 Cr
40% INR 3 Cr
Maintenance
Labor
INR 12 Cr 32.8%
Maintenance Labor
INR 11.1 Cr

BEFORE AFTER
Copyright@ VAS Tribology
 The Economics of Maintenance & Lubrication

Sample study on Causes of Machine Failure with effect of Lubrication Program Development

Incorrect Choice & Usage of Lubricants Lubricant Related

43% 4.3%

10%
Mechanical
Fatigue
38.7% 27%
Increased Incorrect Assembly
Reliability & Misalignment
20%
Misc

27%
Incorrect Assembly 10%
Mechanical 20%
& Misalignment
Fatigue Misc

BEFORE AFTER
Copyright@ VAS Tribology
 LPD: Lubrication Excellence

Though there may be differences from plant to plant in equipment, culture and
resources, a standardized approach and a cohesive plan for improvement across all
plants can have a significant impact on a companys bottom line.
 LPD : Phases

An engineered approach to achieving Lubrication-

Lubrication-Enabled Reliability.

Phase 1 Phase 2 Phase 3

Benchmark Design Implement

Benchmark Assessment Engineering Design Implement Engineering

SWOT analysis Collect engineering Design
Build business case data Procure and install
Design for best practice hardware/equipment
Plan and scope
Assign procedures Optimize lubricants
Detailed
improvement Consolidate lubricants Educate team
guidelines Build routes Run program
Initial team education Lubricant Storage and Measure Key
Handling Design. Performance Indicators
(KPIs)
 LPD Phase 1 Methodology & Process

ASCEND is ISO 55000 compliant and utilizes the Six Sigma DMAIC methodology to achieve
lubrication excellence

Platform (P)
The outer ring considered as
the foundation of the program.

Program Management (M)

The middle ring enable personnel management processes,
resources, scheduling and monitoring of lubrication tasks.

Key Performance Indicators (K)

The inner ring evaluate performance in each of the stages of
the lubrication process, help keep the program within its
objectives, identify deviations from the goals.
 LPD Phase 1
1) Selection (S)
S1P Lubricant Selection Process
S2P Lubrication Supplier Selection
S3P Lubricant Identification System
S4M Consolidation and Optimization
S5M Lubricant Selection Training
S6K Lubricant Selection Process KPIs
4) Lubricant Analysis (A)
A1P Machinery Selection for Lubricant
Analysis Program
A2P Test Slate Selection
A3P Lubricant Laboratory Selection
A4P Sampling
A5M Limits Selection for Lubricant
Analysis
A6M Lubricant Analysis Interpretation
A7M Lubricant Analysis Training
A8K Lubricant Analysis KPIs
n <30% Decient Implementation n 30%-90% Basic Implementation n >90%-100% Implemented
Lubrication Elements
2) Reception and Storage (R)
R1P Lubricant Storage 3) Handling and Application (H)
R2P Lube Room H1P Lubricant Application Tasks
R3P Quality Control Process H2P Machinery Configuration
R4P Safety Practices H3P Handling and Application Devices
R5M Inventory Management H4P Lubrication Program Management
R6M Reception and Storage Training H5M Lubrication Routes
R7K Reception and Storage KPIs H6M Machinery Inspection Devices and
Practices
H7M Goals and Rewards System
H8M Management and Application
Training
H9K Handling and Application KPIs
6) Environmental Disposal (D)
D1P Storage and Disposal of Used Oil
D2P Storage and Disposal of Material
Contaminated with Oil
D3M Leak Management
5) Contamination Control (C) D4M Environmental Disposal Training
C1P Contaminant Exclusion D5K Environmental Disposal KPIs
C2P Contaminant Removal
C3M Contamination Control Objectives
C4M Contamination Control Training
C5K Contamination Control KPIs
 LPD Phase 2 Engineering Design

ASCEND Discovery Software

Our proprietary technology tools
significantly cut project survey and
engineering time which reduces
project costs.

Username
MyName

Password
******
 LPD Phase 2 Deliverables

Lubrication Program Excel Workbook

Lubricant consolidation On-condition tasks
Hardware modifications
Oil analysis and manpower assessments
Lubricant change
Lubrication Storage and Handling Design
Routine lubrication (lube routes)
 LPD Phase 3 Implementation

Implementation of the Engineering Design

consists of:
modifying hardware

building the lube room

running the lubrication program

We use proprietary processes

to streamline implementation
and can turnkey procurement
and installation of proven
lubrication products.
 LPD: Overall Focus

Current practices and suggest Oil analysis including sampling

Lubrication management, storage, frequency & methods, test slate,
best practice alternatives handling, &disposal on-site oil analysis, target
cleanliness levels etc.

Lubricant consolidation Contamination control and Training and procedure

and purchasing standards. proactive maintenance practices documentation
 LPD: How it transform? Few Examples

Handling & Application Device Reception and Storage Sampling

Disposal of used oil Contamination Control Lubricant Identification

 LPD : Case Study

100
Action Plan:
90
Cleanliness targets
Relative Percentage of Pump Failures

Sampling ports
80
Improved filters and breathers
70 On-site particle counts

60

50 Achievements:
75% reduction in oil consumption
40 80% reduction in hydraulic repairs
50% reduction in bearing purchases
30
Areas for Improvement
20 Right Lubricant
Right Amount
10 Right Time
Address other contaminants; heat, water, etc.
0
1 2 3 4 5
Years
Success Stories

Copyright- VAS Tribology Solutions

Lubrication Program Development(LPD) Enables to
Save More Than 2 Crore Rupees in a
Coal Fired Power Generation Company

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 Case Study- Coal Fired Power Generation Company

Findings:

For the plant where project were undertaken, lubrication was always important,
but know-how and expertise were lacking.

To catch problems before they occurred, one of the things that plant relied on was
vibration technology.

Oil sampling for predictive maintenance was another area in which plant was
deficient. A one-line instructional document only suggested to draw a sample.

Transitioning to best practices:

It started with a plant-wide, top-to-bottom analysis of all plant systems that

required lubrication.

This was followed up with recommendations down to the component level.

With best practices for lubrication in place, fewer unplanned outages are occurring
at the plant. In one example, technicians were able to analyze and stop a piece of
equipment from breaking down. Copyright- VAS Tribology Solutions
 Case Study- Coal Fired Power Generation Company

Benefits:

Yearly saving of $350,000 equivalent

to Rs.2,35,00,000

Previously, plant used 23 different

types of oil. That number was reduced
to 16 after transitioning to best
practices.

Training the entire maintenance staff

of more than 200. Training materials
were customized to their job
functions.

Copyright- VAS Tribology Solutions

Lubrication Program Development Enables to
Cut Downtime by 50 Percent

Copyright- VAS Tribology Solutions

 Case Study- Manufacturing Company

Achievement of Lubrication
Excellence:
Our experts developed lube routes,
proper oil handling practices and
written procedures for each task.

Recommendations were made for

installing filtration units, desiccant
breathers and
Color-coded identification systems
for machines and oil transfer
containers.

A new lube room was also designed

to keep oil in a climate-controlled
environment.

Potential cost savings of $1 Million

Equivalent to Rs.6,70,00,000.
Copyright- VAS Tribology Solutions
 Power Companies Benefited with LPD Program

More than 20 Power Generation Companies Benefited from our LPD Program.

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 Other Companies Benefited with LPD

Steel Plant

Miscellaneous

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Contact Us:

info@tribologysolutions.com

+91657-2383238

http://www.tribologysolutions.com/

Copyright- VAS Tribology Solutions

Thank You!

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