How to Avoid Common Lubrication Mistakes

Every organization with machinery understands that proper lubrication is essential for smooth operation and longevity. Despite this understanding, even the most diligent teams can encounter challenges in mastering lubrication best practices. Without proper guidance, these challenges can lead to mistakes that affect machine performance, increase downtime, and drive up operational and maintenance costs. In this post, we will explore some of the most common lubrication mistakes and provide practical solutions to avoid them, ensuring your machinery runs efficiently and reliably. 

Lubrication Mistake #1: Using the Wrong Lubricant 

Every lubricant has its own properties and characteristics that provide specific protection against wear and tear. Additionally, each machine or machine part requires a specific type of lubricant based on its operational and environmental conditions. When you use the wrong lubricant on a particular machine, you risk providing inadequate protection against wear and tear or, worse, causing damage to your machinery. 

Solutions: 

• Refer to the machine manufacturer’s guidelines. Follow the lubricant types or brands recommended by the manufacturer of your machines to avoid using the wrong lubricants. 

• Consider your operating conditions. Often, your machine’s operating temperature, load, speed, and other conditions dictate the type of lubricant it needs. Make sure that the lubricants you are using perform at their optimum in your operating conditions.  

• Seek expert advice. If in doubt, consult with lubricant experts or hire professional lubrication services. You can also conduct your own lubricant performance evaluation by gathering data on machine performance for every type of lubricant you use. 

Lubrication Mistake #2: Over-Lubrication 

Also called over-greasing, this mistake of applying too much lubricant can be as damaging as adding too little. Over-lubrication increases friction, heat, and pressure within the machine, potentially leading to damaged seals and grease leaks. 

Solutions: 

• Refer to the manufacturer’s recommendations. Apply the correct amount of lubricant as recommended by the lubricant and machine manufacturer. These amounts underwent rigorous testing and have been proven to be the optimum for protection and performance. 

• Use the right applicators. Use oil and grease applicators that are appropriate for the type of lubricant you are using. Make sure these applicators are properly calibrated to dispense the right amount of lubricant at the right time. You can also use automatic lubricating systems for more accuracy and efficiency. 

• Perform regular monitoring. Regularly check whether the right amount of lubricant is present on your machines. Develop ideal lubrication monitoring routes to ensure that you don’t miss checking any critical machine or machine parts. 

  
  

Lubrication Mistake #3: Under-Lubrication 

Insufficient lubrication happens when the intervals between lubrications are too long or when lubrication schedules are neglected. Under-lubricated machines are prone to premature failures and breakdowns due to excessive wear and tear. 

Solutions:  

• Develop an effective lubrication schedule. Create an effective lubrication schedule based on the frequency demands of every machine or machine part in your facility. Conduct regular lubrication monitoring and adjust your lubrication schedules if necessary. 

• Use condition monitoring. Perform oil analysis and vibration analysis or use other condition monitoring tools to detect early signs of under-lubrication. This allows you to resolve any under-lubrication issues before they cause major damage to your machines.  

• Train personnel properly. Make sure that your lubrication technicians or staff adhere to your lubrication schedule by training them on best lubrication practices. Help them understand the importance of these practices so that they can comply more easily. 

Lubrication Mistake #4: Contaminating Lubricant 

Contaminants such as water, dirt, and debris can degrade the active components within a lubricant, decreasing its lubricating properties and can even damage machine parts. Most organizations do not consider contamination sources or take measures to control them, thus making the mistake of contaminating their lubricants. 

Solutions: 

• Store and handle lubricants properly. Contamination can happen even during lubricant storage. Make sure that you keep lubricants in a clean and dry environment protected from dust or the elements. In addition, use clean transfer vessels or applicators when handling lubricants. 

• Use appropriate seals and filters. Use the right sealing and filtration systems to effectively keep contaminants out of your lubrication systems. For machines equipped with manufacturer’s breathers or dust caps, make sure to double-check their effectiveness and replace them with higher-quality versions if necessary. 

• Inspect and replace. Perform regular inspections of lubricants, seals, and filters to detect early signs of contamination or damage. Discard contaminated lubricants and dispose of them according to state regulations. Replace damaged or ineffective seals and filters to prevent further contamination and damage. 

Lubrication Mistake #5: Mixing Incompatible Lubricants 

The chemicals and additives within a lubricant can react with the other components of another lubricant. This chemical reaction can lead to decreased lubricating performance and potential machine damage. You must understand that different lubricants are always at risk of incompatibility to avoid the mistake of mixing one lubricant with another. 

Solutions:  

• Stick to one lubricant type. Always use the recommended lubricant for your machine. If you must replace your current lubricant with another type, ensure to clean all lubricated surfaces and remove any trace of your current lubricant before using a new one. 

• Implement a labeling system. Prevent the mixing of different lubricants by properly labeling all the containers of lubricants and their transfer or storage containers. To further prevent mixing and reactions, use dedicated containers and handling equipment for each lubricant if possible. 

• Maintain cleanliness. Aside from thoroughly cleaning in between lubricants, you can also avoid mixing by maintaining overall cleanliness. This is to prevent any spillage, fumes, leaks, and other extraneous lubricants from mixing and reacting with other lubricants.  

Lubrication Mistake #6: Incorrect Application of Lubricants 

Ineffective lubrication can still happen even with the right amount and type of lubricant. Incorrect application is a common mistake that can lead to over and under-lubrication, contamination, and other lubrication mistakes. 

Solutions: 

• Use appropriate application tools and methods. Use special applicators for hard-to-reach or inaccessible lubrication points to ensure that a component gets the lubrication it needs. Ensure correct application by adhering to recommended methods and procedures of lubrication application.  

• Perform regular monitoring. Regularly monitor the lubrication conditions, checking whether lubricants are properly distributed over the necessary surfaces of components. Reapply lubricants and adjust application procedures if necessary. 

Lubrication Mistake #7: Improper Oil Sampling 

Oil sampling is an essential step in analyzing the lubricant's condition and performance. Improper oil sampling can lead to inaccurate oil analysis and misdiagnosis, and ultimately, machine failure. Mistakes in oil sampling may result from an inadequate understanding of the process and failure to train personnel properly. 

Solutions: 

• Train personnel properly. The personnel or team member in charge of collecting oil samples must know and strictly follow all oil sample best practices. You can further increase their oil sampling knowledge and skills by encouraging them to get certified in oil analysis and lubrication management. 

• Maintain cleanliness. Using clean, uncontaminated tools and containers is critical for accurate oil analysis results. Also, oil sampling must be done in a clean and controlled environment to further prevent the contamination of the sample and ensure accurate oil analysis results.  

Lubrication Mistake #8: Ignoring Environmental Factors 

Even with the perfect lubricant and lubrication procedures, failure to consider environmental factors can lead to lubrication failure. You must consider your facility or worksite’s temperature, humidity, and dust to devise the ideal lubrication management strategies that can achieve optimum lubrication benefits. 

Solutions: 

• Assess environmental conditions. Assess your operating environments to select the ideal lubricant or set of lubricants for your conditions. Note the changes that these conditions can undergo with the changing weather or seasons. 

• Employ protective measures. Use protective coverings, enclosures, or shields to protect your lubricants or lubricating systems from the harsh environment. You can also use elevating or other protective infrastructure if your environment is prone to flooding, earthquakes, or similar catastrophes. 

• Adjust lubrication practices. Develop a flexible lubrication plan and procedure that can be adjusted and modified based on seasonal changes and other changes in environmental conditions. 

Lubrication Mistake #9: Neglecting Lubricant Analysis 

Lubricant analysis is critical for the early detection of contamination, degradation, and abnormal viscosity levels. If not addressed, these issues can lead to poor lubrication and, ultimately, machine failure and breakdown. Most organizations perform lubricant analysis, but not frequently enough to be effective in detecting the early signs of lubrication issues. 

Solutions: 

• Establish a lubricant analysis program. An in-house analysis program allows for a more frequent routine analysis of lubricant condition and performance. This program can also train company personnel to perform the analysis and interpret its results, allowing for more immediate corrective actions when needed. 

• Employ professional services. If an in-house program is not feasible, consider using third-party analytical laboratories for a more detailed and expert analysis and recommendations.     

Prevent Common Lubrication Mistakes with Redlist 

Implementing lubrication management best practices is the best way to prevent lubrication mistakes. And you can’t get better lubrication management support from anywhere than Redlist’s Lubrication Management Software. This software provides a powerful platform with advanced lubrication management tools to help you implement the solutions to common lubrication mistakes listed above.  

With Redlist, you can keep tabs on lubricant selection, application, monitoring, and analysis easily and from any location. Thus, you ensure that lubrication best practices are in place and being followed. Get Redlist and start implementing a data-driven and effective lubrication management program today!