Lubrication is no longer a minor maintenance task but is now considered vital for the efficiency and reliability of machines and similar assets. An effective lubrication program involves a complex interplay of tasks to achieve its goals. To ensure that these lubrication tasks are done consistently and effectively, teams must implement a well-structured lubrication checklist.
A lubrication checklist is more than just a list of lubrication chores. It requires specific technical knowledge, attention to detail, practical skills, and first-hand experience in using the machinery or asset. The goal is to integrate lubrication checklists seamlessly into your preventive maintenance (PM) program. Thus, you ensure the effective implementation of PM without much effort or complexity that might prevent the long-term adoption of your PM program.
In this post, we offer practical tips on creating and implementing lubrication checklists that work. Use these strategies to build and implement a PM program that minimizes downtime, boosts efficiency, and keeps operations on track.
1. Identify All Lubrication Points
The best way to start with your lubrication checklist is to identify and define the lubrication points. These points are the machinery parts that require lubrication, such as bearings, gears, chains, and shafts. Do this for all the machinery, equipment, and other assets in your facility.
Prioritize these lubrication points based on factors such as their criticality to operation, likelihood of wear, and replacement costs. Map out these points to avoid missing any. We especially recommend using a cross-functional approach by gathering insights from operators and technicians who work directly with the machinery, ensuring every lubrication point is accounted for.
2. Specify the Right Lubricant
Not all lubricants are created equal, and not all lubrication points require the same lubricant type. Using the right lubricant is crucial to ensuring maximum equipment performance and longevity. On the other hand, using the wrong type of lubricant can harm your equipment instead of improving its reliability.
We recommend you refer to the equipment manufacturer’s guidelines or consult with lubrication experts to select the ideal lubricant types for your needs. Consider also the operating conditions of your assets because these also dictate the lubricant type you must use.
3. Set the Application Frequency
How often you apply lubricants is crucial to prevent under and over-lubrication, both of which lead to harmful effects on machine components and overall machine reliability. The frequency of lubricant application depends on an asset’s usage intensity, environmental conditions, and manufacturer recommendations.
Establish a frequency for each lubrication point, whether daily, weekly, monthly, or quarterly. Our valuable tip is to begin by following the asset manufacturer’s frequency recommendations. You can always adjust this frequency by monitoring the asset health and lubricant conditions over time.
4. Standardize Application Methods
Different lubrication points also require different application methods. You must define these methods and issue clear instructions to minimize errors and standardize lubrication tasks. Otherwise, you risk technicians basing their methods on guesswork or instinct, which can lead to under or over-lubrication.
Here is an example of a clear application instruction:
Lubrication point: Conveyor chain links
Type: Chain lubricant
Frequency: Weekly
Application method: Using the brush applicator, brush along the entire chain length. Make sure no dripping or excess lubricant remains after brushing.
5. Include Safety Steps
Although often taken for granted, safety should be an integral part of any lubrication checklist. Lubricants can be hazardous when ingested, inhaled, or come in contact with the human body. These safety steps minimize these hazards and protect your maintenance team’s health and wellness.
Include detailed safety steps in your lubrication checklist, such as using the necessary personal protective equipment (PPE) like gloves, eye protection, or masks. Take note of any especially harmful items, such as spray lubricants or high-temperature applications. Incorporate lockout/tagout instructions to ensure the equipment is safely powered down before lubrication or maintenance.
6. Prevent Lubricant Contamination
Contamination is one of the major causes of ineffective lubrication and eventual machine failure. When lubricants are contaminated with dirt, dust, water, and even components of other lubricants, their lubricant performance can decrease. In addition, these contaminants can react with the lubricant and form harmful chemicals that speed up machine damage.
Detail anti-contamination instructions in your lubrication checklist, including:
Receiving - Order from reputable lubricant suppliers, check whether lubricants were delivered in clean and properly labeled containers using clean delivery vehicles.
Storage - Store lubricants in clean and protected storage facilities away from extreme heat and the elements.
Application - Use clean designated applicators like grease guns or brushes and maintain the cleanliness of the application area before and after each application.
7. Incorporate Visual Aids
Diagrams, pictures, color codes, and similar visual aids can help technicians perform their lubrication tasks faster and more accurately. These are especially useful for newly acquired equipment or in training new technicians.
Add simple illustrations or schematics to the checklist to make it more user-friendly. You can also mark the actual lubrication points with colored or numbered labels that correspond to the checklist, helping technicians locate these points more easily while removing guesswork and potential errors.
8. Track and Log
Tracking and logging each lubrication task helps keep a historical record that can empower future lubrication and PM decisions. With these records, you can observe trends and gather insights on lubrication performance. From there, you can identify the lubrication points that are prone to failure and devise the appropriate corrective actions to prevent future failures.
For each lubrication task, log the date performed, technician initials, and observations like unusual noises or leaks. Also, allot a space on your checklist for the technician’s recommendations, which can be valuable when making your decisions.
9. Use a Digital Lubrication Checklist
Using digital checklists can take your lubrication checklist to the next level in terms of accessibility and efficiency. Digital records are easier to fill out, submit, store, and retrieve. You can use templates for lubrication checklists or customize your own using Lubrication Management Software (LMS) like Redlist.
By going digital, you can access your checklist in real time, put out alerts or reminders for technicians, and receive updates on task status and feedback. It also makes tracking and logging tasks more efficient because the software instantly logs in data. Furthermore, most sophisticated LMS solutions today can be used to analyze data and identify trends for data-driven decision-making.
Create Your Digital Lubrication Checklist for Preventative Maintenance
A comprehensive and properly implemented lubrication checklist brings you closer to more reliable operations and smoother maintenance workflow. However, this goal can be challenging for organizations handling large numbers of complex assets and lubrication points. This is where digitizing lubrication checklists can be the most valuable.
Redlist’s Lubrication Management Software is your ticket to handling large and complex lubrication data points more efficiently and accurately. With user-friendly, mobile-enabled, and cloud-based features, Redlist is the ultimate in accessibility and transparent information.
Also, Redlist is easy to integrate with lubrication monitoring tools, devices, and management systems, allowing you seamless data transfer and faster communication within teams and devices. Finally, with advanced analytics and powerful computing, Redlist is indispensable when it comes to processing lubrication data and gathering insights for continuous improvement.
Create and implement lubrication checklists that drive your preventive maintenance forward. Schedule your free demo and experience our lubrication solutions today!
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