Operational costs are eating into profits more than ever.
Many plants are seeking opportunities to cut costs without reducing production. The issue is that cutting costs in the wrong areas can damage costly machinery and lead to greater expenses.
Here’s the good news…
Smart lubrication management saves money AND maximizes equipment performance. Lubrication management is one of the only maintenance programs that can pay for itself in months rather than years.
Cut costs with smarter lubrication… and how NOT to! This manual will show you.
Inside This Guide:
- Why Lubrication Management Matters
- The Real Cost Of Cutting Corners
- 5 Ways To Slash Operational Costs
- Choosing The Right Lubricant Supplier
Why Lubrication Management Matters
Lubrication management is the secret weapon for cutting costs without sacrificing equipment performance.
Why lubricate? Because lubrication affects every moving component of every machine in your facility. Proper lubrication lengthens equipment life, prevents failures and reduces energy costs.
When done wrong… it costs you a fortune.
A solid lubrication management program goes way beyond just topping up oil. It covers:
- The right lubricant for each application
- Correct application intervals and amounts
- Storage and handling procedures
- Routine oil analysis and monitoring
- Contamination control
Individually, each of these categories can save you big money. Put them together into one program and you can save a fortune.
Many facilities partner with a reputable Mobil distributor in Tennessee to source appropriate lubricants along with the professional expertise and technical support they need to establish a comprehensive lubrication management program. Partnering with a reputable supplier ensures you have the proper product for each piece of equipment instead of guessing.
Did you know that lubrication spend only typically represents 2% or less of the overall maintenance budget. However, poor lubrication decisions can destroy as much as 15% of your budget with equipment failures.
The Real Cost Of Cutting Corners
Cutting corners on lubrication feels like a smart cost-saving move…
Until your equipment breaks down.
The reality is harsh. As much as 43% of equipment failures are linked to incorrect lubricant selection or use. Nearly half of all breakdowns occur due to one easily remedied issue.
And downtime events are costing companies more each year. Siemens says the world’s top 500 companies lose $1.4 trillion annually due to unplanned downtime. That’s 11% of annual revenue.
A mid sized plant can lose $25,000+ per hour of downtime. Automotive plants can lose upwards of $2.3 million hourly.
[Think about it:]
For every dollar you save by not lubricating properly, you could be costing yourself thousands in repair bills, downtime and emergency service calls. Ouch!
And that trade-off occurs daily in plants without a formal lubrication management program.
5 Ways To Slash Operational Costs
Ok, now on to the good news. Here are five surefire ways to reduce operating expenses and not sacrifice equipment performance…
Use The Right Lubricant For Every Job
This sounds obvious, but most facilities get it wrong.
Different machines require different lubricants. Using “same oil” everywhere… might seem economical….until things start failing. Proper lubricant will:
- Lasts longer between changes
- Reduces friction and wear
- Saves energy
- Prevents heat damage
Don’t Guess! Match each lubricant to each application. Work with a good supplier to create a full lubrication chart for your facility. This one simple step can increase bearing life 5-10x and cut your lubricant costs dramatically.
Run Regular Oil Analysis
Oil analysis is one of the best-kept secrets in lubrication management.
Routine oil testing allows you to nip trouble in the bud before expensive breakdowns occur. You will know:
- When contamination is building up
- When wear metals are spiking
- When additives are depleting
- When the oil actually needs changing
The real benefit? You stop guessing when to change oil and start changing oil based on factual information. Most facilities with oil analysis programs increase their oil change intervals by 50% or more. Longer oil life. Longer equipment life. And more life in your maintenance budget.
Switch To Synthetic Lubricants Where It Makes Sense
Synthetic lubricants cost more upfront…
But the long-term savings are huge.
Synthetics provide 3-5 times longer service life than traditional oils. They perform better in severe conditions, reduce energy consumption and can significantly prolong machinery life. Consider synthetic if you have high temperature or heavy duty equipment.
The economics are easy: spend slightly more now to save substantially more later.
Train Your Maintenance Team
Even the best lubricants fail if applied wrong.
Too much grease blows seals. Too little grease causes friction damage. Mixing the wrong lubricants destroys your equipment. Make sure your team understands this.
- How much lubricant to apply
- When to apply it
- Which lubricants can be mixed
- How to store and handle lubricants
Hours of training can prevent thousands of dollars in unnecessary repairs. Well-trained teams also use less product, reducing your annual lubricant spend.
Set Up A Proper Storage System
Contaminated lubricants destroy equipment.
If you store oil drums outside. Leave containers open. Or use dirty transfer hoses or cans….you are contaminating your lubricants BEFORE they even enter the machine.
Set up a clean, organised lubrication storage area with:
- Sealed containers
- Colour-coded labels
- Dedicated transfer equipment
- Climate control
The majority of plants bleed more lubricant to contamination than they know. Cleaning out your storage area is one of the least expensive ways to reduce waste.
Choosing The Right Lubricant Supplier
The supplier you choose makes or breaks your lubrication management program.
A good supplier provides you with much more than materials/services. They become part of your operation by offering:
- Technical advice and product recommendations
- Oil analysis services
- Training and support for your team
- Equipment surveys and lubrication audits
- Emergency support when things go wrong
Inexpensive suppliers can save you some money on the gallon… but they’ll charge you with horrible service & advice.
[Look for suppliers who:]
- Carry premium industrial-grade brands
- Have certified lubrication experts on staff
- Offer ongoing technical support
- Provide oil analysis services
- Stock the products you need consistently
Partnering with a quality supplier you can trust is one of the easiest ways to save money and protect your equipment.
The Bottom Line
Reduce operating costs without compromising equipment performance. You can. Manage your lubrication effectively.
By focusing on the right products, proper application and regular monitoring, you can:
- Cut maintenance costs by reducing emergency repairs and breakdowns
- Extend equipment life so you replace expensive machinery less often
- Save on energy because well-lubricated equipment runs more efficiently
- Reduce downtime and keep production running smoothly
Typically the majority of facilities will realize significant savings during year 1 of a proper lubrication management program. The return on investment can be many times that of the initial expense.
Probably the only maintenance investment you will make that pays for itself the first day. Stop viewing lubrication as an expense. Start viewing it as an investment into your bottom line.
