Planned lubrication maintenance is the best protection against catastrophic machine failure, according to machine operation experts. While plant maintenance managers and owners understand that fact, they are slow to allocate the funds and time necessary to complete a comprehensive yearly program, according to lubrication experts. All too often, plants review their lubrication policy only after a catastrophic machine failure.

One way to create a successful lubrication plan and keep it going is to put the details in writing, says Mike Ramsey of Noria Corp., a provider of oil analysis services and information.

"Get busy putting your lubrication plan on paper. Involve as many people (and departments) as possible to share in its creation and to communicate what's in it for them," Ramsey said.

Successful plans have several common factors, according to Jerry McLain, general manager of the services division of Applied Industrial Technologies of Cleveland, Ohio. A program demands consistency, attention to detail and dedication to a timetable.

"Regardless of the quality of products and seriousness of technicians, a program must be consistent. Machines must be lubricated or overhauled on time," he says.

Secondly, install the right product, in the right quantity, for the application. Always follow the machine manufacturer's recommendations. Not doing so, and under- or over-lubricating, are reasons for machine failure. Too often, the program gets blamed, rather than the products, McLain said.

Applied Industrial recommends that a third party analyze oil and perform machine maintenance. Oil analysis involves setting a benchmark of performance for the lubricant in a specific machine. McLain recommends analysis by a party independent of lubricant manufacturers. That way, there is a tendency to evaluate all products equally.

"You won't consistently get one brand recommended over another. That's best for the customer," he said.

Common sense and a strong schedule that will be followed go a long way toward avoiding catastrophic machine failure, he added.

Product consolidation is also an important distributor function, as are leakage studies and contamination control, Ramsey said.

"A plan of attack may involve ... upgraded oil storage areas, lubricant procurement standards, oil sampling procedures, or better labeling," he says.

McLain says Applied does not store lubricants at the customer's plant or supply service personnel. He also agrees that too many products encourage errors and omissions.

"In general, the best practices for lubrication are to be conscious of the OEM's specifications and be aware of what the customer is already using, " McLain said. "Too often, there's confusion because a number of brands are used for the same application."