1. Do not over lubricate
More does not always mean better. Excessive lubrication is a mistake made too often, especially among inexperienced technicians, and for different reasons affecting negatively when calculating the CTP. First, it causes unnecessary consumption of lubricants in inventory costs money then replaced. Secondly, excessive lubrication requires more labor or work hours that could have been spent on more important or productive tasks. Finally, the presence of too much lubricant between the functional parts of the machine, causes excessive friction and wear of the key components, leading to a net loss of performance during the time the machine is stopped for repair and Unwanted a cost in purchasing spare parts.
It is advisable therefore work closely with the manufacturer of lubricants to eliminate these situations. Some of the best manufacturers offer as an integral part of its package of products and services, training of technicians and a computer program that helps to calculate a lubrication schedule indicating what the exact amounts of lubricant to be applied, when and where. Thus unnecessary consumption thereof is reduced, investing too much time working in the maintenance of machinery and the risk of breakdowns, all contributing to lower TCO.
2. Minimize waste and its treatment
Lubricating wear and lose their effectiveness over time and have to be changed periodically. Treatment and disposal of this waste, in accordance with current legislation, a process which inevitably increases the CTP of machinery.
However, this cost can be minimized with the use of high quality synthetic lubricants rather than conventional mineral lubricants. Synthetic have a three or four times longer than mineral lubricants, and therefore the lubrication interval is extended considerably, reducing the time needed for the lubrication of equipment and the amount of waste to be treated life.
3. Reduce energy consumption
The energy consumption for the operation of machinery contributes greatly to the equation to calculate the CTP, and optimum energy efficiency positively influences the final result.
You can not achieve that energy efficiency if the manufacturer is using a lower quality lubricants or those who are not suitable for the application in question. If for this reason, the equipment becomes worn or if components undergo oxidation or corrosion, there is increased friction and temperature on the functional parts, and hence should be increased energy consumption to maintain the levels of production. As before, synthetic lubricants are the solution to the problem and offer a way to get the best performance and energy consumption of the equipment. To be of a higher mineral lubricants and be specially formulated for specific applications quality, better prevent damage and corrosion in the machinery and significantly reduced levels of friction.
4. Conduct regular audits lubrication
A good lubrication audit, conducted regularly, provides manufacturers and their technical department detailed maintenance strategy that allows them to get a higher return on their machines, and consequently reduce their TCO. Some of the leading companies in the manufacture of lubricants offer a service audit conducted by specialists who analyze the reports of maintenance and equipment components to determine the weaknesses in the management of lubrication.
A complete audit helps identify, for example, areas where there is an abnormal frequency of lubrication or damage, or that could cause problems in the future unplanned stop the machinery. It also analyzes the operating environments and storage of lubricants, to see where there is a risk of contamination of the water, dust, dirt or chemicals. The auditor may also examine the practices of operators and handling of lubricants, and advise in case there is potential for cross contamination.
The final audit report contains a series of recommendations to improve the management of lubrication and provides technical maintenance of the plant a valuable reference tool to help them optimize equipment performance and reduce TCO.
5. Invest in good quality
As in many other aspects of life, the saying ‘If you buy cheap, pay double’ also applies in the case of the purchase of machinery. A good investment in equipment and machines as long-term help lower your TCO, as they will have greater operational life than those of a lower quality and will not replace some of its components so often, which means fewer hours job losses and less spending on spare parts, etc.
But it is important to note that the machinery lubrication requires high quality lubricants also of the best quality – synthetic lubricants are formulated for specific applications and can further extend the useful life of machinery and increase its performance. One luxury car then do not buy lubricate your engine with an oil white label.
Some of the best manufacturers of lubricants now lead the market thanks to the effort and investment they have made in the area of R & D, working closely with its customers and / or suppliers of machinery, to create ranges of lubrication products that meet the requirements specific end users.
The formulation of these synthetic lubricants are often based on chemicals such as esters, polyalkenes glycols (PAG) or polyalphaolefins (PAO), giving the concerned lubricant suitable properties for a particular application. Depending on the base used, the lubricant can exhibit one or more of the following qualities: high thermal stability, high tenacity, good ability to operate in a wide temperature range, good resistance to water or cleaning products, low volatility, good resistance at high pressures, etc.
Therefore, on the market a multitude of highly skilled, high-quality lubricants that allow the manufacturer to select one that offers the best lubrication solution, make optimal return on their investment in equipment and reduce your TCO.