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How to manage equipment lubrication?

2023-10-29View Original

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There are currently two main organizational forms for lubrication management: centralized management and decentralized management. 1. Organizational Structure: To ensure the proper conduct of lubrication management, a company’s lubrication management organization should be established in a manner that takes into account the size of the company and the requirements related to equipment lubrication. Appropriate personnel should be assigned to various levels of this organizational structure, as this is an important aspect and organizational guarantee for effective equipment lubrication. (1) The centralized management approach involves establishing lubrication stations and lubricant regeneration teams within the company’s equipment and power department, to directly oversee the lubrication of equipment in all workshops across the plant. The advantage of this management approach is that it facilitates the rational use of labor force, helps to improve the professionalism, work efficiency, and work quality of lubrication personnel, and promotes the adoption of advanced lubrication technologies. The disadvantage of this organizational structure is its poor coordination with production. Therefore, this organizational structure is mainly used in medium and small-sized enterprises. (2) The decentralized management approach involves establishing a central lubrication station within the equipment and power department, which includes a lubricant preparation team, a cutting fluid preparation team, and a used oil recycling team responsible for managing all the lubricants, cutting fluids, and recycled used oil across the entire plant. Each workshop is equipped with a lubrication station responsible for lubricating the equipment there. The advantage of this approach is that it can fully motivate the workers in the workshop, which is beneficial for coordinated production. The disadvantage is that technical expertise is spread out, making it easy to neglect equipment lubrication. The decentralized management model is mainly used in large enterprises. 2. Allocation of lubrication management personnel: In large and medium-sized enterprises, engineering and technical personnel in charge of lubrication work should be assigned to the equipment and power departments. Small enterprises should have full-time (or part-time) lubrication technicians in their equipment and power department. The number of lubrication technicians can be determined based on the complexity factor of the enterprise’s equipment. Use the repair complexity coefficient to determine the reference value for staffing proportions. To meet the needs of lubricant condition monitoring and used oil recycling, large and medium-sized enterprises should be equipped with oil testing laboratories and laboratory technicians. A dedicated person should be assigned to manage the used oil treatment station. Lubrication technicians should have received education at a secondary vocational school or above in mechanical or friction lubrication engineering, be able to select lubricant materials appropriately, keep up to date with information on new lubricant materials, and possess the skills to operate common oil analysis and monitoring instruments in order to assess the quality of oils and continuously improve lubrication management practices. Lubrication workers are technical professionals; in addition to possessing the technical knowledge required for their role, they should also have skills equivalent to those of a repair fitter at level 2 or above. To carry out cleaning, oil changing, and oil topping tasks, it is necessary to regularly check the lubrication status of the equipment, manage various lubrication tools properly, and also assist in handling all aspects of lubrication management, including regular sampling for inspection. 3. Responsibilities of lubrication management personnel: (1) Formulate management systems for equipment lubrication and prepare lubrication charts for the equipment ; (2) Prepare lubrication cards for all mechanical equipment in the plant, and establish oil change schedules for the equipment ; (3) Prepare plans for equipment cleaning, oil change, and filtration, and organize their implementation ; (4) Implement the \"five fixed principles\" for equipment lubrication, check the quality of the oil, and replace or filter it based on the test results ; (5) Regularly check the lubrication condition and leakage of in-use equipment, propose preventive measures, and prepare a leak repair plan ; (6) Responsible for organizing the laboratory analysis of lubricating oils and the recycling of used oils ; (7) Prepare an application plan for the required quantity of lubricants, and submit it to the supply department for procurement ; (8) Responsible for providing guidance on the selection, substitution, blending of lubricants, as well as the preparation of cooling cutting fluids ; (9) Regularly track the consumption of lubricants and prepare various reports ; (10) Lead the technical work at the lubrication station, as well as the lubrication technicians, grease formulators, and laboratory analysts. 4. “Five-fixed management” and “three-filtering” for equipment lubrication (1) Fixed location. Fill with oil, add oil, or change the oil at the locations, lubrication points, and inspection points (oil level sight glasses) specified on the lubrication chart, and check the oil level and oil supply condition. (2) Qualitative determination. Determine the type, grade, and quality requirements of the oil needed for lubrication; the oil to be used must pass quality tests. The use of substitute materials or their incorporation must be based on scientific evidence. The lubrication devices and tools must be thoroughly cleaned to prevent contamination of the oil. (3) Quantification. Perform regular lubrication of all lubrication points in the prescribed quantities, implement a quota system for oil consumption, and ensure proper addition of oil, refilling of oil tanks, as well as cleaning and oil replacement. (4) Regularly. Refilling oil at the intervals specified on the lubrication card, and conducting sampling tests at those same intervals, are important steps; based on the results, it is determined whether cleaning, oil replacement, or circulation filtering is necessary, as well as when the next sampling test should be carried out. This is a crucial aspect of proper lubrication maintenance. (5) Designate a person. According to the division of tasks specified in the chart, the operators, maintenance workers, and lubrication staff are responsible for filling with fuel, adding oil, cleaning, and changing oil, while it is also specified who is responsible for taking samples for testing. The equipment department should prepare a standard table for the \"five fixed aspects of lubrication management,\" specifying which equipment and which parts require lubrication, what type of oil to use, the frequency of oil filling (or oil change), what lubrication devices to employ, and who is responsible for these tasks. With the advancement of science and technology and the accumulation of experience, “fixed-point management” needs to be further enhanced and improved in practice. To ensure the cleanliness of lubricating oil, it must undergo three stages of filtration (i.e., “three filtrations”): filtration upon arrival, filtration before distribution, and filtration during refilling. 5. Organization of oil change: Theoretical analysis and practice show that it is necessary to change the oil in equipment in a timely manner. There are two methods for changing the oil in mechanical equipment: regular oil change and oil change based on oil quality. The regular oil change method is mainly used for equipment that consumes little oil and operates at high frequencies. The main drawback of the regular oil change method is that sometimes oil whose key quality parameters still meet the usage standards is forced to be replaced, resulting in waste. The oil exchange by quality method is mainly used for equipment with high oil consumption or low operating rates. Oil testing technologies should be promoted to enable oil replacement based on quality.

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