Lubrication in Machine is like Blood in Human Body. Total Lubrication Management (TLM) leads to Energy Conservation & reduces machine maintenance cost.


TOTAL LUBRICATION MANAGEMENT on single window operations is an outsourced model, being adopted by industries, as industry has felt the importance of Lubrication Management in their Mechanical Maintenance Programme, which leads to Machinery Health Management.
Total Lubrication Management on single window operation is adopted by Global Technical Services, (GTS) where GTS provides trained man-power and all Lubrication Equipment including a site oil testing laboratory to do the activity by their own trained technicians.
At present, GTS is providing Total Lubrication Management on a single window basis with all major Multi-national Cement Companies working in India, such as Lafarge, HOLCIM and several other cement plants and mining industries.

Total Lubrication Management (TLM)

Knowledge of lubricants and management of lubrication is a subject that a majority of oil users do not appreciate.
  • They are aware that plant, equipment and machinery cannot run without lubrication. However little importance is attached either to know about lubricants or to practice a scientific lubrication system.
  • If machine downtime has to be reduced and overall cost reduction is to be achieved, knowledge of lubricants and lubrication is a must.
  • The hidden costs of down time and maintenance which escape attention have to be identified and eliminated or reduced.
  • It is here that the Total Lubrication Management concept of Global Technical Services - steps in order to assist industries.

Implementation Phase : 1

  • Conducting a diagnostic study in each and every department of the plant to study the Lubrication Management practices currently being adopted.
  • Identifying areas of improvement from the point of view of enhancing the lubricant service life and equipment life by condition monitoring of lubricants.
  • Study current lubrication practices, leakages and wastages.
  • Submit a diagnostic study report with: 1. Observations - impact and 2. Recommendations – benefits.

These observations and recommendations are supported by photographs in our report.

Implementation Phase : 2

  • Review of a diagnostic study report with the management.
  • Seek management approval and develop an implementation plan on the time frame.
  • Assisting management in launching the total war on leakage and wastage.
  • Introducing scientific lubrication practices, indenting, receipt, storage, handling and dispensing systems.
  • Introducing colour - coding systems and dust free containers for different lubricants to ensure that even illiterate operators can be easily guided to use correct lubricants for specific equipments.
  • Assisting management in establishing in-house lubricants condition monitoring laboratory and systems to arrive at correct lube oil rejection limits. (Extend life of lubricants in machines / equipment.)
  • Offering technical advice and assistance in installing and operating used oil filtration systems specially designed by Global Technical Services (globetech filters) and offering guidelines for alternate use for such regenerated oils within the plant. This leads to direct lube oil conservation.

Implementation Phase : 3 ( Implementation & Action )

  • Assisting management in creating awareness by training, awareness programmes and highlighting importance of TLM at different levels in the organization / plant.
  • Conducting job - oriented training sessions at the level of operators actually handling lubrication, supervisors and managers. Organize TLM week to create awareness all around the plant people.
  • Motivating workers - suggestion schemes / rewards, etc.
  • Studying the possibilities of replacing lubricant grades in use with higher performance level products to prolong equipment life and extend an oil drain period both of which contribute cost effective efforts.
  • Assisting management in vendor evaluation, wherever felt necessary by management.

Implementation Phase : 4 ( MID - Term Review Of performance)

  • MID - Term review at the end of six months of the MOU.
  • Evaluate actual performance and achievements v/s those projected - in MOU / diagnostic study report.
  • Take corrective action to achieve targets set by diagnostic study report./ MOU - If required

Implementation Phase : 5 ( Final Review Of Performance)

  • Final review at the end of one year of MOU.
  • Awareness
  • Systems
  • Savings of lube oils
  • If required - involvement for future years - Audit etc.

A Bird's eye-view of the services offered by Global Technical Services

  • Conducting intensive awareness programs on Lubrication and Fuel Conservation.
  • Conducting detailed diagnostic study of the client's plants, to ascertain the prevailing indenting, receipt, storage, handling, dispensing, condition monitoring, reclaiming and re-using and/or disposal of used lubricants and recommending adoption of scientific practices from 'cradle to grave'.
  • Providing training for operating and maintenance to staff of correct lubrication practices, and effective utilization of lubricants and fuels.
  • Providing training for stores personnel in correct inventory management, storage, handling and dispensing of lubricants
  • Establish systems - e.g. Color coding, records keeping, from receipt of new Lubricants to rejection and disposal of used oils from the plant use of Dust-free Containers, etc.
  • Establishing in-house condition monitoring systems and arriving at rejection limits for different lubricants.
  • Developing in-house used oil reclamation systems and recommending the use of such reclaimed oils for original / top up / alternative non critical applications based on the laboratory tests.
  • Critical review of grades in use to examine the possibility of introducing oils of higher performance levels to extend life of oil / drain period, while estimating the cost of an oil change, and many of the hidden costs which are more than the cost of the product, are lost sight of as illustrated below

Reproduced below in an interesting item on the real cost of an oil change.

An article published in lubricants word speaks about the true cost of an oil change. It is amazing to observe at how much money directly and indirectly goes into what seems to be a simple procedure. Oil changes include six basic costs :
  • The cost of new oil
  • Cost of removing old oil - (without evaluating its rejection limits)
  • Labor’s costs incurred in changing the oil
  • Administrative cost towards procurement of Lubricants
  • Assisting management in vendor evaluation as technical basis
  • Cost of machine down time

These are obvious direct costs that should be included in all cost analysis for an oil change. The several hidden costs that must be considered while analyzing the cost of oil change

  • The total time it takes to change the oil.
  • The total time the machine is not in operation.
  • All the paper work and pursuits involved plus tracking, verifying and inspection costs.
  • Cost of labor should include the human resources that needed to support the labor. This has been estimated at 1.5 times the hourly rate for the total number of hours needed to change the oil.
  • Indirect activities such as a wait time, travel time and tool and material collection, which can all cost 2 - 8 times the normal “wrench” time.
  • Supervisory tasks (work order and monitoring) add another 20% to labour costs.
  • Cost of rags, gloves, filters, sampling material.
  • New oil overheads, inventory and storage areas. Purchasing department activities for purchase oil bids, credits, checks, payments etc.
The end of major oil change, with all are often overlooked overhead costs, a change (at $ 5 per gallon) with two hours of labor and a purchase order to receive would cost $ 988.70.

Some Case Studies

Case Study - 1
One of the major manufacturing units in India needed suitable oil for heavy duty tapping operations. They were using different metal working fluids in a hit and miss method, and they found that the oil mixed with swarf is clogging the filters. On their own they cut back the viscosity of the oil with kerosene, and this eliminated clogging problems. However, this operation also suffered as the oil did not have any E.P additives, and the tool life was reduced by 50%. A well-formulated oil of low viscosity, sufficiently doped with E.P. Additives solved the problem, on our advice.
Case Study - 2
Scott Mizell at Weyerthaeuser Flint River Operations (USA) implemented an aggressive contamination control and on - site oil analysis programmed. Four primary sources of contamination were targeted, i.e. - New Oil contaminated due to wrong storage and handling practices, - Built in during operations / repairs, - ingested from environment and Externally generated. Multiple changes were made including an addition of desiccant breathers (dehydrators) on reservoirs and new oil storage tanks. Off-line filtration employed random cleanliness checks at repair / shops conducted and seal small-volume containers were used for top -up purpose.
Case Study - 3
At the East Word Power Station, contamination control at an underground storage facility has really paid off. Historically dirty oil was the cause of frequent suction and failure of hydraulic shuttle valves. In addition to labor, at peak times, repair costs can be as high as $ 200 per month in lost production. Since installing fine filtration and onsite condition monitoring only one failure has occurred. This improvement has saved hundreds of man-hours. In time, it will yield hundreds of thousands of dollars in increased profits to the organizations.

Laboratory Services & Its Equipment

GTS has always propounded that ‘Oil in Machine is like Blood in Human Body’. Keeping this in view, GTS has commissioned a Lubricant Testing Laboratory at Vasai, near Mumbai.
Oil Testing determines the condition of the Lubricant and in turn the condition or health of the machine. Therefore, in order to improve mechanical maintenance, it is absolutely necessary that Oil and Grease Testing should be done periodically for every machine. Good lubrication in machines reduces maintenance cost, energy consumption, therefore energy cost and in turn leads to longer machine life. Good lubrication supported by laboratory service, therefore, are extremely critical to cost reduction in manufacturing. Therefore, periodical testing of lubricating oils and greases is extremely important for ‘Machine Health Management’ and manufacturing cost reduction.
Details of the suggested tests can be had on contacting GTS through “Contact Us” Menu and our laboratory location and contacts are as follows:
B - 234, Oshiwara Industrial Centre, Goregaon (west),Mumbai - 400 104.
Telephone: 91+9892545299