Many industrial operators are using a diverse range of lubricants in their facilities from a multitude of brands like Klüber, Fuchs and Mobil.
From grease and gear oil to hydraulic fluid and coolant, all lubricants must be ordered, delivered, stored and managed – processes that add up to significant time and money for firms.
Lubrication consolidation refers to companies optimising the lubricant inventory at their site. It involves reducing the number of lubricant products used at facilities and streamlining the process of managing lubrication overall, so it is more efficient. Similar lubricants are grouped together, and any redundant or unnecessary lubricants are eliminated.
The optimal result of consolidation is a more effective lubrication programme that provides substantial cost savings. Here, we explore the process in detail, how it works and the gains it offers.
Reducing the number of lubricants
Lubrication consolidation doesn’t involve stocking a wide range of lubricants from multiple suppliers. Instead, it focuses on choosing a smaller, carefully curated selection of lubricants that are suitable for use across several applications and types of operating equipment.
Optimising inventory
A critical element of lubricant consolidation is optimising inventory. This step involves meticulously evaluating and understanding the specific requirements of every item of equipment on site and selecting the correct type of lubricant. When multiple types of lubricants serve a similar purpose, operators narrow the field and minimise how many lubricants are being ordered. In many cases, a single product can serve multiple applications.
Streamlining processes
Lubrication consolidation can help companies streamline how they operate. For instance, having fewer lubricant varieties simplify how products are stored, handled and dispensed. This means there is a reduced risk of the wrong lubricant being used in an application, and less chance of cross-contamination that can impact performance and lead to maintenance issues. It can also help declutter lubricant storage areas, making them safer and easier for staff to use.
How does lubricant consolidation work?
Lubrication consolidation starts with a comprehensive appraisal of your current lubricant programme. The assessment involves making a detailed list of all equipment in use on site.
Begin by identifying the most critical pieces of machinery as well as those still under warranty. Consult paperwork or take advice from original equipment manufacturers on the best suited lubricants required for optimum operation.
With a full understanding of the needs of all equipment at your facility, group similar products together that deliver the same characteristics. This will narrow the number of lubricants down and inform your selection process.
A lubricant consolidation audit effectively minimises any risk of similar product duplication and helps companies cut unnecessary expenses. When implementation begins, companies can restrict ordering to a limited set of products and suppliers. This process typically results in efficient solutions, like the use of cost-saving larger lubricant packages and bulk products that simplify ordering – taking goods in as well as storing and using lubricants.
Training is an essential step when any significant change is made on site, and lubrication consolidation is no different. All team members operating equipment and managing and handling lubricant use at facilities must understand the new approach and what products should be deployed in different applications. Training should also cover use of the lubricant storage area to avoid cross-contamination and product use errors.
Ongoing management is a critical element of any lubrication consolidation strategy. Companies must ensure that they never use inferior or inappropriate products to make savings, or they will experience significant losses from insufficient lubrication – leading to mechanical damage and downtime. Lubrication consolidation should be reviewed periodically to assess if selections are effective and whether further streamlining is possible.
Understanding lubricant consolidation benefits
Finally, companies in a wide range of sectors and applications can access the many benefits of lubrication consolidation. There are significant cost savings to make by adopting this approach.
In reducing how many lubricants they order, store and use, enterprises can greatly lower inventory costs and minimise waste from unused or expired oils, fluids and greases. Companies also find they can negotiate more favourable pricing with their suppliers due to larger orders and exclusivity.
Companies also discover that lubrication consolidation improves efficiency. Applying a more streamlined lubricant programme can result in fewer maintenance problems, reduced downtime and enhanced equipment dependability.
