The engineers worldwide are busy designing new plant equipment that is better and more efficient and millions of dollars are spent in this. But, the reality is whatever new machines come, they continue to break down and in the industrial circuit, the biggest cause of equipment downtime is found to be the bearing failure. Any bearing failure is bound to impact the production cycle directly. These bearings then need to be replaced. Though they are not very expensive, the loss caused due to lost production is often huge.
Adhering to a strict lubrication schedule is a difficult task even for the most diligent maintenance staff. The improper lubrication scenarios include applying inadequate amounts of lubricant or over lubricating the bearing and contamination of the lubricant, which can be by dirt, moisture or dust. It is also possible that the person responsible for lubrication is busy with some other task and hence lubricating the bearings comes down on his priority list.
To get rid of all these problems, it’s better to use automatic grease dispenser.
Here’s how it benefits:
All bearings need lubrication irrespective of the size or location for proper functioning. Improper or no lubrication will result in breakdown leading to unnecessary costs both direct and indirect. The direct costs include replacement of the bearings, labour charges for repair and replacements and excess lubricant and man power for carrying out the inefficient manual practice. The indirect cost includes the downtime or the lost production, the product spoilage that can happen by the excess lubricant, excess energy consumption and the safety, environmental and housekeeping issues.
The manual lubrication gets the job done, but the pneumatic grease dispenser is far better when it comes to worker safety, productivity and environmental issues. It helps in providing the right amount of lubricant to the right place and most importantly at the right time.
When the manual lubrication is done, the technicians normally follow a set schedule, which might not be completely in line with the need of the bearings. They also tend to over lubricate thinking that it will compensate for the time till they come back again. The fact is that for the bearing to work optimally both under or over lubrication is bad. It needs to be lubricated constantly by an appropriate amount, which is possible only with automated lubrication.
When lubrication is maintained properly by an automated process, it reduces the breakdown time leading to better production. Also, the man-hours required to repair gets reduced saving both time and money.
Performing lubrication manually when the machinery is in operation is not only a difficult task, but also risky at times. The same can be managed easily through the automated process keeping the worker’s safety in place. As the right amount of lubricant goes into the bearings, there is no issue of it seeping into the finished product, work surfaces or the plant floor. Thus, the chances of rejections in finished products get reduced. You don’t need frequent clean-up drives and there is no wastage of lubricant.
All these benefits affect the company’s bottom line positively.