Equipment Reliability: How to Ensure Your Success

The Number One Objective

The American Society for Quality (ASQ) defines reliability as:

The probability that a product, system or service will perform its intended function adequately for a specified period of time, or will operate in a defined environment without failure.

Equipment reliability is the number one objective of any predictive maintenance program, but often times programs are started without completing the first, most important step – know the age and performance of the equipment you have.

Don’t Put the Cart Before the Horse

Often preventive maintenance programs are kicked off without having enough asset knowledge to be successful. As they say, “don’t put the cart before the horse.” Before you launch your program, it’s important to:

  1. Survey | Take inventory of all of mechanical components you own.
  2. Organize | Make sure that they are cataloged in a Computerized Maintenance Management System (CMMS) or other organized system.
  3. Rank | Put together a team to rank the criticality of the equipment.

Criticality rankings can be based on a number of different criteria. There is no one right way to do it, but the important thing to keep in mind when assessing criticality is risk – primarily safety, quality, and cost. For example, at POLARIS Laboratories®, we have a preventive maintenance schedule for all of our laboratory instruments, but if our air circulation system experiences downtime then none of those instruments can be operated. It’s a piece of equipment that is often taken for granted, but the risk associated with any downtime is catastrophic and impacts safety and cost.

Once you know what equipment you have and how critical it is to operations, then you can start to assess your fluid analysis program and other predictive tools.

Are you getting the right testing?

If the cost of failure for a specific asset is high, it might be worthwhile to pay for more advanced testing or do analytical ferrography routinely. If the cost is low, you may be able to reduce the sample frequency of some of your equipment. We often talk about preventive maintenance optimization – talk to POLARIS Laboratories® about how we can help you optimize your predictive maintenance intervals.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you. 

Published  January 22, 2019

Making a Difference in the Transportation Industry

There are numerous elements that go into a fluid analysis program achieving operational efficiency and program success. For the transportation industry, that could be compliance with consistent sampling, seeing the return on investment, saving on fleet maintenance costs or gaining buy-in from leadership. But, what really makes the difference for a transportation company when participating in a fluid analysis program is a program champion. A transportation company could have anywhere from just one single maintenance facility handling all samples, to more than 100 locations. The program champion provides effective communication, ownership and consistency – all affecting the success of the program.

Communication | managing all shop or facility managers can be time consuming – the program champion makes certain that any updates, changes, etc. are communicated properly to the appropriate people.

Ownership | having one individual own the fluid analysis program helps the program stay compliant

Consistency | the program champion ensures everyone is on the same page and is meeting compliance goals

A program champion who communicates effectively, owns the fluid analysis program and consistently checks in to see if the team is meeting their compliance goals, will lead their teams to the ultimate goal: success of the fluid analysis program.

What does it take to be a program champion? Check out our checklist:

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you. 

Published  January 15, 2019

Shipping Samples: How to Guide

So you’ve successfully taken your oil sample, what next? Ship it to the laboratory, of course. It’s important to ship the sample as soon as possible after you collect it – don’t let your samples pile up and ship a large amount at a time.

After you’ve submitted the sample’s information via online sample submission in HORIZON (or hand-written paper form), use the corresponding label to place on the sample bottle.

  1. Take the sample from our equipment while it’s running or within 30 minutes of shut down and do not overfill the jar.
  2. Close the sample jar as soon as you collect the sample.
  3. Hand tighten only – the bottles have a wedge seal so no tools are needed.
  4. Depending on what kit you ordered, place the sample jar(s) into the appropriate shipping container.
    1. Appropriate sized box, envelope mailer or hard plastic mailer.
  5. Label the outside of the package with the laboratory address, your return address and apply the appropriate postage.

It’s that easy! Check out our latest Technical Bulletin for more detailed, step-by-step instructions:

Want more helpful shipping tips? Check out our blog 4 Tips for Shipping Success.

 

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you. 

Published December 11, 2018

Dirty Dozen: 12 Types of Contamination

 

The life of components in automotive, industrial and other equipment is reduced when contaminants circulate through their systems. Water, solid particles, varnish and even air can lead to a decrease in drain intervals and an increase in foaming, oxidation, sludge and varnish formation—potentially causing serious damage and catastrophic failure.

What’s causing damage? Below are the four main categories of contamination:
  1. Air Contamination
    • Air causes foam to form and it may be a sign that the antifoam additive may be depleted and the oil needs to be changed out. Air causes the oil to look cloudy – often mistaking it for water contamination.
    • An easy way to visually tell the difference between air and water contamination: take a small oil sample in a clear container and allow it to sit undisturbed for 24 hours – air will rise to the top while water will settle to the bottom.
  2. Water Contamination
    • Water can get into your system through vapor in the air – but it can also come form rain, splashing, leaking fittings or power washing the equipment.
    • Measuring the current moisture level in your equipment’s oil, and then finding ways to reduce the moisture level, can significantly extend your machine’s life.
  3. Particle Contamination
    • Particle contamination can be caused by particles entering the system via air movement or oil degradation.
    • Here are some powerful facts for you:
      • Greater than 80 percent of machine wear is caused by particle contamination.
      • The industry spends upwards of $200 billion annually filtering fluids to prevent mechanical problems caused by hard particles.
  4. Varnish Contamination
    • Varnish buildup, whether it be hard or soft, can occur in reservoirs and throughout lube and hydraulic systems on components and filter elements. Once varnish formation begins, the equipment becomes unreliable and potentially unsafe.

Discover all 12 types of oil contamination, by reading my featured article in Lubes ‘N’ Greases’ October 2018 edition: Dirty Dozen: 12 Types of Oil Contamination by clicking below.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you. 

Published November 27, 2018

Fluid Analysis: Cost vs. Price

Customers and potential customers often ask “what is the cost per sample?” This information is important for purchasing and supply chain reasons, but what is even more important is the savings a well-managed fluid analysis program can bring to any organization. Organizations that associate items with only cost will have little or no Return on Investment (ROI) – whereas those utilizing a complete fluid analysis program with value-added services can see an average ROI of 20:1, with some experiencing levels as high as 45:1.

Where Can You Save More?

Many fluid analysis program decisions are based solely on cost or price per sample as the major factor used to decide a supplier. What is often not considered are some of the unknown costs associated with a fluid analysis program. These include:

  • Day-to-day operational coordination to manage the program
  • Chance of incorrect or inefficient reporting
  • Manual, traditional, handwritten sample submission

It’s important to know these additional costs, how to leverage available solutions and maximize your ROI. Traditional handwritten submission forms can take up to five more minutes than submitting your sample online for via the mobile app or automated submissions from CMMS systems (check out DataConnect).

Take Advantage of Value-Add Services

True savings can only be measured by monitoring the efficiencies that your fluid analysis provider can offer you in your maintenance and reliability programs, and the services they provide integrate and enhance your strategies. POLARIS Laboratories® offers many value-add services included in the sample price – to help you decrease your operational costs.

  • Documented, transparent turnaround time
  • Sample status notifications and online tracking
  • Mobile app and online sample submission
  • CMMS integration (DataConnect)
  • Certified, experienced data analysis team
  • Automated, customizable data management reports
  • Hierarchical report structure and asset watch

 

 

 

 

 

 

 

 

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you. 

Published October 30. 2018

VIDEO: How to Bridge the Gap with Filter Debris Analysis

Oil filters are designed to remove contaminants and particles that would have otherwise damaged the system – but did you know this also removes the evidence that data analysts can use to provide in-depth maintenance recommendations? Dive deeper into the particles, contamination and evidence of wear that are caught in the oil filter by sending in your oil filter for Filter Debris Analysis.

FDA Dives Deeper Into Contamination Causes

Standard oil analysis (Elemental Analysis by ICP) can provide you with information on what’s going on in your equipment – but, there are limits to what ICP can detect. ICP can only detect fine particles of approximately 10 microns or smaller – leaving larger particles unidentified. Filter Debris Analysis helps identify larger wear particle debris as well as outside contamination. The wear morphology, metal type(s) and contamination types can be identified to help determine the possible source of the wear or contamination.

How is FDA Performed?

The FDA process involves flushing the filter, extracting the particles and performing several tests (including micropatch and analytical ferrography) to identify wear particles. Check out the video below to see how we perform Filter Debris Analysis at POLARIS Laboratories®:

Learn more about Filter Debris Analysis by reading our technical bulletin.

Interested in adding FDA to your current fluid analysis program? Contact customer service or your account manager.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you.

Published October 9, 2018

How Gasoline Engine Technology Affects Fuel Dilution

Do you have a newer vehicle? Are your reports showing high fuel dilution?

Changes in gasoline engine technology, along with direct injection, have affected the internal combustion process in a gasoline engine. But, what does this mean for oil analysis? We’ve received a large amount of inquiries and questions regarding this topic from our customers. Click below to download the newest Technical Bulletin to learn the differences in engine technology and how it can affect your fluid analysis results.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you.

Published September 4, 2018

How to Get Your Sample Results Faster

Are you wanting to receive your sample results and maintenance recommendations faster? There are many steps you can take to ensure you get your results in a timely manner – so you can quickly take action to save your equipment.

  1. Use HORIZON®
    • Register your equipment and components online or mobile app through our HORIZON data management system online or use the mobile app
    • Log your fluid sample (and barcode information) in HORIZON and submit it with the equipment information
    • Apply a barcode to your sample and send it in the mail to one of our laboratory locations
    • When we receive your sample in the mail, the barcode is scanned and automatically pulls up the sample and equipment information you submitted via HORIZON
    • Submitting your sample information online provides us with all the necessary information ahead of time – allowing us to send your results back to you faster
  2. Submit samples on the go
    • Using the convenient HORIZON mobile app for Android or Apple for mobile devices, you can submit samples right at your equipment, immediately after you take the sample
    • Submitting your sample information via the mobile app requires less fields of information
    • Read more about the benefits of online sample submission by reading Take Five and Submit Your Sample
  3. Eliminate errors if sending manually
    • If you choose not to register and submit your sample information via HORIZON, you will need to fill out the form by hand
      • It’s best to use an quick-dry ink pen to fill out the paperwork (make sure the writing is legible and the paperwork isn’t damaged from from oil spills). This will eliminate the need for sample processing to decipher handwriting or dirty paperwork – resulting in inputting incorrect information into our system.
    • Send in the sample information form with the sample to one of our laboratory locations
  4. Pull the best sample

In the maintenance field, timing is key – it can be the deciding factor whether your equipment breaks down and you have unexpected downtime. At POLARIS Laboratories®, we are continually making improvements so you can get your results back faster. After all, your equipments’ health and lifecycle depend on it.

If you have any questions about sending in your sample or need help setting up a HORIZON account, contact us at 317.808.3750 or email custserv@eoilreports.com.

 

4 Tips to Help You Become a Sampling Pro

Since we introduced our new 3 oz. sample jar that is better equipped for sampling, we’ve seen a drastic decrease in leaking, messy bottles arriving at our laboratory – meaning you get your results back faster.

There are many benefits to the, somewhat still new, 3 oz. sample jar we released to our customers in the beginning of 2017. These benefits include translucency, higher temperature threshold and cap-locking with a wedge seal feature to prevent leaks.

Below are some extra tips to make sure you’re properly using the bottle like a pro and sampling correctly, so you can get the most accurate and reliable test results.

  1. Pull samples utilizing safe sampling practices [see our blog Fluid Analysis 101: 5 Tips for Collecting the Best Sample] and proper protective equipment. While the 3 oz. sample jar is designed to withstand higher fluid temperatures, safety should always be top of mind.
  2. Once the fluid sample has been taken, inspect the jar for particles – now that you can see the fluid that was pulled out of your equipment (due to the translucency of the jar), be aware of what is floating inside so when your results come back, proper action can be taken.
  3. Fill the sample bottle only to the designated “Fill Line” – no higher.
    • If there is fluid in the neck of the bottle, air may not release causing the cap to not seal properly.
  4. Do not over tighten (torque) the sample cap. The cap’s unique locking feature helps to ensure that it doesn’t loosen when the sample jar cools and the wedge seal prevents leaking.

We hope these extra tips will come in handy when you’re taking your next sample. Here at POLARIS Laboratories®, we’re continuously making improvements and providing useful resources to help our customers maximize their fluid analysis program.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you.

Published August 6, 2018

Achieving Operational Efficiency Through Program Improvement

Achieving maintenance operational efficiency requires focus, smart thinking and innovation. Mammoet, a heavy-lifting and transport company, was able to identify areas and opportunities for program improvement – this included leveraging teamwork, maximizing data management, implementing shipping enhancements and taking advantage of program management solutions available.

The improvements Mammoet implemented in their program opened up the opportunity for the company to move from preventive maintenance to predictive maintenance and significantly extending their oil drain intervals. Learn more by reading the case study.