Condition-Based Maintenance


Preventative maintenance only occurs when a set intervals of time or usage passes. This leaves equipment problems unaddressed for long periods, which leads to unexpected failures.

True condition-based maintenance programs perform equipment maintenance only when condition-monitoring technologies provide sufficient evidence that the condition of the fluid and/or the equipment merits action. Then maintenance can be scheduled to minimize any disruption to the equipment’s uptime, but it is necessary for technology to prove there is a problem and establish a clear direction for correcting it.

EXAMPLE 1: Diesel engine re-builds are typically done at around 750,000 miles with oil drain intervals around 10,000 miles. Unexpected issues can reduce that interval, including fuel scheduling issues (bad injectors, excessive soot) or coolant contamination (leaks in the engine or the EGR cooler). This creates wear and leads to premature failure. Normal scheduled maintenance every 25,000 miles will spot these issues, but this leads to unscheduled downtime as the unit waits for parts. In the worst-case scenario, a problem develops and causes a failure before the next scheduled maintenance, causing collateral damage to other components.

EXAMPLE 2: A typical diesel engine can use a condition-based maintenance strategy and rely on oil analysis trends to optimize drain intervals. When wear, contamination and/or fluid degradation approaches levels that could result in engine damage, the data analysis will recommend to change the oil, resample to verify the result or perform additional diagnostics. This allows parts to be staged for the unit so there is no delay when maintenance is performed. All of this increases the unit’s uptime and can even delay a rebuild.

Benefits of Condition-Based Maintenance

  • Operating costs are significantly reduced.
  • Extending maintenance and oil drain intervals reduces wrench time and oil consumption.
  • Performing the appropriate maintenance on the appropriate unit at the appropriate time increases component life and improves overall fleet management.
  • Trending data provides early knowledge of possible failures, allows for scheduled maintenance and drastically reduces unscheduled downtime. This requires changing from a preventive maintenance strategy to a predictive maintenance strategy that identifies and addresses small problems before they develop into catastrophic failures.
  • Regularly reviewing trends of condition monitoring results provides more accurate root-cause analysis of preventable failures.

Condition-Based-Maintenance-TimelineNeed a plan to move your program from interval-based to condition-based maintenance today?
Take a look at our simple 8-week timeline.

Learn more about getting an oil analysis program started with POLARIS Laboratories®.

 

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

Published June 9, 2015

Advancing Fluid Analysis with Data


Recently, POLARIS Laboratories® changed how we apply flagging limits to our particle quantifier (PQ) test results. Changes to flagging limits happen fairly regularly as we get new information and reach new data accumulation milestones. The change to the PQ is noteworthy for several reasons, but first let me explain a little more about the test.

PQ is a relatively new test in the oil analysis industry, so there isn’t a lot of historical data to examine. Also, unlike most other oil analysis tests, the results are an “index” with no unit of measurement (like microns or millimeters). Flagging limits are set on the index, and our data analysts compare the test results to the flagging limits to determine severity level and maintenance recommendations.

Until now, the flagging limits were limited to the type of component, like engine or differential. The size, configuration or application was not considered because there wasn’t enough historical data to affect the maintenance recommendations.

After offering PQ testing for several years, we have accumulated enough data to go beyond component type and make maintenance recommendations based on component manufacturer and model, like we do with the majority of our other tests. As you can imagine, contamination does not affect equipment made by different OEMs the same way, so being able to flag PQ by manufacturer and model is expected to improve the accuracy of our maintenance recommendations.

We’re proud of our flagging limits because of the time and effort that goes into this kind of data-driven analysis helps our customers identify wear early, safely extend fluid drains and save money. If you have any questions about PQ or our new flagging limits, please don’t hesitate to call (317.808.3750) or email.

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

Published April 23, 2015

Testing Confirms When To Extend Recommended Drain Intervals


As engine oil manufacturers continue to develop new products designed to be stronger and last longer, some also are recommending drain intervals. Original equipment manufacturers also specify drain intervals and qualify oils for use in the equipment they sell. In both instances, it is important to recognize these recommendations may not be all inclusive of every operating condition or every application in which the oil might be used. For more information and clarification, please contact one of our data analysts.

How do you know an oil manufacturer’s recommended intervals will protect your equipment? Will the oil last as long as they say it will in your operating conditions? Could it last longer?
Yes, no or maybe! Only testing in-service fluids can answer that question. Combining the manufacturer’s specifications with laboratory results and recommendations from certified data analysts is the best way to safely optimize drain intervals, minimize wear and preserve equipment health.

What tests are needed to safely extend drain intervals?
An Advanced Mobil test package is required to safely extend drain intervals. This test package examines the three main fluid properties – base number (BN), oxidation/nitration and viscosity – that assess the oil properties responsible for protecting equipment. Tracking the values of these tests will alert you when a fluid is no longer capable of performing as expected until the next oil sample or drain.

Are there maintenance practices that will help me extend drain intervals?
When extending drains, the most important maintenance activities are to replenish depleted fluid properties, continue changing filters and monitor contamination/wear levels. If possible, replenish depleted additives or sweeten with new oil as needed. Filters are vital to capturing contaminants, so continue changing oil filters if it doesn’t require draining the sump. Finally, make sure to continue oil analysis testing at the old drain interval in order to monitor contamination levels to determine if the extended exposure to contaminants harms the equipment.

Safely-Optimize-Drain-Intervals

Learn more about tracking BN, oxidation/nitration and viscosity to ensure you’re safe.

Learn more about starting an oil analysis program with POLARIS Laboratories®.

 

 

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

Published April 7, 2015

The 2015 Customer Summit


Tailor made to address your biggest challenges

If you’ve ever had anything custom made, you know the feeling. It fits like a glove and meets your needs. It helps you get the job done—and done right. The fact is, there’s inherent value in having something made especially for you or with you in mind.

Imparting this kind of tailor-made value is our goal with the 2015 POLARIS Laboratories® Customer Summit. Sporting the theme, “Driving Action,” this summit will use both our day-to-day experience working with our customers and feedback from our customers to address the topics and challenges YOU—our customer—say are most important. Whether you’re a reseller, distributor, OEM or end user, you’ll find the information, insights and ready-to-implement strategies you need to extend equipment life, increase uptime and realize cost savings.

More detailed programming information about this exclusive, customers-only summit (October 5-7 at the Conrad Hotel in Indianapolis) is available online. For now, I’d like to share with you some of the key takeaways you can expect in October.

First, we’ve structured some of the topical sessions along three tracks—Program Management, Contamination Control and Program Execution. Within the three tracks, we’ll target common concerns, problem areas and frequently asked questions. While you’ll hear from members of our POLARIS Laboratories® team, you’ll also learn from customers just like you who are achieving success with their oil analysis programs. Customers sharing their insights, strategies and successes are what will really set this meeting apart from other conferences you might attend this year.

Here are just some of the program highlights you can expect in October:

Structuring your oil analysis program to fit your needs – Learn how to customize and follow a systematic oil analysis program that considers your organization’s strengths and weaknesses and helps meet your objectives.

Increase equipment uptime – Know and understand which oil analysis recommendations are “musts” and which ones you can schedule for a later time. Finding the right balance about when to take action will help maximize equipment uptime.

Calculate and assess your return on investment – Gain insight into how you can calculate a reliable ROI for your oil analysis program. We’ll show you how in this highly anticipated, must-attend presentation.

Move from preventive and reactive to predictive and proactive – If the 2015 Customer Summit has an overall theme, this might be it. Nearly every successful oil analysis program is more predictive and proactive than anything else. You’ll learn strategies for moving your program beyond short-term, reactive fixes to actions that are forward thinking, reducing the likelihood of equipment damage and increasing profitability.

Take a proactive step now. Register for the summit today – or at least by May 15 – and save $200.

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

Published March 10, 2015

What does your coolant color really tell you?

There was a time when we could use the color of the coolant to help determine the type of coolant formulation in the equipment. The majority of the heavy-duty engine coolants in the market would have been a conventional formulation. The only difference was in the type and amount of inhibitors but they were still compatible with one another. Some brands were a nitrite/silicate/borate blend while others might be a nitrite/molybdenum/silicate/phosphate blend. Sustaining the coolant simply meant maintaining the SCA level. Maintenance on the fluid was relatively easy as long as there weren’t any mechanical or contamination issues present.

Today, there seems to be a coolant for every color under the rainbow, and we can no longer base the coolant formulation by color alone. The color of the coolant cannot be used to determine the formulation. Testing the coolant and fluid properties will help determine the type of coolant inhibitors present in the formulation so you can maintain that fluid properly. The coolant formulation will be based on the type of coolant inhibitors in the fluid for prime metal-pitting protection.

The most commonly known coolant formulations on the market today are Conventional, Organic Acid Technology (OAT), NAPS (nitrite, amine, phosphate, silicon free), Hybrid Organic Acid Technology (HOAT), and Universal. The conventional formulations will use inorganic inhibitors. The OAT formulations will use organic acid inhibitors and may use a combination of nitrite and molybdenum in the formulation. The NAPS formulations will only use organic acid inhibitors. The HOAT and Universal formulations will use a combination of inorganic and organic acid inhibitors. Mixing different coolant formulations may dilute the inhibitors to a point that the coolant inhibitor won’t be adequate to protect the equipment. Coolant formulations are constantly evolving to help extend coolant drains and to maintain equipment longer.

Proper-Coolant-FormulationIt’s easy to become overwhelmed when trying to understand the multitude of variation among formulations, but it can actually be broken down quite simply. Take a look at our list of five considerations for selecting and using the proper coolant formulation.

Learn more about getting a coolant analysis program started with POLARIS Laboratories®.

 

 

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

Published March 2, 2015

New EZ Label is Available


We’ve been listening.

“This form is too complicated.”
“Do I really need to provide all this info?”
“There has to be an easier way to submit samples.”

Based on the customer feedback we’ve received over the years, we have improved our sample labels to make it quicker, easier and simpler to submit sample information, which reduces the likelihood of errors. You can request the new label be sent with your next sample jar order.

During the process of redesigning our sample information forms, much research was conducted internally and externally to thoroughly understand:

  • how customers complete the sample forms
  • how samples are packaged and shipped to us
  • how samples and paperwork are cleaned when fluid leaks during transit
  • how sample details are entered into our systems

We also tapped into our customers to serve as beta testers and confirmed the new label really does make it quicker and easier to submit samples.

The new label includes detailed HORIZON® instructions to simplify adding or updating equipment and submitting sample information online. This allowed us to simplify the required information on the form and reduce the paper size. In addition, the sample jar label features a coating to improve its resistance to absorbing oil.

Customers may or may not have access to the Internet all the time, so we left a very simple component and sample information form on the label. If a paper copy needs to be sent in with the sample, the form can be detached from the label and easily wrapped around the sample jar.

The label’s new features could benefit all our customers, so I encourage everyone to make the switch and reap the benefits. You can view the new label and how to fill it out by downloading our instructions. When you’re ready to try the EZ Label at one or more of your locations, contact our Customer Service team at custserv@eoilreports.com or 877.808.3750.

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

Not your run-of-the-mill conference

Customer Summit offers new approach

It’s February, and they’ve already started trickling in. You know what I mean – the 2015 conference mailers, invitations and “you won’t want to miss this” messaging that clutter our desktops and inboxes. The dilemma for you is which events should you really consider?

This year I’m going to make it easy for you by saying the 2015 POLARIS Laboratories® Customer Summit will be unlike any event you’ve attended before. This unique, peer-to-peer Customer Summit, sporting the theme Driving Action, features an exclusive opportunity for you – our customer – to hear firsthand how industry peers have taken action to solve some of the same critical challenges you face today.

Need fresh ideas and perspective on prolonging equipment life or increasing uptime? Feeling pressure to show savings with your maintenance program? We’ll discuss it all, in depth, providing you with relevant best-practice insights and valuable takeaways to maximize your oil analysis program and drive operational performance.

Scheduled with you and your team in mind, we also have some unique, one-of-a-kind experiences in store for you as part of our two-day agenda in early October. Also, coordinate a time on Monday or Wednesday to participate in our new, exclusive Strategic Account Review (STAR) briefings with your POLARIS Laboratories® account manager to review how your oil analysis program is currently performing and explore how you can maximize its impact, uptime, and savings.

A visit to the city known for the “Greatest Spectacle in Racing” wouldn’t be complete without a closer look at auto racing. That’s why we’re hosting a special customer appreciation event at Dallara Indycar Factory. We have a fun evening planned, offering a chance for you to network and learn about all things Indycar.

Learn more about the agenda and topics, the exclusive laboratory and headquarters tour, STAR briefings, hotel accommodations, fees and more. Take advantage of our early registration discount, which will save you $200 on each registration through May 15.

Drive action with your oil analysis program today. Clear your calendar for October 5-7 and join us in Indianapolis at the 2015 POLARIS Laboratories® Customer Summit. Believe me, this is one event you really won’t want to miss.

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

Published February 10, 2015

Filter Analysis Tells You Things Your Oil Won’t

Filters prevent large particles from damaging component parts, but they also may mask the significant component wear from regular fluid analysis. Analyzing what the filter catches may expose pieces of the puzzle you didn’t know were missing.

Filter Debris Analysis identifies contaminants and evidence of wear that are either removed from the oil by the filter or are too large to be detected by traditional elemental analysis. In addition to the data and microscopic pictures, the analysts reach out to each customer and modify maintenance recommendations based on customer needs. Click the report icon below to see the bigger picture.

Example-FDA-ReportFilter Debris Analysis Report:

• Detect early stages of component failure
• Bridge the gap between elemental analysis and particle count/quantifier
• Determine particle size, type and wear mechanism
• Provide a roadmap to any actions that need to be taken

Catch major problems before symptoms occur so you can plan equipment downtime. Contact us today to learn how you can protect your investment with Filter Debris Analysis.

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

Published February 5, 2015

Turn Up the Heat on Your Turnaround Time


The speed of business has accelerated in today’s on-demand, instant-access world. This makes me wonder why some of our customers don’t take advantage of the shortcuts and speed-ups HORIZON® offers. There are simple ways to have your samples tested faster, but only a small portion of our customers take advantage of them. Now you can avoid unnecessary delays before your samples are tested.

Online Sample Submission: Customers have the ability to enter sample information directly into HORIZON instead of shipping paperwork with the sample. Sounds easy, right? Well, it is! When this information already exists in the system, it accelerates our internal process and reduces errors. Handwriting equipment and sample information is not fun for your technicians and reading that handwriting can be quite challenging for ours. With HORIZON, all your account and component information is there from previous samples so all you have to do is scan a barcode, enter is a few fields of sample information and click submit. Some paperwork errors stop our laboratory technicians from being able to run tests on the sample or data analysts from providing accurate, reliable recommendations. With HORIZON sample submission, all the information is entered an approved by you. We just apply a lab number, assign testing and your sample moves directly to the lab in front of thousands of other samples. Which brings me to my next point…

Shipping: We accept packages from UPS, FedEx, DHL and the United States Postal Service (USPS). The shipping time for each service will vary depending on your location(s), and you should weigh the cost of faster shipping against the business cost from waiting for oil analysis results. We recommend using UPS, FedEx and DHL so you can utilize their package tracking systems.

Samples on Hold: From missing information to account issues, there are a several reasons why a sample may be placed “on hold”. A delayed sample is frustrating to both us and our customers. Here’s how you can find out if a sample is put on hold.

  • HORIZON offers a Sample Hold Subscription, which sends an email when a sample from that account is put on hold. The email can be sent immediately for each sample, in a daily summary or in a weekly summary.
  • The Sample Hold Summary Report can be run on-demand. Customize it to show what samples are currently held or use it to discover the root cause of why a sample was placed on hold.

Using these tools will improve your overall experience and help ensure your samples are received as soon as possible, minimize errors and avoid unnecessary delays.

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

Published January 28, 2015

The Difference One Year Makes


As POLARIS Laboratories® marks the one-year anniversary of our new laboratory and corporate headquarters, the real celebrants of this milestone should be you – our customers!

POLARIS Laboratories® is committed to providing the most accurate, reliable and timely fluid analysis processing and recommendations in the industry. When we prepared to open the doors to our headquarters a year ago, we were excited about the opportunities a new, expanded state-of-the-art facility would offer our customers, partners and employees.

As we envisioned, one year later we’re better able to employ proven processes and improvements that generate more efficient results for our customers. As the demand for our testing and analysis services increased, the more evident it became we needed a new foundation to support how we service our customers, integrate our teams and deliver recommendations to our customers to help them improve their reliability and maintenance programs.

Sporting a new 63,000-square-foot facility in northwest Indianapolis – which is double the size of our previous headquarters — POLARIS Laboratories® has deployed more efficient manufacturing principles that empower the employees to be more effective and efficient in processing your samples. We are deploying new testing processes in our headquarters that will become mainstays in all our laboratories around the world. Our new laboratory has helped create new process flows that help identify root causes of potential testing delays, create new efficiencies and leverage new process improvements.

Indy-Lab--old

Duplicate pieces of equipment were grouped together in the old Indianapolis Laboratory. This resulted in the samples moving all over the lab before receiving the testing they needed. 

 Indy-Lab--new

This is the base titration cell after the move. The cell only contains equipment for the standard testing associated with samples requiring a base number, minimizing the movement of the samples.

As Lean principles continue to define our processes, POLARIS Laboratories® remains committed to the continuous improvement that accompanies it. The Lean process and new building has taken us leaps and bounds beyond where we were just one year ago, and we will continue to evolve in order to provide the most efficient, high-quality oil analysis possible.

Indy Lab - Office AreaOur commitment to Lean principles isn’t limited to just the laboratory. Our entire team in the Indianapolis laboratory is embracing the many advantages of transparency, flexibility and open communication. To foster greater collaboration and idea sharing, we designed the new facility with low cubicle walls and glass walls in most conference and break rooms. This open environment facilitates collaboration and team work so we can provide better results and solutions for our customers.

Once again, happy anniversary to our customers, partners and employees on the new corporate headquarters, a state-of-the-art laboratory and the improved customer experience.

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

Published December 10, 2014