Site Assessments for Plastic Injection Molding

Our customers typically see site assessments as a great way to improve their overall lubrication programs. Since most companies are focused on similar goals, including keeping their equipment running and reducing costs, we focus our evaluation of their operations on managing the total cost of ownership (TCO) of their equipment.

At its core, a site assessment is a needs analysis of the customer’s lubrication program — first, we have a kickoff meeting in the office to explain what we’ll be doing out in the field. Then, we go execute in the field.

We discuss the life cycle of the lubricant — how it’s selected, how it’s stored and dispensed, how it’s used in the application, and how it’s disposed of. Next, we perform an inspection of any bulk tank storage and the fuel and lube trucks, and look at the equipment in the field. Finally, we check the maintenance facility and talk to the appropriate personnel, if possible.

Once the field analysis is done, we create and deliver a report that details the current lubricants used and makes optimization recommendations. We may also suggest site-specific projects to bring areas or procedures into “best practice”. When the customer has had a chance to review our report and agree on what, if any, projects they would like to work on, we formulate a game plan.

One example is contaminants that affect stored lubricants, such as water that may have found its way into drums, if a customer is storing them outside in the elements. After production, drums still breathe with temperature changes which can cause any pooling water to be drawn in. This water displaces the oil.

Another common contamination situation is improper breathers on bulk tanks. This can also allow water and particulates to enter the tank. Water contamination greatly affects lubricant performance. Oils lose film thickness, which causes accelerated wear. Cleanliness is extremely important, and if there is too much contamination in the oil, it not only leads to premature wear but can even cause equipment failure.

Incorrect or poor lubrication can lead to catastrophic equipment failure, which can result in near misses or damage to plant, process, or personnel.

Leakage is a potential safety hazard of slips, and it can also be an environmental issue. There are also application-specific requirements to consider, such as with gearboxes — you must use the right lubricant if they have internal backstops. Not doing so can cause the safety backstop to malfunction, leading to the conveyor system moving backward.

We tend to find that customers have too many or even incorrect lubricants on hand. Where appropriate, we will help consolidate their product lists down to something simpler and more efficient.

A simplified lubricant inventory does two key things: It makes it easier for technicians to ensure they are using the right products in the right equipment, and second, it reduces the cost of maintaining products because fewer are stored in the warehouse.