A Comprehensive, Human-Enabled Lubricant and Machine Inspection Strategy for Early Condition Monitoring

The lubricant condition monitoring industry is entering a technology-enabled frontier. Sensor data are more accessible via the industrial Internet of things and scrutinized more closely with the help of artificial intelligence. Meanwhile, human-enabled inspections are often overlooked despite the unmatched capabilities of human inspectors. Like other lubricant condition monitoring strategies, human-enabled inspections need guidance. By developing a set of standards, condition monitoring professionals can ensure the right observations are made and followed with the right corrective actions. Otherwise, these efforts can end up counterproductive and waste resources. A major opportunity with sensor-based condition monitoring is the ability to achieve real-time surveillance of the machine. When subtle unfavorable changes in lubricant condition are noticed quickly, proactive corrective actions can be taken before any incipient machine fails, avoiding costly downtime. Human-enabled inspections, although not continuous in nature, are often just as effective at detecting machine failures early, particularly when performed with the correct frequency and abetted by the human factor. Typical maintenance procedures for inspections are unspecific and poorly defined, with one-line instructions that may simply read “inspect this machine.” These create three inaccurate assumptions: (1) that the inspector is knowledgeable in what to examine, (2) that the inspector knows what inspection tools to use, and (3) that the machine is modified appropriately for the necessary inspections. If detailed standards are not in place, not only could potentially inspectable “alert” conditions go unreported, but there is also no accountability from the inspector about what may have gone unnoticed. This paper presents the suggestions for standardized requirements for human-based inspections. The needs are supported by findings from an extensive study of lubricated equipment identifying the lack of well-equipped machines for routine inspections. The suggestions are supported by the validation of effective measures, such as with improved inspection procedures and machines better equipped for inspections.