Transforming Lubrication Maintenance - An Invitation
PEMAC Members who work in lubrication-intense environments are invited to collaborate on a University of Waterloo Project described, below. Contact the author directly to learn more about the opportunity to participate in this project.
Transforming Lubrication Maintenance
As an engineer passionate about solving real-world industrial challenges, I’ve encountered firsthand the complexities of preventive maintenance in manufacturing plants. One critical yet often overlooked process is manual lubrication—a task that, despite its importance, remains prone to human error, inefficiencies, and inconsistencies. These challenges inspired me to explore a solution that could bridge the gap between traditional lubrication practices and modern technology.
The Problem: Inefficiencies in Manual Lubrication
In manufacturing environments, maintenance teams are responsible for greasing hundreds of lubrication points under tight operational constraints. However, ensuring that the right grease is applied in the correct quantity and at the right intervals is a difficult task. Common challenges include:
• Tracking which lubrication points have been serviced and ensuring none are missed.
• Identifying the correct grease type for each lubrication point.
• Applying the precise amount needed to prevent under-greasing or over-greasing.
Maintenance managers face additional difficulties, as they often lack real-time visibility into completed lubrication tasks, leading to inefficiencies and mechanical failures. Given that improper lubrication is responsible for nearly 70% of equipment failures, it is clear that a more reliable and precise approach is necessary.
The Spark of Innovation
While pursuing my Master’s at the University of Waterloo, I revisited these challenges with fresh perspective. I realized that the tools available to maintenance teams were outdated and lacked the necessary technology to ensure accurate and efficient lubrication processes. Determined to find a better way, I began developing a smart grease gun system—an intelligent tool that integrates tracking, automation, and data analytics to reduce downtime, enhance equipment reliability and ...revolutionize lubrication maintenance.
The Smart Grease Gun Solution
Our research at Waterloo is focused on bringing intelligence and precision to manual lubrication with an innovative smart grease gun technology. Here’s how it works:
1. Automated Tracking – Each lubrication point is digitally mapped, and our smart grease gun records which points have been serviced, ensuring complete coverage.
2. Lubricant Matching – The system identifies and verifies the correct grease type for each application, reducing mismatches that lead to equipment failures.
3. Precise Application – Sensors measure and control the amount of grease dispensed, eliminating over- and under-lubrication.
4. Real-Time Data Visibility – A central dashboard provides maintenance managers with live updates on lubrication tasks, ensuring accountability and optimized preventive maintenance schedules.
5. Data-Driven Maintenance – Historical lubrication data is analyzed to improve scheduling, identify recurring issues, and enhance overall equipment reliability.
A Call for Collaboration
As we refine and test our technology, we are looking to collaborate with maintenance professionals, reliability engineers, and plant managers who are interested in improving their lubrication maintenance processes. If you are open to sharing insights, participating in interviews, or exploring the potential of implementing and testing our technology in your facility, we would love to connect with you. Your expertise and on-the-ground experience are invaluable in shaping a solution that integrates seamlessly into daily operations. Together, we can reduce downtime, enhance equipment reliability, and transform the way lubrication maintenance is performed.
If you are open to sharing insights, participating in interviews, or exploring the potential of implementing and testing our technology in your facility, we would love to connect with you.
If you’re interested in learning more or participating in this research initiative, please reach out. Let’s work together to push the boundaries of manufacturing maintenance.
About the Author:
Jesh Ramesh is doing research at University of Waterloo to create a smart grease gun to improve lubrication preventative maintenance process in industry.
Email: j2ramesh@uwaterloo.ca
Phone: 731-616-7553