Esco Products, Inc. submitted their Magnetic Oil Monitor (MOM) product into the Solution Awards brought to you by Uptime^® Magazine and Reliabilityweb.com.^®   The Solution Awards recognize innovative products, software, training and services for reliability and asset management.  Products can be submitted under one of the five categories:  Reliability Engineering for Maintenance, Asset Condition Management, IoT (Internet of Things Digitization), Work Execution Management or Asset Management.  One winner will be chosen for each category, as well as a best overall award. The Esco Magnetic Oil Monitors are a kit of three magnetic strips that adhere directly to equipment, providing a real-time and quantifiable scale with which operators can track an oil's color, clarity and temperature.  While laboratory tests exist to identify an oil’s color and clarity, it requires operators to take an oil sample, send it to a lab, and await the results. While laboratory tests are more accurate than an operator’s ability to visually monitor these changes, the time and expense required to perform these tests for all in-service equipment is prohibitive. The Magnetic Oil Monitors give operators the ability to identify these changes themselves and take immediate corrective action.

MOM Benefits:

Identify lubrication issues early to prevent downtime and costly equipment failures.

Easy-to-install and minimal training required; start tracking changes in oil condition immediately.

Low cost to implement and high return on protecting machine longevity.

Learn more about the MOM product here. Voting ends March 26, 2019 and The Solution Awards Ceremony will take place at The RELIABILITY Conference, May 7th in Seattle, WA. You can learn about all the product submissions for each of the categories and vote here.   Don't forget to vote for Esco's Magnetic Oil Monitors under the Asset Condition Management category.  We appreciate your support!

Time flies when you are having fun and 2017 has definitely flown by.  As another year ends, we reflect on the past year and think of everything we accomplished or didn't accomplish and strive to improve. Our goal every year is to provide our customers with a positive customer experience - including quick responses, quotes and shipping turnarounds.  Keeping an open line of communication of price changes, lead times, and delivery updates.  Offering our technical expertise and product recommendations based on each of our customer's unique needs.  We hope that we exceeded your customer service expectations in 2017 and will strive to do so in 2018.  If not, please let us know how we can improve. We believe in our products and how they can make your equipment more reliable and in turn, save your company time and money.  We'd love to share with you how in 2018! And finally, we would like to say thank you to all of our partners, vendors, and customers for making 2017 such a great year.  We are looking forward to working with you in 2018.  Thank you for your continued support and business.

People often think that to make a big impact to your bottom line, one must spend a lot of money on complicated parts, or overhaul complete systems and procedures.  Just like with dieting, making small changes, like eliminating soda from your daily diet, can make a huge impact to your weight loss over time.  The same applies to equipment reliability.  You don’t need a huge budget, complicated products, constant oil changes, or complicated procedures to see an immediate and big cost-savings.  Esco Products has four affordable products you can install today which will have a huge impact on reliability improvements and future cost-savings.

1.  Monitor Oil Level.  Installing a reliable oil sight window, such as a 3-D BullsEye, gives you a fail-proof reading of your oil level.  Surprisingly, a huge cause of equipment failure is because there was too little or too much oil in the equipment.  Installation will take you about two minutes and checking the oil level is as easy as walking by the machinery.  Read here how one plant estimated millions of dollars in savings by installing 3-D BullsEyes on their equipment.

Average 3-D BullsEye Cost:  $30

2.  Control Contamination.  Contamination is the leading cause of machine failure.  The smallest amount of debris or water can cause abrasion, erosion, fatigue and corrosive wear on machinery.  A quality desiccant breather takes little time to install and prevents contaminates from entering the equipment.  As it is spent, the desiccant changes color from blue to pink, alerting operators it is time to change the breathers.

Standard breather Cost: $60

3.  Visually Analyze Oil & Discharge Water.  Being able to see and analyze equipment's oil and diagnose problems can extend the life of industrial lubricants.  An Oil Sight Glass, or Bottom-Sediment & Water Bowl, can be added to the drain valve and allow for immediate oil inspection.

Standard Oil Sight Glass Cost:  $70

4.  Compare Oil Quality Over Time.  Lubricants can quickly change color, temperature and clarity over time.  These changes are hard to track how quickly and to what degree the characteristics of the oil has changed if you aren't keeping adequate records and have nothing to provide a comparison.  No need for fancy equipment, the use of Magnetic Oil Monitors are tools to help you track and measure a lubricant's temperature, color, and clarity that can give an operator a basis for measuring how quickly their oil is changing and degrading over time.

Oil Monitoring Kit Cost:  $20

Total Investment:  Around $180.00

Cost Savings:  Priceless

It’s not always the most complicated or costly solutions that make the most impact or give the greatest return on your investment.  Small, affordable changes to your equipment can not only improve your reliability program, but they can save you more money in the long run.   Key Takeaways & Things to Consider:

- Start Small.  Choose one piece of equipment, critical or not, and see how you can make simple tweaks to improve reliability.  A little investment up front to make small changes daily or even monthly, can add up to thousands of dollars and man hours saved over time.  Big budget requests for complete reliability overhauls tend to draw attention from upper management and are harder to get approved.

-Rely on the expert.  The people who manufacture reliblity products are extremely knowledgeable of how and where to install products, and will often come on site to audit current equipment and procedures and make recommendations.  These services areusually offered free of cost with no purchase requirements.

-Keep it simple.  Complicated, costly reliability software or products don't always guarantee the best return on investment.  No only can these services have a large upfront cost, they can have a lot of unforeseen long-term costs, such as the time it takes to train employees and implement the new program, or cost of repair and replacement of highly technical driven products.

 

There is an old proverb "A stitch in time saves nine," meaning that expending a little effort to fix a small problem will prevent it from becoming a large problem, requiring more effort to fix later.  Some might say the industry's approach to equipment reliability has proven this proverb time and time again.  My belief in this universal truth helped lead to the development of Esco Product's new Magnetic Oil Monitors, known affectionately as MOM. Esco Products has always focused on giving operators the ability to catch early-warning signs of problems.  Our Visual Oil Analysis products allow users to easily monitor the fluid level in their equipment, as well as collecting and draining water contamination.  We have seen the positive effect our products have had, and we had to ask ourselves, “What other aspects of an equipment’s oil should our customers be paying attention to”? Over the past few years, I’ve taken the time to educate myself on reliability by attending various training courses and gaining several certifications.  First I became a “Certified Lubrication Specialist” through the Society of Tribologists and Lubrication Engineers (STLE).  Then I got my MLA1 (Level 1 Machine Lubricant Analyst) issued by the International Council for Machinery Lubrication (ICML).  Both organizations are trusted among the industry as being leaders in reliability practice and theory, and both organizations inspired the MOM. During my education, I was taught that there are several other aspects of oil that are early indicators of problems.  I was told over and over that an oil’s temperature, color and clarity are all things operators should be monitoring, but often there was not any tool offered to help users track the changes in these important characteristics.  How do you know if the oil has changed color from one day to the next?  How can you tell if the oil is cloudier than it was a week ago?  Monitoring the temperature can be achieved using expensive probes and components, but how can you easily tell if your equipment is running hotter than it was last time you checked? Many facilities have hundreds of pieces of equipment, so tracking these changes on each individual machine can quickly become a cumbersome task.  The solution was both complex and simple:  The Magnetic Oil Monitors (MOM). MOM, operators can adhere these magnets to every machine they want to monitor.  Utilizing this product, users can easily mark where each measurement was last taken, so they can instantly see if there has been a change since the last time they checked.  Noticing these changes will act as an early warning system, allowing users to take corrective action before the problem grows out of control. Esco Products did a small beta-test to see how the MOM worked in real world situations.  Supplying these to a few dozen testers, we asked for their honest feedback after a month in service.  The results surprised and inspired us. We had two separate companies notice spikes in the operating temperature on their equipment.  In one case, it was found that a pump had not been greased on its last maintenance schedule.  At a different facility, another user noticed a gearbox was running about 40°F hotter than usual.  Upon inspection, it was found that the equipment was not setup properly.  In both instances, the users caught the problem early, took corrective action, and avoided a potential failure. Having operators use the MOM requires that they physically inspect the equipment.  This act alone is increasing reliability, because operators might catch other early indications of equipment problems (strange noise, increased vibration, leakage, low oil levels, etc). When used in conjunction with our various Visual Oil Analysis products, operators can identify a wide range of problems, simply by walking by their equipment and taking a quick glance.  Utilizing the Magnetic Oil Monitors will give users even more ways of tracking their equipment’s health.  Reliability is a never-ending journey, and Esco Products wants to ensure you have the tools you need. Esco continues to operate under the belief that a stitch in time saves nine.  We hope these products can help users do as little “stitching” as possible. To learn more about how these magnets work, visit our MOM product page HERE.

I recently interviewed a person who developed, implemented and sustained their company’s reliability program. The company realized tremendous results from these changes, extending the intervals between oil changes and reducing repairs and downtime on their equipment.  How did they succeed where so many others have failed?

1. Having a Reliability Leader - It’s important to have someone in charge of developing the lubrication practices at your facility. Choosing a leader who is knowledgeable and passionate about reliability is imperative. This person should create procedures and make sure all employees are aware of any changes
2. Consolidating Lubricants - Reducing the different types of lubricants being used is a good starting point. You may find that you can cut the number of oils your facility uses in half, simply by evaluating the current recommendations. You may also find that you haven’t been using the best type of lubricant for each application.
3. Centralized Storage – Designating an area for lubricant storage is imperative. Making sure everything is properly stored and labeled is the first step. Many failures are attributed to someone adding the wrong type of oil. These failures are easy to avoid if the type of oil is clearly labeled and easy to locate. You want to be certain that everyone knows where to find a lubricant and where to put it back when done with it.
4. Documentation - Having written procedures is essential in creating a proper lubrication program. Without documentation, it’s going to be difficult to evaluate your current practices, sustain any improvements, or ensure new employees know how you expect things to be done.  There needs to be clear instructions every step of the way.  This includes:  Receiving & storing new lubricant's;  dispensing new lubricants;  drawing proper samples for analysis; equipment checklists
5. Oil Analysis - Sampling oils is one practice in which I see a lot of confusion. If done properly, this is a great way to catch early problems before they result in critical failures.  If done wrong, this can be a complete waste of time and money.  There are some important things to consider before implementing oil sampling.  a.)  Will you make changes based on those results?  b.)  Do you know how to read the oil analysis reports?  c.) Are you testing your oil for the correct things?  d.)  Are you pulling samples in a proper way to ensure you get accurate representative samples?

When implementing changes to your current lubrication practices, it’s important to do so methodically. Choose a reliability leader to guide your program.  Gradually improve your practices, document them, and keep others informed of the changes.  Over time your reliability will improve as you continue to adjust and tweak your program.  You can then continue to evaluate your program to look for other areas that need improvement.  As the old adage says, “Slow and steady wins the race”.   This article was written by Chris Haught, CLS, is a Technical Sales & Product Manager for Esco Products, Inc.  Chris is available to work with customer to establish reliability and lubrication best practice programs, conduct facility surveys, and offer on-site training, action items and product recommendations.  

Original Equipment Manufacturers, also known as OEMs, can be heartless when dealing with smaller distributors and often offer the contracts to larger distributors believing they are somehow easier and more efficient to work with but I believe the pendulum will swing the other way. Bigger is not always better.  Big distributors can choke on their bureaucracies and management layers built into the fabric of the organization.  Small business is efficient and flexible to change, every penny is accounted for wherein big distributors are prone to abuse and waste.  Often times the right hand doesn’t know what the left hand is doing.  A well run small distributor prides itself on communication, organization and accountability.  Small distributors have simplistic visions and values and are in the best position to know and satisfy their customer needs.  Overhead structures make them extremely competitive.  Most products sold are commodities which are price driven and the larger distributor with this higher overhead typically have higher prices. According to Industrial Supply magazine, the Industrial Supply Ass (ISA) conducted a 2015 survey of 144 members to determine that for small distributors to gain an edge they typically focus on the following:

•  Problem-solving
• Product application expertise
• Long standing customer relationships
• Excellent customer service
• Intimate market knowledge

 Esco’s motto for over 50 years has been “Service and Solutions”.  We pride ourselves on superior customer service, a commitment to assist in correct product selection for specific applications and the ability and willingness to ensure customer satisfaction with price, superior products and on-time delivery.  In other words, all the points determined by the ISA study.  So the next time and OEM says they want to work with a larger distributor, explain the small distributor advantages!  

About 3 to 4 times a year, Esco Products hosts a 1-Day Lubrication Workshop in our hometown, Houston, Texas.  Lubrication is the foundation to any reliability-driven maintenance program and, done correctly, can save thousands of dollars- not to mention increase equipment uptime. The 1-day workshops are designed to teach you the basics of implementing lubrication best practices at your own facility.  If free training wasn’t enough to get you there, we also bribe you with a free, delicious lunch (dessert too).  We are hosting our last workshop of 2016 on Tuesday, November 15^th at Maggiano’s Little Italy in the Galleria area and you do not want to miss it.   What you need to know: Who: Esco Products, Inc. will be hosting &  Des-Case Corporation’s Jarrod Potteiger presenting What: A Complimentary, full-day of professional instruction for reliability and lubrication professionals (valued at $400) – A light breakfast and full lunch included When: Tuesday, November 15^th from 8:00 AM to 3:30 PM Where:  Maggiano’s Little Italy’s Trentino Room – 2019 Post Oak Blvd – Houston, TX 77056   This course will help you: Evaluate the current status of your lubrication practices relative to best-in-class programs Understand the fundamentals of lubrication & lubrication management Create a customized action item list to help you transform your lubrication practices   Lubrication Training Course Curriculum: * Role of lubrication in machine reliability * Lubrication theory & fundamentals * Lubricates failure modes * Grease application methods * How to select the right lubricant * Lubricant contamination control * Storage and handling of lubricants * Oil sampling methods * Equipment modifications * Lubrication policy development * All attendees will receive a Lubrication Best Practices Course Certificate.   This workshop is not a sales pitch. We guarantee that the content of the course is strictly educational. For more information or to SIGN UP for the workshop, contact: Lindsey McGee - 713.661.5514 – lmcgee@esco-inc.com One more thing, there will be CHEESECAKE!  Hope to see you there!

I was recently assisting a plant evaluate their lubricant storage practices. During this trip, I was brought to four drums of the same type of oil.  These drums were all stored vertically on a pallet with absolutely no protection from the elements.  Dirt and water was pooled on top, and many of the labels had been bleached almost illegible from continuous exposure to sunlight.  Only one of these drums had been opened.  Upon further inspection we realized that the opened drum was six months old, and the oldest unopened drum was over five years old. When I pointed out that one of the drums of “new” oil had been sitting there for over five years, the person I was with didn’t understand why this was a problem. “Oil is millions of years old.” they said, “How can 5 years in storage do any damage?”  We then examined the drum for a “use by” date and quickly discovered it didn’t have one.  This left a big question; how long can oil be stored? While searching for an answer, I found many conflicting opinions. One thing was consistent; oil does indeed have a shelf life.  This shelf life will depend on many factors, the top one being the conditions in which the lubricant is stored.  

Oil Storage
Outdoor storage of oil drums will contribute to the contamination and degradation of the oil. A sealed drum of oil will still expel and pull in air as the temperature within the drum changes.  If water and dirt is allowed to collect on top of the drum, the water and dirt will enter the drum during this venting process. Gradual ingression of dirt and moisture will have a cumulative effect on the quality of the lubricant. Water content will increase the rate of oxidation and can react with certain additives to form sludge. Exposure to the sun will increase the oil’s temperature, also increasing the rate of oxidation (for every 18°F increase in temperature, the oxidation rate doubles, cutting the usable life of oil in half).  The longer the drum is exposed to these conditions, the greater the damage done. Improving the storage practices will reduce the exposure to contaminants, but extended storage, even in the best conditions, will degrade the quality of lubricant. One of the biggest concerns with long term oil storage is the separation of additives.   Oil Additives Additives are added to base oils to improve the performance of the lubricant. Specific purposes of various lubricant additives are to reduce friction and wear, prevent corrosion, improve oxidation resistance, and stabilize a lubricant’s viscosity over wide range of temperatures.  However some additives, such as sulfur, are insoluble to oil.  Excessive storage can result in the additives separating, thus rendering the additive unusable.  If this occurs, the lubricant may not function properly. 

 

Shelf Life Estimates            

The usable shelf life of a lubricant is greatly dependent on the type of lubricant, the method in which it is stored, and the container size it is purchased in. Lubricant manufacturers have differing opinions on how long a lubricant can be safely stored.

Source: “Lubricant Storage, Stability, and Estimated Shelf Life.” 2013 Chevron Marine Products, LLC

 

Shelf Life & Container Type ExxonMobil estimates that their oils will last up to 10 years in storage, while their greases will last anywhere from 2 to 6 years. However, the life expectancy of oil changes based on the type of container it is stored in.  Oils stored in quart containers have an estimated shelf life of 10 years, while drums only have a 5 year shelf life.  Quarts will last longer in storage for two main reasons; plastic containers do not promote oxidation (as do steel drums) and quarts will typically be properly sealed, so they will not be exposed to outside contaminants during storage.

Source: “Aviation Lubricant Shelf Life.” 2015 Exxon Mobil Corporation  

Confirm Oil Condition with Analysis

Lubricant manufacturers are adamant that their estimates on shelf life are not absolute, but rather a guideline. Once their estimated shelf lives are reached, it’s suggested that a user should utilize oil analysis to validate if the lubricant is suitable for use.   

Take Action

• Make sure you pay attention to the length of time a lubricant is allowed to sit before being used.  Document the date you received and opened any lubricants.
• Try to cycle inventory to use the oldest material first and purchase lubricants in a quantity that will be used in a timely fashion.
• Improve the storage practices of your lubricants.  Moving to indoor storage in a climate controlled area will greatly reduce the degradation of your oils and greases.
• If you must store oils outside, do so in a way that prevents water and dirt from freely collecting and entering the bungs.

 

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Continued Education To learn more about proper storage and handling techniques, take advantage of online resources. The links below are organizations that are dedicated to lubrication fundamentals and best practice: http://www.lubecouncil.org/ - ICML (International Council for Machinery Lubrication) offers training and certifications for a wide range of lubricating topics. www.machinerylubrication.com - Noria’s online publication focusing on current best practice.  They also offer training courses relevant to lubrication fundamentals. www.reliabilityweb.com – This online resource offers articles, videos and tips on everything from asset management to condition monitoring.

"I know a guy." Standing 6 foot 5 inches tall with a solid frame, Esco's Coy Christoffel, isn't your typical social butterfly. I really can't imagine him fluttering around at all so maybe we should just refer to him as a social bull? Whatever you want to call him, Coy has been crowned Esco's expert networker. When Coy joined the Esco outside sales team in 2015, we joked that when we went looking for resources outside of our company, Coy always, "knew a guy." I always wondered how one could know that many “guys” and if they could actually help us. The thing is, "his guys" have pulled through on more than one occasion. Coy helped us bolster our cyber security best practices, connected us with a professional who improved our IT support and staff situation, and provided a reliable vendor for marketing promotional activities, all while bringing in new customers for our business - and all of it resulting from knowing someone or knowing someone who knows someone in each industry. How does he do it?  What makes him a good networker?  Why are making personal connections so important and how do you leverage these relationships to benefit you, other networkers, or your company?  I sat down with Coy to learn a thing or two about improving my networking skills, because no matter what industry or job position you are in, it is always good to know a guy. How do you meet people? Coy:  Everywhere – the clerk at the gas station, a fellow customer at the dry cleaners, my local produce guy, the pizza delivery guy (For most it's a second job.  He could be a petroleum engineer going through a Dave Ramsey program).  I've had a beer with the CEO of major energy companies who look like beach bums.  Appearances can be deceiving. What are some of the organizations you are involved in? Coy:  I'm the Secretary for the local STLE Chapter, SMRP Houston Chapter, as well as Cub Master for my son’s Boy Scout Pack. But my passion is the RedNet, which I run out of the Redneck Country Club.  I started this group almost three years ago as a business networking/small business incubator to help small business owners or corporate guys pursue their small manufacturing company they run out of their garage.  During this time we've helped five small business owners start their companies and generate enough revenue to leave their corporate life.  Currently the RedNet consists of about 450 members with an average meeting attendance of 80 each month.   How do you leverage your networks to bring in business? Coy:  It takes one very important ingredient - a servant mentality.  Like the Boy Scouts, the RedNet's main mantra is dedication to being a service organization.  We are here to serve each other.  Many other networking groups are filled with vampires looking to line their pockets and move on.  I follow up on all referrals 100% of the time because my name is attached to that business, and I want to do good business. What are some of the ways you have directly benefited from your networking? Coy:  It's not all about the money.  Influence and trust is a much more valuable currency, but always requires a large amount of respect.  From coming to work at ESCO because of my relationship with you guys over the years. It has brought me business as well.  It brought me what I expect to turn into my first white paper by helping one of the largest airports in the nation revamp their maintenance program.   What’s the number one thing to remember when networking? Coy:  I'm a Tim Ferris junky.  I listen to every podcast, and the 4hour work week is one of my main reference books.  Tim has a great podcast on networking and one of the best quotes for networking.  “Don’t dismiss people, don’t be a d*ck, and don’t rush. Play the long game.” – Tim Ferriss How do I combat any social anxiety and start up a conversation with people I don’t know? Coy:  Realize that the other person may be just as uncomfortable as you are, and that's ok.  What’s not ok is going through life without taking any risks.  Are there any other important takeaways or tips to improve networking? Coy:  THE MOST IMPORTANT THING TO TAKE AWAY FROM THIS IS THAT IT IS ALL ABOUT THE RELATIONSHIP.  People do business with people they like and trust.  I want every client to trust me with their business, their money, and their trust. I recommend reading Malcolm Gladwell’s The Tipping Point: How Little Things Can Make a Big Difference, to determine where you fit in the networking spectrum.   Coy gives great advice when it comes to networking, and we are lucky to have him on the Esco Sales team. As a company, we try to grow our network all of the time.  Not only can you meet new people, it’s a way to share ideas and start new partnerships or develop new products.  We attend industry tradeshows and networking events like Noria’s Reliable Plant or The Society for Maintenance and Reliability Professionals Annual Conference and local Houston chapter conference.  Some of our best products and product improvements were developed from talking with attendees at tradeshows.  We also sponsor corporate events, like golf tournaments, and host events such as lunch-and-learn presentations as a way to interact with our customers. Volunteering is a great way to network and do something good for your community. What are some of the ways you like to network?

Esco has launched a new monthly blog that we plan to fill with useful information about the reliability world.  Our goal is to post helpful reliability tips, lubrication best practices, training opportunities and ideas for professional growth.  We hope you enjoy reading and will stop by often.