extracting oil samples from critical gearboxes was developed along
with a comprehensive plan that included remote-access minimess
extraction ports, catch pipes and breathers. Total productive mainte-
nance (TPM) lubrication standards like machine lube maps would also
be important in the transformation process. However, the biggest
step was changing how the facility managed lubrication in general,
primarily its lubricant storage and handling.
The outdoor oil shed was abandoned after space inside the plant
was allocated for the new lubrication center, which would be centrally
located, insulated from the elements and offer a means to control
access. Only approved technicians would now have access to all the
lubricants needed to perform preventive maintenance (PM) tasks.
Dedicated point-of-use containers were color-coded to bulk storage
containers to simplify tasks, and technicians no longer would have to
brave the elements outside to retrieve the necessary resources. Every-
thing was also designed to eliminate contaminant ingression.
Decreasing Lubricant Consumption,
Increasing Cleanliness
With a new approach to lubrication management, the facility's
average consumption of its two primary food-grade lubricants
dropped from 650 gallons to just 110 gallons annually — a reduc-
tion of more than 80 percent, which resulted in more than $15,000
a year in savings. This made a sustainable difference in the plant's
operations budget.
Despite the dramatic decrease in consumption, the plant's lubri-
cant vendor, Tulco Oil, continues to support Gerber's efforts in all
aspects of its lubrication program.
"The relationship between a plant and its lubricant supplier is
crucial because that is where lubrication management starts,"
Gonzagowski said. "If your vendor does not provide or is not
willing to take steps to provide a quality product based on specific
requirements, cut them loose."
The lubrication training center developed by Gerber's Fremont
Michigan TPM team and duplicated at the Gerber
Fort Smith Arkansas Plant
