Machine Lubrication SOP Template

1.Purpose

To make sure every lubrication point on covered equipment receives the correct lubricant, in the correct quantity, on schedule, to reduce wear and prevent lubrication-related failures.

2.Scope

Applies to scheduled lubrication routes on production and facility equipment, including grease points, oil reservoirs and gearboxes. One-time lubrication performed during a repair or PM task on other equipment is covered by those SOPs.

Definitions

Lube route

A defined sequence of lubrication points visited on a schedule, often grouped by area or frequency.

Lube chart

The reference showing the correct lubricant type and grade for each point on a piece of equipment.

Oil analysis

Laboratory testing of a lubricant sample to check for contamination, wear metals and remaining useful life.

Re-lubrication interval

The recommended time or run-hours between applications of grease or oil to a given point.

3.Responsibilities

Lubrication Technician

Follows the lube route, applies the correct lubricant and quantity, and records completion and any abnormal findings.

Maintenance Planner

Maintains the lube chart and route schedule in the CMMS and orders lubricants.

Maintenance Supervisor

Reviews route completion and oil analysis results, and follows up on flagged issues.

Equipment Operator

Reports leaks, low oil sight glass levels or unusual noise between scheduled lube visits.

RACI matrix

R = Responsible, A = Accountable, C = Consulted, I = Informed

4.Materials and PPE

Materials, tools and systems

• →Lube chart for each asset
• →CMMS with the lube route schedule
• →Grease guns and oil transfer containers labeled by lubricant type
• →Lubricants specified for each point (grease, gear oil, hydraulic oil)
• →Oil sampling kit
• →Clean rags and drip pans

Personal protective equipment

• →Safety glasses
• →Chemical-resistant gloves
• →Coveralls or apron
• →Hearing protection near running equipment

5.Procedure

1. 5.1

   Review the lube route for the day

   Lubrication Technician

   Technician pulls the day's lube route from the CMMS, noting which points are due and any special instructions from the lube chart.

2. 5.2

   Verify the correct lubricant grade

   Lubrication Technician

   Technician checks the lube chart for each asset to confirm the correct lubricant type and grade before drawing it from storage, since mixing incompatible lubricants can damage equipment.

   Warning: Never mix incompatible lubricant types or substitute a grade not listed on the lube chart.

3. 5.3

   Inspect lubricant condition and level

   Lubrication Technician

   Technician checks oil sight glasses, reservoir levels and grease fitting condition before servicing, noting any sign of contamination, discoloration or leaking.

4. 5.4

   Clean fittings before applying lubricant

   Lubrication Technician

   Technician wipes dirt and old grease from each fitting or fill point before connecting the grease gun or opening a reservoir, to avoid introducing contamination.

5. 5.5

   Apply grease or oil per specification

   Lubrication Technician

   Technician applies the specified lubricant in the quantity and re-lubrication interval called for on the lube chart, avoiding over-greasing bearings.

   Checkpoint: Quantity applied matches the lube chart specification for each point, not a generic amount.

6. 5.6

   Top up oil reservoirs and check filters

   Lubrication Technician

   Technician tops up gearbox and hydraulic reservoirs to the correct level and replaces oil filters that are due per the schedule.

7. 5.7

   Pull an oil sample where required

   Lubrication Technician

   Technician draws an oil sample from designated points on the schedule using a clean sampling kit and labels it for laboratory analysis.

8. 5.8

   Clean up spills and dispose of used lubricant

   Lubrication Technician

   Technician wipes up any spilled lubricant, places used oil and rags in the designated waste containers, and disposes of them per the site's environmental procedure.

9. 5.9

   Inspect for leaks and seal wear

   Lubrication Technician

   Technician checks each serviced point for leaks, worn seals or damaged fittings while completing the route, and notes anything needing follow-up repair.

10. 5.10

    Record the completed route

    Lubrication Technician

    Technician records completion, quantities applied and any abnormal findings for each point on the lube route in the CMMS.

11. 5.11

    Review oil analysis results

    Maintenance Supervisor

    Maintenance supervisor reviews returned oil analysis reports for contamination or wear trends and assigns follow-up action if results are outside normal range.

    Checkpoint: Oil analysis results outside normal range trigger a follow-up work order before the next scheduled sample.

12. 5.12

    Update the route and lube chart as needed

    Maintenance Planner

    Maintenance planner updates the lube route or chart when equipment changes, a lubricant is substituted by the manufacturer, or a repeated leak is found.

6.Quality checks

• →Lube routes are completed on schedule at least 95 percent of the time.
• →Quantities applied match the lube chart, with no generic 'grease until full' shortcuts.
• →Oil analysis results outside normal range are followed up within the same week.
• →No lubricant is applied without first checking the lube chart for that point.

7.Records

• →Completed lube route log in the CMMS
• →Lube chart per asset
• →Oil analysis reports
• →Follow-up work orders from abnormal findings

8.KPIs

• →Lube route completion rate
• →Oil analysis samples returned outside normal range
• →Bearing and gearbox failures linked to lubrication
• →Lubricant consumption against baseline

9.Common mistakes

• →Over-greasing a bearing, which can cause seal failure and overheating.
• →Using whatever lubricant is closest instead of checking the lube chart.
• →Skipping the leak and seal check because the route is running behind schedule.
• →Not following up on an abnormal oil analysis result.
• →Leaving fittings dirty before connecting the grease gun, pushing contamination into the bearing.

10.Revision history