The 5S methodology, originally developed for lean manufacturing, can significantly enhance lubrication reliability when properly applied. It provides a practical framework for organising workspaces, reducing waste, and improving maintenance precision. When adapted to lubrication practices, 5S ensures that lubricants are stored, handled and applied in a way that minimises contamination and human error.
Remove what is unnecessary
Go through all lubrication tools, containers, fittings, and consumables. Eliminate redundant, damaged or expired items. Only keep what’s required for efficient and safe lubrication. This reduces clutter and the chance of using the wrong tool or lubricant.
Example: Remove unlabelled grease guns or expired lubricant drums from the lube room.
Create a logical, visible storage system
Organise all lubrication equipment, tools, and lubricants so that everything has a defined place. Group items by type or application, and locate them as close as possible to where they are used. Use visual aids such as shadow boards, shelving, or tool stations.
Example: Store all gearbox oils in one colour-coded area, with clearly labelled containers and dedicated transfer tools.
Clean the workplace and equipment
Cleanliness directly impacts lubrication quality. Clean lubrication areas, tools, containers, and fittings regularly to prevent dirt, debris, or moisture from contaminating lubricants. This also includes wiping down machinery and lubrication points.
Example: Wipe grease fittings before and after greasing. Keep the lube room floor free of spills and dust.
Create consistent processes and visual standards
Develop standard operating procedures (SOPs) for lubrication tasks. Use consistent labelling systems, storage practices, and inspection routines. Visual cues like colour codes for oil types, signage for PPE, and labels for lubricant application points reduce confusion and errors.
Example: Use red labels for hydraulic oil, blue for gear oil, and assign matching transfer containers and grease guns.
Maintain discipline and continuous improvement
Implement regular audits, training, and team responsibilities to sustain the 5S system. Engage the team in maintaining order and improving the process over time. Make 5S part of your lubrication culture, not just a one-time activity.
Example: Assign a lubrication 5S leader in each department to conduct weekly checks and suggest improvements.
Poor organisation and cleanliness are major causes of lubrication contamination, cross-mixing, and delays. A well-implemented 5S system reduces the risk of mistakes, improves uptime, and makes lubrication a more efficient and reliable process.
In short: a clean, organised lubrication environment supports clean, reliable equipment.