The GreaseBoss monitoring system led to the detection of a bypassing injector on the swing box and an incorrect pump timer setting, resulting in estimated cost savings of $70,000 per year and prevented a potential swing box failure.
$70,000/yr
In grease savings
12
Endpoint LF units installed
successful alert
detected a bypassing injector that was not being directly monitored (on the swing box)
The CHALLENGE
repeated failures, no clear root cause
The customer, a tier 1 Australian mining company had experienced repeated failures in the boom foot and hoist cylinder areas of their Liebherr fleet.
GreaseBoss implemented the Critical Point Monitoring solution by installing 12 Endpoint LF units, which provided near real-time lubrication volume data and allowed for visibiilty of the planned vs actual greasing volumes.
The GreaseBoss monitoring led to the detection of a bypassing injector on the swing box (not directly monitored by endpoints) and the identification of an incorrect pump timer setting, resulting in significant grease consumption cost savings and prevented a potential swing box failure.
The Solution
critical point monitoring
1
12x Endpoint lf installed
on a custom made bracket and directly mounted to injectors, measuring the grease volume data to the boom foot and hoist cylinders.
2
precise grease flow tracking per point
OEM lubrication specification data was set in the GreaseBoss Cloud as the target delivery volumes.
Key findings
the greaseboss system found faults at unmonitored points
An unexpected, and unprecedented discovery, from this pilot was that the GreaseBoss system successfully alerted the maintenance team of lubrication issues on a bypassing injector that was not being directly monitored (on the swing box).
the result
measurable outcomes
Identifying and rectifying the incorrect pump timer setting allowed the customer to grease exactly as per the OEM specifications and avoid approximately $70,000 in wasted grease per year.
The GreaseBoss system has provided visibility and certainty to the site maintenance team over the grease volume application to the critical boom foot and hoist cylinder points over the past 7 months. During this time, there has been no failures of these components.
The installation demonstrates the ability for the GreaseBoss system to provide a cost effective solution that provides detailed monitoring for critical grease points, whilst also providing a full lube system “health” monitoring benefit to detect issues across the whole lube system.