In many industrial plants, lubrication is still handled the same way it was decades ago: routine intervals, fixed quantities, generic greasing charts, and limited follow-up. And yet, despite major advancements in predictive maintenance and reliability strategies, lubrication remains one of the leading causes of rotating equipment failure.
According to a widely cited study by the Massachusetts Institute of Technology, up to 80% of mechanical failures are due to poor lubrication. That means not just the wrong grease or contaminated grease, but also too much, not enough, or applied at the wrong time. These errors aren’t just technical… they’re costly.
According to a widely cited study by the Massachusetts Institute of Technology, up to 80% of mechanical failures are due to poor lubrication. That means not just the wrong grease or contaminated grease, but also too much, not enough, or applied at the wrong time. These errors aren’t just technical… they’re costly.
Downtime, emergency repairs, production delays, and labor costs all add up quickly. In some facilities, millions are lost annually due to lubrication-related failures. Yet many of these losses are accepted as normal, part of “the way things are.” But it doesn’t have to be this way.
Why lubrication fails, even in modern plants
Most lubrication programs are based on time. Grease is added every month or every quarter, regardless of how the machine is actually behaving. Maintenance technicians might carry a route sheet and a grease gun, adding two or three pumps per bearing, just like they always have. But without information about the condition of the bearing or how much grease is already inside, every pump is a guess.
Worse still, no feedback loop exists. Was that application effective? Did it reduce friction? Was the bearing in need of grease at all? If no one knows, there’s no way to improve the process.
This is where the LUBExpert Implementation Master Class comes in.
A training built around real-world impact
Unlike traditional courses that focus only on lubrication theory or generic best practices, the LUBExpert Implementation Master Class is hands-on, field-tested, and outcome-focused. It’s designed to teach teams how to implement a precision lubrication program from scratch or overhaul an existing one.
Participants not only learn how to use ultrasound tools, they also learn how to interpret the data and take action that leads to fewer failures, fewer surprises, and a noticeable drop in maintenance costs.
The training is broken into three detailed modules:
Module 1 – Advocate: The Basics of Precision Lubrication
The first module establishes the foundation. It explains how over-greasing and under-greasing occur, how they lead to failure, and how to identify the early signs. Teams learn to differentiate between lubrication myths and realities, and gain a deep understanding of how friction, load, speed, and temperature all interact with lubrication.
This is where technicians often have their first “aha” moment, realizing that their current practices, while well-intentioned, might be doing more harm than good. Module 1 also introduces the LUBExpert device, showing how ultrasound gives direct feedback from the bearing itself.
Module 2 – Specialist: Route Building and Execution
Once the fundamentals are clear, the next challenge is organizing work. Module 2 dives into how to build and manage lubrication routes using real asset data. Teams learn to plan routes based on asset criticality, lubrication needs, and technician workload.
The purpose is to ensure lubrication is done with a clear goal in mind and recorded in a way that leads to insight. This module also teaches how to configure LUBExpert devices, how to track and document results, and how to apply condition-based decisions.
Module 3 – Strategist: Program Management and Continuous Improvement
A good start is important, but sustainability is critical. Module 3 is all about making the program stick. Participants learn how to set KPIs for their lubrication strategy, how to integrate data with CMMS systems, and how to audit and adjust routes over time.
Leadership buy-in, communication between teams, and alignment with broader reliability goals are emphasized here. The result is a clear path forward: a program that evolves, improves, and continues to deliver value month after month.
What plants gain after the training
By the end of the Master Class, teams walk away with more than knowledge. They leave with a plan. They’ve built routes, tested tools, interpreted results, and learned how to manage a lubrication program that works in the real world.
The benefits speak for themselves:
- Bearings that last longer
- Maintenance teams that work smarter
- Less unplanned downtime
- Better use of labor and resources
And perhaps most importantly, a culture shift. Lubrication becomes something teams understand, control, and optimize. No longer an overlooked checkbox on the calendar.
