Clean Oil Is A Must

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Clean Oil

Made Simpler

Clean oil is a must, get there with our simplified solutions!

Why Clean Oil?

70-80% Machinery and Hydraulic Failures
Are Due To Contaminated Oil

Every business wants to save more and make more. Oil cleanliness is proven great for lowering operational costs and machinery failures. It is a low-hanging fruit for most businesses, easy to adopt yet offers substantial return.

Struggling For Clean Oil?

The Journey For Clean Oil Can Be A Monumental Challenging Process

The importance of clean oil is well understood, but without proper strategy, many found out that the journey for clean oil is rather challenging and costly. 

Adopting A Time Based Maintenance?

In keeping the oil clean, the majority choose to adopt a time based maintenance (TBM) where oil change was done based on predetermined intervals, such as calendar time or usage, either following OEM recommendation or historical data. While TBM offers some benefits, it has the following weaknesses:

  • Risk Of Over Maintenance: Can lead to unnecessary maintenance activities, resulting in wasted time, resources, and money. Over-maintenance can also increase the likelihood of introducing faults or causing premature wear and tear on equipment.
  • Potential For Under Maintenance: Some components may deteriorate faster than anticipated due to factors such as operating conditions, environmental factors, or variations in usage patterns. Failing to address these issues promptly can increase the risk of unexpected failures and downtime.
  • Limited Adaptability: Maintenance activities may not always align with the actual condition of equipment. Equipment may require maintenance sooner or less frequently than scheduled due to variations in operating conditions, usage patterns, or other factors. This lack of adaptability can result in suboptimal maintenance practices and reduced equipment reliability.
  • Cost Inefficiency: The fixed intervals of TBM can lead to unnecessary maintenance costs, including labour, materials, and downtime expenses.
  • Potential For Missed Issues: TBM does not account for sudden or unexpected changes in equipment condition or performance. Critical issues may arise between scheduled maintenance intervals, leading to missed opportunities for early detection and intervention. This can result in an increased risk of equipment failures, safety hazards, and unplanned downtime.

It is not surprising that some TBM practitioners, more often than not, suffer from skyrocketing expenses yet failures and downtime remained high.

Adding An Oil Analysis Program

To minimise the above weaknesses, oil analysis programs are added into the maintenance operation. This is where the operation gets a little bit complicated. For many, aiming just to keep the oil clean feels like climbing a steep hill.

Oil analysis program is implemented by getting the oil sample and sending it to the oil lab for analysis. It requires an insane amount of work and procedures from taking oil samples, labelling, sending to the lab, performing oil testing and interpreting the results. It is quite a challenging feat.  

Here are a summary of the challenges in undertaking an oil analysis program::

  • Sampling Errors: Improper sampling techniques can lead to inaccurate results. Sampling should be done correctly and at the right intervals to ensure representative samples are collected. Errors in sampling could lead to false readings and incorrect maintenance decisions.
  • Contamination: Contamination of the oil sample can occur during the sampling process or while the sample is being transported to the lab. Contaminants such as dirt, water, or other fluids can skew the analysis results and lead to incorrect interpretations.
  • Interpretation Challenges: Mistakes or errors made by the laboratory technicians during the analysis process can also impact the accuracy of the results. This could include errors in sample preparation, instrument calibration, or data interpretation.
  • Baseline Establishment:  Establishing accurate baseline values for different parameters is crucial for detecting abnormalities or changes in oil condition over time. However, determining baseline values can be challenging, especially for newly installed equipment or when historical data is limited.
  • Cost And Turnaround Time: Oil analysis can be time-consuming and expensive, especially if samples need to be sent to an external laboratory for analysis. Long turnaround times for results may delay maintenance actions or decision-making.
  • Limited Detection Sensitivity: Some oil analysis techniques may have limited detection sensitivity for certain types of contaminants or wear particles. This can make it difficult to detect early signs of equipment degradation or impending failures.

Complicated Solution?

During the height of the space race in the 1960s, legend has it, NASA scientists realised that pens could not function in space. They needed to figure out another way for the astronauts to write things down. So they spent years and millions of taxpayer dollars to develop a pen that could put ink to paper without gravity. But their crafty Soviet counterparts, so the story goes, simply handed their cosmonauts pencils.

This phenomenon happens in most aspects of the business world. And clean oil solutions are no exception. Sometimes, organisations are awed with technologies and invest heavily without a clear understanding of how these tools contribute to achieving their maintenance goals. This can lead to a disconnect between the technology implemented and the desired results, resulting in wasted resources and ineffective maintenance practices.

Furthermore, complex solutions require specialised skills to implement and operate effectively. If the focus is solely on adopting the latest technology without considering whether it aligns with the organisation’s capabilities and needs, it can lead to unnecessary complexity and confusion among maintenance personnel. More often than not, implementation and operation of such solutions is beyond average engineers and technicians.

With the proliferation of sensors and data collection tools, there’s a risk of collecting vast amounts of data without a clear plan for how to analyse and act upon it. This can result in data overload and analysis paralysis, where valuable insights are lost amidst the noise of irrelevant information.

Implementing technology-driven maintenance solutions without adequate training and support for maintenance personnel can lead to resistance and low user adoption. If technicians and engineers don’t understand how to use the technology effectively or don’t see its value in improving their daily work, it can hinder the success of the maintenance program.

Ultimately, the success of a clean oil maintenance program should be measured by its impact on key performance indicators such as equipment uptime, maintenance costs, and overall operational efficiency. If the focus is solely on implementing technology without evaluating its impact on these outcomes, it’s difficult to determine whether the investment is delivering a return on investment.

Data Overload

Having data is better than no data but too much of it is noise!

We have presumed that more data we have equals more helpful information and could lead to better decision making. But this line of thinking has caused many to focus on getting the data and lose what is important as they are drowned in the sea of data.

The challenge lies in distinguishing useful information (signal) from irrelevant information (noise). Understanding what data is required at different stages of the maintenance process is crucial for effective decision-making and optimization of maintenance activities.

During monitoring, for example, getting an overall overview is preferred. When there’s too much data available, it can become overwhelming and difficult to extract meaningful insights. This phenomenon is often referred to as “information overload” or “data overload.” When maintenance personnel are inundated with excessive data, it can lead to confusion, analysis paralysis, and inefficiency.

Instead Of Excitement And Inspiration. Most Feel Defeated And Overwhelmed

The truth is most businesses would jump at the opportunity to implement the clean oil initiative…and many usually do.

Dived into clean oil initiatives and learned about the challenges and complicatedness of the available solution, it quickly started to feel like diving into an ocean with no seabed in sight, getting deeper and deeper, with no clear path of reaching the destination

Clean Oil Initiatives Shouldn't be This Difficult

Hidden gems

Reason For Complicatedness

“Simplicity is hard to build, easy to use, and hard to charge for.

Complexity is easy to build, hard to use, and easy to charge for.”

Chriss Sacca (A venture investor)

Reason For Simplicity

Many great companies advocate simplicity in their management as well as product design and development approach, resulting in improved reliability and profitability. Apple and Tesla are some of them, to name a few. 

Indeed, simplicity often serves as a prerequisite for reliability in various systems and processes. Simplicity fosters reliability by reducing complexity, facilitating diagnosis and maintenance, improving robustness, minimising human error, enhancing cost efficiency, and promoting adaptability. Prioritising simplicity in system design, operation, and maintenance can help organisations achieve greater reliability, resilience, and overall performance in a wide range of applications and industries.

Recent technology discovery has made the journey for clean oil and the shift from time based to condition based maintenance simple and easier than ever. We believe that it will be just a matter of time that these technologies will revolutionise the way we do our equipment and lubrication maintenance.

When organisations start to focus on the goals and keep things simple and practical in getting things done, they will immediately gain a lot of benefits in terms of lower operational and energy cost, improved reliability and higher productivity.

Things To do

Don't Simply Change Your Oil

It is quite common practice to change oil because overtime oil accumulates contaminants, undergoes chemical and physical changes, and depletes its additives, which can degrade its quality and lubricating properties. 

However, it is unwise to simply change oil according to time or usage, as you could be changing it too early or too late. Either one will badly affect your operation or not economical.

Change Your Oil Only
When It Is Bad

By changing the oil only when it is bad, one can minimise oil consumption, unnecessary maintenance activities and downtime.

Doesn’t know the exact timing to change the oil? This is the job of a real time oil condition monitoring tool, with capability to accurately detect changes of all oil parameters that lead to oil losing its usefulness. The second by second monitoring and trending also render great insight on the oil condition and detect any anomaly happening to the oil so that action can be taken to avoid catastrophic failure and damage.

Introducing Tan Delta online oil condition monitoring sensor. It is powerful yet very simple for average engineers and technicians to implement and use.

Clean Your Oil
Instead Of Changing It

Cleaning oil instead of changing it entirely is a practice known as oil filtration/purification. Oil filtration involves passing the used oil through specialised filtration equipment designed to remove contaminants and impurities. The filtration equipment removes various contaminants from the oil, including dirt, metal particles, soot, oxidation by-products, moisture, and acids. By trapping these contaminants, the filtration process helps restore the oil’s cleanliness and lubricating properties.

By removing harmful contaminants that contribute to oil degradation and breakdown, oil filtration can extend oil usable life. Maintaining the oil clean and free of contaminants, oil filtration also helps protect machinery components, reduce wear and tear, and maintain equipment reliability and efficiency resulting in improved system reliability by preventing oil-related failures and minimising downtime associated with equipment maintenance and repairs.

Oil filtration can lead to cost savings compared to frequent oil changes. By extending the life of the oil, organisations can reduce the consumption of new oil, minimise waste disposal costs associated with used oil, and lower overall maintenance expenses. Reducing the volume of used oil helps minimise environmental impact and promotes sustainability by decreasing the need for new oil production and disposal of used oil. 

Overall, cleaning oil through filtration offers several benefits, including extended oil life, cost savings, environmental sustainability, and enhanced equipment performance and reliability. 

Introducing CJC offline oil filtration system. The filtration performance is powerful yet comes in very simple design. It is often regarded as “4 in 1” as it has the capability of removing particles, water, varnish and acids utilising just 1 filter unit.

our offers

Keep Your Oil Clean

Proprietary CJC Offline Oil Filtration system uses just one filter to remove particles, water, varnish and neutralise acidity.  It has successfully helped – for many decades – our customers to keep their oil clean.

Tell You If It's Not

Patented Tan Delta Oil Monitoring Sensor uses just one sensor to monitor the overall oil health and detect if something is happening with the oil. The technology is simple and practical that engineers or technicians with no prior knowledge on oil will be able to benefit from it.

Effortlessly Shift To
Condition Based Maintenance

Many studies concluded that condition based maintenance is much more realistic…and thus more worthwhile to apply than the time based ones.  Maintenance is done right on time where oil and parts to be repaired or replaced prior to failure. Failures and downtime are kept to a minimum, thus offering significant cost savings.

Keep It Simple

The virtue of the solutions is the ability to keep the oil clean and exactly tell if it is not. But solutions will not be gratifying unless it is powerful yet simple to implement, easy to use and deliver good return on investments.

Payback Period
As Low As 1 Day

Typical payback period ranges from a few months to one year. However, there were cases of some customers’ investment payback period going as low as 1 day.

Who Has BENEFITED?

Malaysia

What They Said