Quick Win: Grease Gun Calibration & Technician Training

Quick Win #1: Low Cost, High Return, Easy to Implement

Small change. Massive savings.

 Here’s a one-day reliability win that can double your bearing life.

Pain Point: Most premature bearing failures are caused not by bad design or poor materials, but by improper lubrication. Over 60% of bearings fail early due to over- or under-greasing. Every technician’s grease gun dispenses a different amount per stroke, yet few know how much they’re applying. This creates hidden variability that quietly destroys seals, overheats bearings, and wastes thousands of dollars in downtime.

Solution: Implement grease gun calibration and labeling across all maintenance tools.

OPL Grease Gun Calibration

1. Pump ten strokes into a cup, weigh the grease, and divide by ten to determine grams per stroke.

2. Label each gun (e.g., Gun A = 1.0 g/stroke).

3. Train technicians to calculate the required amount using the bearing dimensions and apply precisely that volume.

4. Add color-coded grease fittings to prevent cross-contamination between lubricant types.

This converts lubrication from a “feel-based” task into precision maintenance.

Impact: Extends bearing and gearbox life by 2–5×

• Reduces unplanned downtime by 30–50 %

• Saves $10,000–$100,000 + per year in parts and labor

• Builds technician ownership and pride in workmanship

  
  

A one-day calibration session turns a routine task into a high-ROI reliability practice.

Want more low-cost reliability wins? Follow #MasterReliability for weekly quick wins that drive uptime and cut costs.