Future Forward: How AI Could Lubricate the Future of Manufacturing

In the world of manufacturing, tribal knowledge refers to the shared but unwritten techniques, procedures and practices that a handful of employees hold. This might sound like a secret sauce that gives your manufacturing company an edge, however, it’s also a ticking time-bomb, set to detonate once these key employees decide to move on. Then you’re left to scramble, fill in the knowledge gap, all while trying to maintain efficiency and productivity. Not exactly an ideal situation, right?

But here’s the silver lining: Tribal knowledge doesn’t have to be your kryptonite. You, as a manufacturer, can turn that knowledge into power as a new revolutionary force is taking the future of the industry by storm: Artificial Intelligence (AI). Let’s explore how AI is positioned to change the entire manufacturing landscape, unlocking opportunities for precision, efficiency and optimization.

Predictive Maintenance: Traditional maintenance schedules often lead to unnecessary downtime or catastrophic failures. AI-powered systems can forecast component wear and tear with remarkable precision, enabling targeted preventive maintenance. Lube-Tech and Redlist provide dynamic AI-powered lubrication and asset management to help prevent downtime and premature failure of critical equipment inside of the manufacturing environment.

John Keller, President and Co-founder, of Redlist says,

“A healthy asset is the lifeblood of your business. Unplanned downtimes due to a preventable reliability issue—can be costly and even catastrophic to your business and the people that run it.”

Using AI to predict when your machines may need maintenance, new lubricants or both, reduces downtime, extends equipment life and optimizes lubricant usage.

Dynamic Lubrication: Lubrication plays a crucial role in minimizing friction and wear, but traditional static schedules may not always be optimal. AI-powered systems, like those provided by Lube-Tech and Redlist, can analyze real-time sensor data, including temperature, pressure and vibrations, to adjust lubrication parameters dynamically. This ensures optimal lubrication levels across varying operating conditions while reducing lubricant waste and extending equipment life.

Smart Supply Chain Management: AI can optimize the entire supply chain for lubricants, predicting demand fluctuations and streamlining delivery routes. This ensures the right lubricant is available at the right time and in the right quantity, minimizing inventory costs and ensuring uninterrupted production.

Collaborative Robotics: Collaborative robots (cobots) are designed to work alongside humans, performing tasks like machine tending and quality control. AI can empower cobots to adapt to new tasks, handle intricate components with superior precision and even identify potential lubrication issues, freeing human workers for higher-value activities.

“It really depends on how organized and consistent a manufacturing facility’s data is. If their data is consistent, clean, and organized, it can take a matter of hours to migrate their information and only a few more hours to train their staff. If the data is incomplete or inconsistent it can take several weeks with our team of experts and going through the reps to get your data in the system. This data can and should include pictures of the assets and their respective components and lube points and a basic mapping of where to find these assets within your facilities. It should also include the basic lube instructions of how much of which lubricant goes where and how often.”

As with other hazardous materials, transporting lubricants like motor oil is a very specialized, complex, and highly regulated service requiring particular expertise and experience. As the world is still highly reliant on fossil fuels to make things go, despite widespread EV and green initiatives, its importance cannot be overstated.

By its very nature, bulk lubricant transportation is fraught with difficulties and challenges related to storage, transfer, transportation, and delivery. Carriers handling bulk lubricants must adhere to strict federal and state licensure and regulatory requirements for their overall operations, as well as individual drivers who haul them. For this reason, the everyday sharing of transit and logistics data among shippers, carriers, and partners is even more critical than usual.

It’s surprising, therefore, that in a highly technological age, many companies still rely on email servers, manual data tabulation, and other outmoded means of communication to track and manage the movement of lubricating oils. But such is, unfortunately, the case. In this article, we’ll explore the broader lubricants market and how lubricants companies can significantly improve their logistical efficiency by leaning on technology and niche expertise.

Industry Forecast: In a Dynamic Market, Lubricant Shippers Play a Vital Role

Given regular fluctuations in petroleum production both domestically and worldwide, based on supply and demand patterns and shifting government regulations, transportation of bulk lubricants is a highly dynamic market. Shippers must, therefore, be armed with deep data analytics to ensure they have access to sufficient carrier capacity on a daily basis in this specialized transportation market

While there was a pronounced market slowdown during the pandemic era, the global lubricants market has been roaring back, even in the face of the massive public/private EV push. It’s projected to achieve a 4.5% CAGR between 2022 and 2032, reaching a valuation of $248 billion, according to new data from Future Market Insight.

Considering the vital nature of their loads, shippers and carriers play a pivotal role in ensuring the smooth, efficient transportation of bulk lubricants. Each driver is required to obtain a tanker endorsement by the Federal Motor Carrier Safety Administration. Overall, the industry relies heavily on accurate, real-time logistics and visibility: the exact location of each shipment, volumes in transit, arrival date and time, and other vital data.

Challenges of Oil Lubricants Shipping

As noted above, there are a number of challenges unique to the bulk shipment of lubricants. Shippers and carriers are responsible for proper storage and handling, the use of specialized equipment, regulatory compliance, and the maintenance of risk mitigation strategies.

Here are a few other factors to consider:

Deterioration and Contamination

By their very nature, lubricants and oils are prone to deterioration during storage and transportation. Deterioration can be caused by several factors, including extreme heat and cold, and contamination. Various contaminants can be introduced during storage, handling, and transportation, including water, dirt, and fabrication debris, especially with newer equipment.

Contamination is a major problem. The introduction of outside materials can change the chemical properties, affecting a product’s ability to lubricate and maintain machinery and equipment, leading to costly breakdowns.

All transfer, dispensing, storage, and tanker equipment needs to be inspected regularly to ensure proper functioning and guard against leaks and other hazards. Well-defined procedures, often using federal guidelines, are followed for the loading, transferring, and dispensing of lubricants. Also, each tanker must be dedicated to a particular product type to prevent degradation.

Lack of Visibility

The need for supply chain and logistics visibility, an issue in any business sector, becomes even more pronounced when transporting bulk lubricants. A 30-something professional in Columbus, Ohio, might be upset if UPS is a day late with her set of wine glasses for a Saturday night dinner party.

But a late delivery of lubricants can cause all kinds of issues. In manufacturing, it can adversely impact a plant’s operations, slowing or halting production, canceling orders, and running up costs. The hazardous nature of the product being transported also introduces elements of difficulty, caution, and concern on the part of the shipper, compared with most other sectors.

Without adequate real-time monitoring and tracking of shipments in transit, responding to deviations promptly and ensuring compliance with regulatory standards becomes more challenging. This increases the risk of operational disruptions, financial losses, compromised product quality, and angry customers.

Poor Transportation Software Infrastructure

Without the proper technology infrastructure, including a modern Transportation Management System (TMS), bulk lubricant shippers are severely limited in their ability to efficiently get a product where it needs to go on time.

Outdated, analog processes require a series of manual check-in calls, making it much harder to react quickly in the event of a supply chain disruption or adverse event in transit. Another issue facing most transportation managers in the sector is providers lack sufficient density within their carrier network to provide on-demand capacity sourcing.

These and other factors highlight how an inadequate digital infrastructure can impede the timely, secure delivery of bulk lubricants.

In a Challenging Environment, Bulk Lubricant Shippers Turn to Technology

Companies are realizing the importance of seeking technology solutions that will enable them to transport bulk lubricant shipments more efficiently. From predictive analytics driving smarter routing decisions to capacity planning, visibility solutions, and integration with warehouse systems, there are many ways shippers can see measurable performance results in their transportation operations.

Here are some of the ways technology is being leveraged to enhance transportation operations:

Predictive Analytics

Predictive analytics for oil lubrication transportation shipments enhances efficiency by forecasting maintenance needs, optimizing routes, and preventing potential issues. It reduces downtime, enhances safety, and improves overall logistics performance, ensuring timely deliveries, cost savings, and a streamlined supply chain.

Cost Management

Route optimization tools help minimize fuel consumption and reduce delivery time while improving customer satisfaction. Other ways technology helps drive cost reduction for bulk lubricant transportation include digitalization to optimize the use of logistics assets, control scheduling, and drive efficiencies that deliver greater value.

Integrated Visibility

TMS systems offer end-to-end visibility throughout the lifecycle of each bulk lubricant shipment. A TMS can be integrated with a number of other software systems, such as ERP, CRM, and WMS, to facilitate planning, scheduling, and budgeting. Customized TMS portals provide full carrier integration to track shipments, update delivery times, optimize carrying capacity, and improve sustainability

Real-time tracking and monitoring enhance overall supply chain efficiency by optimizing inventory and order management, routing and scheduling, customer communication and status updates, and carrier management.

Wicker Park Logistics: Control Tower Capabilities in Lubrication Transportation

With a wealth of experience within the energy sector, including challenges particular to bulk lubrication shipping, Wicker Park Logistics provides a range of services that help companies connect their supply chain to North American customers. Our dedicated team of logistics experts has decades of experience managing the unique operational requirements of customers dealing with the transportation of hazardous materials.

By leveraging predictive analytics, regulatory compliance, integrated communications, and real-time visibility, Wicker Park Logistics is a recognized expert in lubrication transportation, enabling seamless, efficient end-to-end operations. A leader in innovative technology solutions, we work with a vast network of specialist carriers in North America to provide you with the best trucking options to meet your specific needs and exacting standards.

Cloud-enabled transportation “control towers” transform logistics and supply chain performance, driving seamless, efficient operations. Working with Wicker Park Logistics, lubricant shippers realize the benefits of true end-to-end supply chain integration with an optimized transportation service network built and maintained by a trusted, collaborative 3PL partner.

See How a Tech-Forward Partner Can Transform Your Bulk Lubricant Shipping

From TMS-enabled visibility to enterprise integration, on-demand capacity sourcing, and a wide variety of transportation solutions tailored to the unique transportation needs of the energy sector, Wicker Park Logistics is your go-to partner for driving operational improvement. Speak to an expert today.

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Importance of Lubrication in Automobiles

Lubrication plays a vital role in smooth and efficient operation of automobiles. Its importance lies in the reduction of friction and wear within various components of the vehicle’s engine, transmission, and other mechanical systems. By providing a protective layer between moving parts, lubricants minimize heat generation and prevent excessive wear and tear, thereby extending the lifespan of critical components. Additionally, lubrication enhances fuel efficiency by reducing energy losses due to friction, leading to improved overall performance and lower maintenance costs. In essence, lubrication is the silent hero that ensures the longevity, reliability, and optimal functioning of automobiles on the road.

Conventional Lubricants in Automotive Industry

Conventional lubricants have long been the lifeblood of the automotive industry. These time-tested lubricants are typically mineral oil-based and have been the primary choice for decades. They serve a multitude of critical functions within an automobile’s engine, transmission, and various mechanical components. Conventional lubricants provide a vital barrier between moving parts, reducing friction and minimizing wear and tear. They also help dissipate heat generated during engine operation, preventing overheating. Additionally, these lubricants serve as a cleaning agent by carrying away contaminants and debris from crucial components, ensuring they operate smoothly.

While conventional lubricants have been reliable, they do have limitations, such as limited temperature stability and a finite lifespan, which necessitates regular oil changes. In recent years, advancements in lubricant technology, including the introduction of synthetic and bio-based alternatives, have aimed to address these limitations, promising even better performance and efficiency for the future of the automotive industry.

Limitations and Challenges

Understanding the drawbacks of any kind of conventional lubricants is crucial in the context of advancing lubrication technology. Here are some key limitations and challenges associated with conventional lubricants:

• Limited Temperature Range: Conventional lubricants may not perform optimally under extreme temperature conditions. They can thin out at high temperatures, leading to reduced viscosity and lubrication efficiency, while thickening in cold temperatures, hindering startup lubrication.

• Shorter Lifespan: These lubricants tend to degrade and break down over time due to exposure to heat and contaminants. As a result, they require more frequent oil changes and maintenance, increasing operating costs.
• Environmental Impact: Conventional lubricants are often derived from non-renewable petroleum sources. Their production and disposal can have negative environmental consequences, contributing to pollution and resource depletion.
• Limited Fuel Efficiency: The friction-reducing capabilities of conventional lubricants have certain limitations. They may not provide the level of energy efficiency needed to meet increasingly stringent fuel economy standards in modern vehicles.
• Compatibility Issues: Some conventional lubricants may not be compatible with new engine technologies and materials, such as those found in hybrid or electric vehicles, potentially leading to performance issues.
• Increased Wear at Startup: During cold starts, conventional lubricants may take some time to reach optimal viscosity, leading to increased wear and tear on engine components, particularly in regions with cold climates.
• Lack of Customization: Conventional lubricants are generally one-size-fits-all solutions. They do not offer the level of customization and precision lubrication that some advanced systems require.
• Environmental Regulations: Stringent environmental regulations and emissions standards have put pressure on the automotive industry to reduce the use of conventional lubricants due to their environmental impact.
• Alternative Fuel Compatibility: As vehicles powered by alternative fuels, such as hydrogen or natural gas, gain popularity, conventional lubricants may not be suitable for these new engine types.
• Maintenance Costs: The need for regular oil changes and maintenance can be an inconvenience and an additional cost for vehicle owners.

The Evolution of Lubricant Technology

The evolution of lubricant technology has been marked by significant milestones. Early improvements in lubricants saw the gradual refinement of mineral-based oils, enhancing their lubricating properties and extending their utility in automotive applications. However, a major turning point occurred with the transition to synthetic lubricants. These lab-engineered lubricants offered several advantages over any kind of conventional lubricants, including superior high-temperature stability, reduced friction, and enhanced wear protection. The benefits of synthetic lubricants extended beyond performance, as they also contributed to increased fuel efficiency and extended engine life. This shift to synthetic lubricants marked a pivotal moment in the automotive industry’s quest for improved efficiency and longevity in vehicle operation.

Nanotechnology in Lubricants

Nanotechnology has ushered in a new era of innovation in the world of automobile lubricants. At its core, nanotechnology’s role lies in the manipulation and utilization of minuscule particles on a nanoscale, and this has had a profound impact on lubrication technology. Nanoparticles, typically measuring less than 100 nanometers, are now being ingeniously incorporated into lubricants to revolutionize their performance. These tiny wonders serve as active additives, forming a protective layer between moving parts within the engine. This innovative approach leads to enhanced friction reduction, one of the most critical aspects of lubrication. By reducing friction to almost microscopic levels, nanoparticles allow for smoother, more efficient engine operation, resulting in decreased wear and improved fuel efficiency. In essence, nanotechnology’s precision engineering has paved the way for lubricants that are not only incredibly effective but also tailored to meet the increasingly demanding needs of modern automobiles, pushing the boundaries of what was once thought possible in automotive lubrication.

Biodegradable Lubricants

In response to growing environmental concerns within the automotive industry, biodegradable automobile lubricants have emerged as a commendable solution. Environmental concerns in lubrication primarily revolve around the potential harm posed by the disposal of traditional lubricants, which often contain non-biodegradable components. Biodegradable lubricant formulations, on the other hand, are consciously engineered with eco-friendliness in mind. These formulations are typically derived from renewable resources or synthesized with biodegradable base oils, making them less harmful to the environment during production and disposal. The sustainability benefits of biodegradable lubricants extend to reduced ecological impact, as they break down more easily in natural environments, minimizing soil and water pollution. This green approach not only aligns with the industry’s commitment to environmental responsibility but also supports a cleaner, more sustainable future for automobiles, making biodegradable lubricants an appealing choice for environmentally conscious consumers and manufacturers alike.

Smart Lubrication Systems

Smart lubrication systems represent a cutting-edge advancement in the automotive industry, seamlessly integrating the power of the Internet of Things (IoT) into lubrication processes. IoT integration in smart lubrication systems allows for real-time monitoring and maintenance of critical components within a vehicle’s engine and other mechanical systems. These systems utilize sensors and data analytics to continuously assess lubricant condition, temperature, and wear, providing valuable insights into the health of the vehicle’s moving parts. As a result, issues can be identified and addressed proactively, minimizing downtime and reducing the risk of costly breakdowns. Moreover, by ensuring that lubrication is precisely calibrated to meet the specific demands of the vehicle’s operation, smart lubrication systems contribute to improved efficiency and performance, ultimately extending the lifespan of critical components and enhancing the overall reliability of automotive systems. In essence, the integration of IoT technology into lubrication is revolutionizing the way vehicles are maintained, making them not only more dependable but also more efficient in today’s rapidly evolving automotive landscape.

Lubrication Challenges in Electric Vehicles (EVs)

Electric vehicles (EVs) have ushered in a new era of automotive technology, but they also bring unique lubrication challenges to the table. Unlike traditional internal combustion engines, EVs rely on electric motors that generate significantly less heat during operation. This reduction in heat means that the lubrication needs of EVs differ substantially, as they require specialized lubricants to maintain optimal performance and longevity. High-temperature greases are one such innovation, designed to counteract the extreme heat generated by the high-torque, high-speed electric motors found in EVs. These greases ensure that components within the motor and transmission remain adequately lubricated, preventing overheating and excessive wear. Moreover, extending the battery life of EVs is of paramount importance to their overall efficiency and cost-effectiveness. Lubrication plays a crucial role in achieving this goal by reducing friction and energy losses in the drivetrain, contributing to prolonged battery life and ultimately enhancing the sustainability and appeal of electric vehicles in the modern automotive landscape.

Future Trends and Industry Outlook

The future of lubrication technology in the automotive industry holds great promise, with several key trends on the horizon. Predictions for lubrication technology anticipate further advancements in nanotechnology and the continued development of eco-friendly, biodegradable lubricants. Key players in lubricant innovation, including major oil companies and research institutions, are expected to drive these developments, investing in cutting-edge research to meet the ever-evolving needs of the automotive sector. As environmental concerns grow, there is a shift towards sustainable and efficient lubrication solutions, presenting substantial market growth and opportunities. Lubricant manufacturers are poised to capitalize on this shift by offering innovative products that not only enhance vehicle performance but also align with the industry’s commitment to reducing its environmental footprint. As the automotive landscape continues to evolve, lubrication technology is set to play a pivotal role in shaping the future of automobiles, paving the way for more efficient, eco-conscious, and reliable vehicles on the road.