Gearbox Life Extended by 3 Years with Simple Oil Filtration, Plus Significant Asset Value Saved Overall

The Challenge

Since 2018, Worthington Steel, a global metals manufacturer, has collaborated with AssetWatch to continually expand its condition monitoring programs across various facilities. Initially, when oil analysis was introduced alongside existing vibration monitoring techniques, there was some uncertainty about its potential benefits. However, taking a few simple recommended steps ended up making a big difference—helping equipment last longer and saving money in the process.

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Simple Improvements, Big Returns

For Worthington Steel’s participating facilities, AssetWatch performs holistic oil analysis using oil samples collected on a regular basis. The results go beyond pass/fail, revealing a wide range of particulates and other matter, which enable AssetWatch experts to calculate the wear rate and estimated lifespan for each asset.

As facility teams get expert help on improving filter use, sampling and other lubrication program practices, they also receive prescriptive recommendations—prioritized in terms of urgency—to help minimize wear and extend asset life.

At one facility, routine oil analysis identified moisture accumulation in a bridle gearbox. To address this, a lubrication change was implemented to eliminate water and restore proper viscosity. Additionally, a Beta 1000, 10-micron filter was installed to remove impurities. These actions transformed the gearbox’s wear rate from 46% faster than normal to 41% slower than normal, effectively extending its operational life by an estimated three years.

When you look at the longer-term strategy and how we’re extending the life of an asset, that asset’s going to last for 12 more years instead of seven. Then our lights start to come on. We start to understand the payback.

– Jeremie Lieb, Corporate Reliability Engineer, Worthington Steel

Wear Rate Below Normal

-41%

End result for a single asset, down from a 46% faster-than normal wear rate, following simple oil filtration

Single Asset Life Extension

Estimated additional years of value from a bridle gearbox following simple oil filtration

Total Asset Life Extension

12.5

Estimated years of cumulative life extension across all assets since incorporating oil analysis

ROI Delivered

15X

Estimate of lubrication program value realized, based on customer feedback

Promising Results & More to Come

“We’ve had great results so far, but we’ve really only scratched the surface. There’s a lot of opportunity ahead to expand and build on this success.” – Jeremie Lieb, Corporate Reliability Engineer, Worthington Steel

15x

Discover How Simple Lubrication Changes Can Maximize Your Assets’ Value.

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