Focused lubrication management to cut failures and free up capacity
Pareto principle: why 20% of causes drive 80% of downtime
In virtually every plant, large or small, the same pattern appears: a small number of causes (around 20%) are responsible for the majority (roughly 80%) of failures. The Pareto principle (the 80/20 rule) is therefore highly relevant to lubrication management.
By understanding which failure modes play the biggest role, maintenance teams can often improve reliability, reduce labour hours and move closer to the ideal maintenance condition in which assets run at peak performance, the Optimum Reference State (ORS).
Pareto principle in practice:
20% of the main failure causes are responsible for 80% of all failure events.
20% of the machines account for 80% of the machine downtime.
The top 3 causes of failure in lubricated assets
Failure analyses show that breakdowns in bearings, chains and gearboxes can largely be traced back to three factors:
- Contamination: responsible for approx. 30-40% of bearing failures (SKF).
Dirt, moisture or cleaning agents penetrate into the contact zone. Even microscopic particles cause abrasive wear and accelerate pitting. - Incorrect or insufficient lubrication: responsible for 40-50% of premature bearing failures (Noria, Machinery Lubrication).
Too much, too little or the wrong lubricant disrupts the lubrication regime. A film that is too thin leads to boundary lubrication and adhesive wear; the wrong viscosity increases friction and accelerates thermal degradation. - Assembly and alignment errors: less frequent, but often with disproportionate impact.
Small deviations in bearing fit or gear alignment increase the load on the contact surface and cause premature failure.
Together, these causes account for the majority of problems in lubricated assets, a direct illustration of the Pareto principle.
How to identify the 20% in your plant
The real power of the Pareto principle is recognising the few causes that create most problems. This does not require complex monitoring—just a structured approach:
- Analyse maintenance logs: Spot assets that fail more often or cause disproportionate downtime. Recurring issues (e.g. chains stretching, gearboxes leaking, bearings failing) usually reveal the critical few.
- Cluster failure modes: Group incidents into categories such as contamination, lubrication issues, alignment errors, overload or corrosion. In most plants, two or three categories explain the majority of failures.
- Conduct a baseline assessment: Review lubrication practices, product selection and routes. This quickly shows where lubrication points are over- or under-serviced, products are unsuitable, or contamination risks are high.
- Use ILAC Pro™ software to prioritise: Visualise which points consume the most time, pose the highest risk or are critical to reliability—making it easier to decide which 20% deserve most attention.
By following these steps, teams can identify the small number of causes that drive most failures and focus their reliability strategy where it counts.
Applied to different components
| Component | Main risks | Approach |
|---|---|---|
| Bearings | Contamination and boundary lubrication | Seal integrity, condition monitoring (vibration, oil analysis), lubricants that maintain a stable film even under variable load and moisture |
| Chains | Contamination, over- or under-lubrication | Minimal Quantity Lubrication (MQL) with penetrating lubricants that do not drip and repel dirt |
| Gearboxes | Oil oxidation, leakage and particle contamination | Semi-fluid greases that prevent leakage, extend service life and reduce the need for frequent oil changes |
Why targeted lubrication pays off
The Pareto principle shows that maintenance teams do not need to do more, but smarter. Key to this is:
- Standardisation and control → through tagging, routes and software such as ILAC Pro™, it becomes clear which 20% of assets deserve the highest priority.
- Precision lubrication → MicPol® technology strengthen the lubricant film and bond to surfaces, ensuring critical functions remain effective even under load, moisture and cleaning.
- Strategic maintenance → with LaaS (Lubrication as a Service), lubrication becomes a standardised process rather than a series of isolated tasks, aligned with the principles of ORS.
Impact on labour time, energy and costs
With staff shortages, every hour counts. By addressing the critical causes:
- emergency interventions decrease,
- teams gain back dozens of hours per month,
- and more capacity becomes available for planned work and structural improvements.
In addition, precision lubrication often delivers 3-8% energy savings on selected drives, directly measurable in kWh and CO₂ reduction.
Conclusion
The Pareto principle makes it clear that 20% of the causes, contamination, incorrect lubrication and assembly errors, are responsible for 80% of failures in bearings, chains and gearboxes.
By focusing on these and working in line with the principles of the Optimum Reference State (ORS), maintenance teams achieve greater reliability, lower costs and more effective use of their scarce labour capacity.
Want to know where the 80/20 opportunities lie in your plant?
Contact us, and book an appointment with one of our technical advisors. No obligations.
Frequently Asked Questions about the Pareto principle
That’s something we hear often. With a shortage of skilled staff, it may feel impossible to investigate where the biggest gains lie. But that’s exactly where the Pareto principle adds value: it prevents you from spending time on issues with little effect. Identifying the 20% causes is often a lot easier than expected, using failure data, maintenance logs or a baseline assessment. The result: fewer emergency interventions, lower workload and more room for planned work. It takes some attention to start, but you get time and capacity back in return.
Not sure where to begin, or would you like expert support?
Contact Interflon. Our technical advisors are happy to help, without any obligations. Whether it’s analysing your results, giving practical recommendations or mapping the potential benefits, we are here to support you.
Finding the main causes does not have to be complicated. They are usually hidden in recurring problems: bearings failing too early, chains stretching quickly or gearboxes leaking repeatedly. Reviewing maintenance logs, failure data and oil analyses side by side quickly shows which assets demand disproportionate attention. A baseline assessment can confirm this further. The outcome: objective data to act on, instead of constantly firefighting.
The Optimum Reference State (ORS) is the ideal maintenance condition in which an asset runs as reliably and efficiently as possible. In practice, this means the right lubricant, in the right amount, applied correctly and free from contamination. Proper assembly, alignment and process control are part of it too. For maintenance teams, ORS is not theory but a practical target: everything in place, fewer failures, longer asset life and more control over time and costs.
