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Operational Guide - 2. Using the GreaseBoss Monitoring System

This chapter explains how to use the GreaseBoss monitoring system day to day — how to respond when an alert is received, how to review the health of individual assets and the wider fleet, and how to use monitoring data to support longer-term reliability improvement.

It is intended for users of the GreaseCloud Dashboard and for maintenance and reliability personnel.

(Click on the below to navigate to the details)

Alert Response

Asset Health Monitoring

Fleet Health Monitoring

Reliability Improvement

Recommended Review Practices

Alert Response

Alerts are the primary trigger for users to review the GreaseBoss system and investigate potential issues.

When an alert is received, the user should review the alert information, access the GreaseCloud Dashboard, review the affected asset and determine what action is required.

Recommended Alert Response Process

When an alert is received:

    1- Review the alert notification

    Note the key details provided in the alert, including:

    • Asset name

    • Grease point or Endpoint

    • Alert type

    • Alert time

    • Alert criticality

    • Any details included in the notification

    2- Log in to the GreaseCloud Dashboard
    • Access the dashboard to view the affected asset and review the available monitoring information.
    3- Navigate to the affected asset
    • Locate the asset identified in the alert.
    4- Find the affected grease point or Endpoint
    • Identify the specific grease point or Endpoint that generated the alert.

    5- Review the available data

    • Use the dashboard information to understand what may have caused the alert.

    • Depending on the alert type, review information such as:

      • Grease activity

         

      • Grease compliance

      • Pressure information

      • Last grease event

      • Device connectivity

      • Last sync

      • Historical trends

    6- Determine the likely issue type

    • Decide whether the issue appears to be related to:

      • Grease delivery
      • Pressure
      • Endpoint connectivity
      • Gateway connectivity
      • Asset operation or downtime
    7- Plan the on-site investigation
    • Use the monitoring information to guide what should be checked on the machine.
    • This may include checking the lubrication system, grease supply, pump operation, grease lines, injectors, Endpoint condition or Gateway condition.
    8- Rectify the issue
    • Complete the required corrective action in accordance with site procedures.
    9- Verify the result
    • After corrective action has been completed, confirm that the issue has been resolved.
    • This may include checking that:

      • Grease activity has resumed

      • Compliance has returned to expected levels

      • The device is communicating

      • The alert condition is no longer present

      • The asset is performing as expected

    10- Record any required follow-up

     

    If the issue is recurring or requires further work, record the details for maintenance planning or reliability review.

    NOTE: Alerts will automatically clear once the condition that triggered the alert has been rectified. Ie; the monitored point becomes compliant again, or, the Endpoint that was offline comes back online.

    Asset Health Monitoring

    Users should periodically review the health of monitored assets, even when no active alerts are present.

    The purpose of an asset health review is to confirm that the lubrication system is performing as expected and to identify issues that may be developing.

    Recommended Asset Health Review Process

    When reviewing an individual asset:

    1- Open the asset in the GreaseCloud Dashboard

    • Review the overall condition of the asset and identify whether any grease points or devices require attention.

    2- Check for active alerts

    • Confirm whether there are any current alerts associated with the asset.

    3- Review grease compliance

    • Check whether monitored grease points are receiving the expected grease delivery.

    • Overgreasing and Undergreasing will reduce the compliance value (%)

    4- Review grease activity

    • Check whether grease activity is occurring as expected.

    • Look for missing grease events, irregular activity or changes from previous performance.

    5- Review pressure information where available

    • For pressure-monitoring Endpoint devices, check whether pressure behaviour appears normal or whether there are unusual changes.

    6- Review device health

    • Check whether Endpoints and the Gateway are communicating as expected.

    • Device health information helps confirm that monitoring data is being received and can be relied upon.

    7- Identify items requiring action

    • Determine whether any grease points, devices or trends require further investigation.

    8- Plan follow-up work

    • If an issue is identified, plan the required inspection, maintenance or troubleshooting activity.

    Fleet Health Monitoring

    Sites with multiple monitored assets should periodically review fleet-wide monitoring information.

    The purpose of a fleet review is to identify broader trends, recurring problems and assets requiring increased attention.

    Recommended Fleet Review Process

    When reviewing multiple assets:

    1- Review all monitored assets

    • Look across the fleet to identify assets with active alerts, poor compliance or recurring issues.

    2- Identify repeat problem assets

    • Note any machines that are regularly generating alerts or showing poor lubrication performance.

    3- Compare similar assets

    • Where similar machines are monitored, compare performance between assets.

    • This can help identify whether an issue is isolated to one machine or common across multiple machines.

    4- Review recurring alert types

    • Look for repeated alerts such as:

      • No grease activity

      • Low compliance

      • Endpoint offline

      • Gateway offline

      • Pressure alerts

    5- Prioritise maintenance attention

    • Focus first on assets with the greatest operational or reliability risk.

    6- Record improvement opportunities

    • Fleet reviews may identify opportunities to improve lubrication settings, maintenance practices, inspection routines or system configuration.

    Reliability Improvement

    Monitoring information should be used to support reliability improvement activities, not only short-term troubleshooting.

    Historical data can help users understand how lubrication system performance changes over time and whether issues are recurring.

    Recommended Reliability Review Process

    Reliability or maintenance personnel should periodically:

    1- Review historical trends

    • Look for changes in grease delivery, compliance, pressure or connectivity over time.

    2- Identify recurring faults

    • Determine whether the same grease points, assets or alert types are repeatedly causing issues.

    3- Review completed corrective actions

    • Check whether previous maintenance work resolved the issue or whether the problem returned.

    4- Support root cause investigations

    • Use monitoring data to help understand when an issue started, how it developed and what conditions may have contributed.

    5- Identify improvement actions

    • Monitoring data may support decisions such as:
      • Adjusting maintenance practices
      • Reviewing lubrication system performance
      • Inspecting recurring problem points
      • Improving asset inspection routines
      • Reviewing alert settings or monitoring requirements

    6- Track improvement over time

    • After changes are made, continue reviewing the monitoring data to confirm whether performance has improved.

     

     

    Recommended Review Practices

    The frequency of review will vary depending on the operation, asset criticality and site requirements.

    The following review approach is recommended as a starting point.

     

    When an Alert Is Received

    Users should:

    1. Review the alert notification.
    2. Log in to the GreaseCloud Dashboard.
    3. Locate the affected asset and grease point.
    4. Review the relevant monitoring data.
    5. Determine the likely cause.
    6. Plan and complete the required investigation.
    7. Verify that the issue has been resolved.

     

    Weekly Review

    Users should review:

    • Active alerts
    • Recent alerts
    • Assets with recurring issues
    • Grease points with poor compliance
    • Devices with communication issues

     

    Monthly Review

    Users should review:

    • Compliance trends
    • Grease activity trends
    • Pressure trends where available
    • Repeated alert types
    • Assets requiring ongoing attention
    • Corrective actions completed during the month

     

    Fleet Review

    Where multiple assets are monitored, users should review:

    • Fleet-wide alert patterns
    • Assets with repeated lubrication issues
    • Common failure modes
    • Performance differences between similar assets
    • Opportunities to improve maintenance practices

     

    After Maintenance Work

    After maintenance work has been completed, users should review the monitoring information to confirm that:

    • Grease activity has resumed
    • Compliance has improved
    • Pressure behaviour has returned to expected levels
    • Communication has been restored
    • The alert condition has cleared

    This helps confirm that the corrective action was effective and that the lubrication system is operating as expected.