Prevent Lubrication Failures with FUCHS and SMARTdiagnostics

The Challenge

Unseen Lubrication Issues Threatening Production

A global leader in heavy haul railcar components, embarked on a pilot project with KCF Technologies and FUCHS to proactively monitor the health of critical machinery. Among the assets covered were high-impact systems like grinders, compressors, motors, and blowers.

Early in the pilot, data from KCF’s SMARTdiagnostics™ platform began surfacing telltale signs of lubrication degradation—an often-overlooked culprit that can quietly escalate into catastrophic failure. In fact, the customer later confirmed that 38% of all flagged issues were directly linked to lubrication—primarily degradation and contamination.

The Incident

Identifying a Critical Gearbox Failure in the Making

One key example came from a gearbox (GBX) supporting grinder operations. The chain of events unfolded with real-time insights and decisive action:

January 28th

KCF Technical Analyst noticed abnormal vibration patterns and called out a lubrication-related issue, recommending an oil sample be taken.

February 14th

During a site inspection, the on-site team heard loud noises from the GBX, triggering an emergency oil change for the next day

February 15th

Oil was drained and replaced. During the process, a leak was discovered at the output shaft cover— quickly repaired.

February 20th

KCF Technical Analyst confirmed through a waterfall vibration plot that amplitudes were returning to normal, indicating the issue was successfully addressed.

February 21st

Oil analysis revealed high levels of wear metals and large particles, indicating severe oil degradation that contributed to gearbox issues. If left unchecked, it could have led to total failure. A stronger oil analysis program could have caught this earlier. Further review is needed to confirm the oil is suitable for these operating conditions.

The Outcome

From Reactive to Proactive Reliability

Thanks to timely monitoring and collaboration between KCF’s analysts and the on-site maintenance team, a critical failure was prevented— demonstrating the value of early intervention. Transition to ongoing reliability planning, including oil sampling every two months.

KCF Analysts review machine health data for a trim blower fan.

The pilot exceeded our expectations and we’re moving forward with a long-term contract. Our grinders are a very unique application and we’re already capturing very interesting data and working with KCF to fine-tune the alarms.
Maintenance + Reliability Specialist

Conclusion

This case is a clear example of how data-driven predictive maintenance transforms operations— from uncovering invisible lubrication issues to saving tens of thousands of dollars in avoided damage and downtime. Most importantly, it proves that with the right technology and an engaged team, proactive reliability is achievable— even in complex environments.

To build on the success of their predictive maintenance efforts, the maintenance team has the opportunity to further strengthen their lubrication program by partnering with FUCHS, a global leader in high-performance lubricants. FUCHS offers advanced lubrication solutions specifically engineered for industrial applications like grinders, motors, and gearboxes—where operating conditions are intense and failure risks are high. By integrating a Lubrication-Enabled Reliability program with FUCHS together with KCF’s real-time monitoring platform, the partners on-site can achieve even greater control over equipment health, extend asset life, and reduce the likelihood of future lubrication-related issues. Together, this combination supports a proactive, data-driven reliability strategy that maximizes performance and minimizes risk.

Catching Lubrication Failures Before They Derail Production