IMPACT OF ADVANCED LUBRICATION MANAGEMENT SYSTEMS ON EQUIPMENT LONGEVITY AND OPERATIONAL EFFICIENCY IN SMART MANUFACTURING ENVIRONMENTS

Abstract

Smart manufacturing depends on stable tribological interfaces. This systematic review synthesizes how Advanced Lubrication Management Systems (ALMS) affect equipment longevity and operational efficiency by integrating online oil and film-state sensing, automated dosing and filtration, contamination control, and connections to CMMS, MES, and digital twins. Following PRISMA 2020, we searched databases for records from 2010 to 2025, screened against predefined criteria, and appraised quality. In total, 115 studies met inclusion and we extracted outcomes for reliability, efficiency, energy, and fluids. Across 64 reliability-reporting papers, median gains were notable: mean time between failures increased by 19 percent and failure or hazard rates declined by 23 percent, underpinned by typical two-step improvements in ISO 4406 cleanliness codes and 35 percent lower moisture. Operational performance improved across 74 studies: Overall Equipment Effectiveness rose by 5.6 points, driven by availability (+3.4), with additional gains in performance (+1.7) and quality (+0.5); unplanned downtime fell by 27 percent and mean time to repair by 14 percent. Energy intensity decreased by 8.5 percent and by 12 percent in dip or splash-lubricated gearboxes; lubricant consumption fell by 22 percent and drain intervals extended by 35 percent. Economic reporting indicated a 13 month payback and first-year return of 86 percent. Moderator analyses show larger, steadier effects when ALMS are closed-loop and digitally integrated, when cleanliness and moisture targets are sustained, and when oil-state sensing is paired with contact-level regime detection. Findings position lubrication as a governed, data-driven control problem that advances reliability, throughput, energy efficiency, and sustainability in smart manufacturing.