Noise monitoring in dynamic manufacturing environments
Our global client manufacturers automotive parts, their manufacturing process is characterised by small batch volume and high variation, and in this dynamic environment, associates are required to wear hearing protection.
Noise-induced hearing loss is an irreversible and debilitating condition, which can be experienced by people who spend a career in manufacturing.
The Control of Noise at Work Regulations (2005) requires employers to monitor noise levels and operate within set exposure limits. The challenge, however, is that noise intensity fluctuates in the factory depending on production levels.
A blanket approach to hearing protection
In these real-world scenarios, how can employers ensure their teams are wearing the right level of hearing protection, at the right time?
We asked the HSE Officer at their UK manufacturing plant,
“The challenge we have is actually overprotection, we operate in a very fluid noise environment where exposure levels vary throughout the day”.
Under such operating conditions, employers tend to err on the side of caution and take a blanket approach to wearing hearing protection at all times.
Overprotection, however, can impair a worker’s situational awareness and their ability to communicate effectively. Becoming isolated in this way means workers cannot safely react to hazards within their operating environment.
As a result, workers often remove hearing protection and Supervisors spend a considerable amount of time reinforcing the rules and educating the workforce about the risk of noise-induced hearing loss.
“The health, safety and well-being of our associates is our highest priority, and we are absolutely determined to protect them from noise-induced hearing loss”.
Taking the CUFF approach with confidence:
“We want to educate our associates about the activities which lead to an increase in noise levels, and how to respond with the appropriate level of hearing protection.”
Ear plugs and ear defenders are standard issue on worksites, but even with diligent use, a worker might still be exposed to potentially dangerous noise levels.
“It’s important to take steps to understand if your hearing protection is doing its job”.
The CUFF approach, recommended by the HSE, encourages employers to assess hearing protection based on:
- Condition: is the hearing protection in good working condition?
- Use: is hearing protection being worn at the right times?
- Fit: does hearing protection fit properly?
- Fit for Purpose: does it provide the right level of hearing protection?
“Until recently assessing the effectiveness of hearing protection was practically impossible in a factory setting”.
A smarter approach to noise surveillance:
Smart Alert is a new generation of hearing protection. The technology not only protects the wearer, but also measures ambient noise using a collar-worn sensor, and the level of noise entering each ear, using sensors mounted within the ear plugs.
Reactec partnered with Minuendo to turn the data, gathered by Smart Alert, into intuitive analytics which help employers to proactively take control of their noise environment.
“We chose Smart Alert because, unlike dosimeters, the technology monitors personal noise exposure directly entering the associate’s ear”.
Exposure levels from noise dosimeters can overestimate, particularly, if the microphone is placed in a position which can be affected by other factors, such as surface friction.
“With this traditional approach, it can be difficult to identify the source and exposure levels accurately. There also isn’t any insight into how well any noise protection being worn is reducing the ambient noise.”
“The combination of Smart Alert with Reactec Analytics creates a system where we can educate our associates about wearing suitable protection effectively”.
The HSE Officer explained: “the system helps our associates to recognise when there is a subtle increase within the noise environment, and how to respond with an appropriate level of hearing protection.”
“This means our associates are learning how, and when, to protect themselves.
“The noise data in Reactec Analytics is invaluable. Data is available for analysis very quickly, which means that our associates can easily recall the noise activities which took place during the previous shift and they can also see how effective the hearing protection they were wearing was. The ear protection can be customised for different associates which allows them to learn what effective noise protection sounds and feels like.”
“Wearing the right level of hearing protection, at the right time, ensures that our associates are protected from noise exposure, and remain fully aware of their surroundings.”
“Reactec Analytics is helping us to answer those CUFF questions with confidence, and to take decisive action to refine controls and protect our people”.