Case Study: Effective Management of Hand and Arm Vibration Exposure in a Manufacturing Environment

A thriving gates and fences manufacturer nestled in the heart of the UK has mastered the intricate art of handcrafting bespoke gates. As staunch advocates of time-honoured techniques, their devotion to producing visually striking and robust gates is matched only by their unwavering commitment to their customers. With an expansive team of over 40 dedicated professionals, including talented joiners, fabricators, painters and sprayers, the company champions the cause of craftsmanship in the UK.

Such craftsmanship does not come without its potential hazards, however. Traditional manufacturing methods often involve the use of hand-operated tools, potentially introducing the issue of hand-arm vibration exposure amongst the workforce. Recognising this risk, the company took the proactive step of appointing us to carry out a comprehensive hand and arm vibration exposure assessment. The goal was to identify potential risks and implement strategies to manage and reduce vibration exposure, ultimately safeguarding their team's health and wellbeing while upholding their commitment to quality and craft. The resulting engagement set the stage for an in-depth exploration of occupational health and safety measures in a high-demand, craft-centric environment.

Handheld power tools such as routers, sanders, multitools, saws, and planers, which are staple instruments in the gates and fences manufacturing process, pose a notable risk of hand-arm vibration syndrome (HAVS). HAVS is a debilitating condition caused by frequent and prolonged exposure to vibrations, which can lead to painful and disabling disorders of the blood vessels, nerves and joints of the hand and arm.

In the UK, there's clear industry guidance and legislation designed to protect workers from the risks associated with hand-arm vibration exposure. The Control of Vibration at Work Regulations 2005 (CVWR 2005) obliges employers to take steps to prevent or reduce the risk of HAVS. To support these regulations, the Health and Safety Executive (HSE) has issued the "Hand-Arm Vibration at Work" guide. It offers advice on how to evaluate the risk of vibration exposure, the steps to control and manage these risks, health surveillance, and employee training.

Companies should assess their procedures and operations in light of this guidance, ensuring that their workers are properly protected and that they are fulfilling their legal obligations. By understanding the tools and tasks that can cause high vibration exposure, and implementing safe work practices and controls, employers can significantly mitigate the risk of HAVS and foster a safer, healthier work environment.

Our Approach

Our methodology for assessing hand-arm vibration exposure involves a multi-pronged approach that ensures precision and accuracy. Initially, we use a highly precise instrument, the Castle Pro-DX Excieo Analyser, to measure the vibration magnitudes. We then complement this data with on-the-ground observations of the work the operators carry out, as well as the specific tools they use.
In order to gain an accurate understanding of work patterns, we also engage in direct conversations with the individuals who use the tools. This enables us to gain insight into the daily routines and tasks involved, which further enriches our data.

For even more precise estimation of tool usage times, we employ Havi-vibration loggers. These are attached directly to the tools, and record the exact time each tool is actively in use. This approach mitigates the need for operators to guess their usage times, leading to more accurate data upon which we base our calculations.
 
Once we have collected all of this data, we use it to create several exposure scenarios. These scenarios illustrate how usage might stack up during a typical workday, as well as on slower or busier days. This nuanced approach enables us to accurately evaluate the actual level of hand-arm vibration risk, ensuring that potential hazards are identified, understood, and managed effectively.
 

Observation

Our observations revealed that the woodworking and metalworking operatives used an array of tools for short durations to shape and finish the final products. The majority of their time was dedicated to aligning and assembling the products from the pre-cut components, and the exact duration and tool usage varied depending on the product being manufactured.

Interestingly, the company had taken measures to reduce vibration exposure, supplying workers with gel-filled gloves designed to absorb vibration. Despite these precautions, however, we discovered that vibration exposure varied significantly between different tools.

For example, in woodworking, tools like the multitools, palm sanders, and orbital sanders were likely to exceed the exposure action value within just 30 minutes of use. Even an additional 30-minute period, which the operatives considered feasible, would lead to an even greater number of tools exceeding the exposure action value. This finding led to the conclusion that the daily hand-arm vibration (HAV) exposure of personnel in the woodworking area was likely to surpass the Exposure Action Value as specified in the Control of Vibration at Work Regulations 2005.

We recommend the implementation of a rigorous program of tool maintenance and more robust tracking of tool usage and vibration exposure. Additionally, the possibility of replacing tools with high vibration exposure points should be considered if the exposure can't be adequately reduced.

Recommendations

Firstly, it is essential to include all tool accessories in the provisions of planned preventative maintenance. This means conducting regular checks and maintenance on not only the tools themselves but also their accompanying accessories. By ensuring that all components are in good condition and that blades and drill bits are sharp and free from blunting, the risk of excessive vibration can be minimized.

Additionally, it is crucial to establish a comprehensive program for documenting task-based trigger times and vibration exposure rotas for staff. This can be achieved by having operatives fill out exposure timesheets throughout a typical working week. By gathering this data, the company can have a more accurate understanding of vibration exposure levels and use it as evidence to inform policy changes and further improve risk management practices.

Furthermore, maintaining a thorough program of tool maintenance is essential. This involves regular inspections, servicing, and repairs to keep the tools in optimal condition. By ensuring that all components are well-maintained, the risk of vibration-related issues can be reduced, enhancing the overall safety and well-being of the employees.
 
If the aforementioned measures do not sufficiently reduce vibration exposure, it may be necessary to consider replacing certain tools. It is crucial to select tools that are suitable for the task at hand and can efficiently complete the work within a shorter timeframe. Prolonged usage of tools can lead to higher exposure levels, so choosing the right equipment is paramount.

By implementing these recommendations, Gates & Fences UK Ltd can effectively manage and reduce the risk of hand and arm vibration exposure, ensuring the health and safety of their employees.

Value delivered

Our comprehensive hand and arm vibration exposure assessment has provided significant value to the client. By conducting in-depth measurements and observations, we were able to accurately assess the levels of vibration exposure faced by the woodworking and metalworking operatives. Our expertise allowed us to identify specific tools and tasks that posed a higher risk of vibration exposure.

Through our recommendations, we have empowered the client to take proactive steps in managing and reducing vibration risks in the workplace. By emphasizing the importance of planned preventative maintenance, documenting task-based trigger times, and maintaining a thorough tool maintenance program, the client can effectively mitigate the risk of vibration-related health issues among their employees.

Our focus on providing tailored and practical solutions has enabled the client to make informed decisions about tool replacements and ensure the selection of equipment suitable for minimizing vibration exposure. By doing so, our client can improve overall work efficiency while prioritizing the health and well-being of their workforce.

Overall, our value lies in delivering comprehensive assessments, practical recommendations, and expert guidance to help our client effectively manage hand and arm vibration exposure risks. By implementing our recommendations, the client can create a safer working environment and protect the long-term health of their employees.