Case Study: Noise Monitoring and Compliance Enhancement for Improved Workplace Safety

In today’s industrial landscape, maintaining a safe and healthy work environment is of paramount importance. Not only does it safeguard the wellbeing of employees, but it also aids in productivity, efficiency, and overall business success. A significant aspect of this endeavour is the management of noise exposure - a ubiquitous risk in various industrial and manufacturing settings. In this case study, we present our noise exposure risk assessment engagement with our client, a leading player in the signage and wayfinding industry.

Headquartered in Rochester, Kent, our client operates from a bustling office, providing high-quality, durable, and customized interpretation boards to an array of sectors including local councils, nature reserves, visitor attractions, and commercial areas. Their offerings range from modern stainless-steel displays, sustainable boards made of recycled plastic, to naturally aesthetic hardwood oak boards. They have carved out a reputation for their expertly designed and durable products, which grace numerous outdoor settings such as parklands, nature reserves, shopping centres, and various visitor attractions.

Our industrial hygiene company was commissioned to conduct an in-depth noise exposure risk assessment for our client. The objective of this exercise was to gauge the noise exposure level within their operations, understand its potential impact on their workforce, and recommend suitable interventions, if necessary, to ensure compliance with health and safety regulations and standards.

Given the breadth and variety of our client's operations, it was critical for our team to not just examine the prevailing noise exposure levels, but also comprehend the specifics of their work environment. With their diverse range of products, each having unique manufacturing requirements and processes, we had to ensure that our assessment captured the noise profile of each segment of their operations. This case study takes you through our systematic approach towards achieving this objective, discussing in detail the methods employed, the challenges faced, and the solutions implemented.

Our Observations

In our assessment of the workshop operatives, we found that they carry out a multitude of tasks within the main workshop and across the site, which fluctuate considerably day by day. These tasks range from cutting and sanding wood with various tools to cleaning the workshop with hoovers and Local Exhaust Ventilation (LEV) systems.

Their typical workday starts at 8:00 am and ends at 4:30 pm, incorporating a 30-minute lunch break and a 20-minute tea break. The breaks are taken away from the production areas, making the total personal exposure to the workshop environment about 7 hours and 40 minutes. Overtime is infrequent and not significant.
 
It was noted that the use of hearing protection within the workshop is task-specific. While they have access to E-A-R Classic earplugs and Hilka Ear Defenders, employees did not utilize hearing protection during the time of the assessment. However, we observed one employee using personal 3M Worktunes ear defenders for specific tasks. Despite the ear defenders and plugs being in good condition and stored properly, they were not used consistently during our observation period.
Regarding health surveillance, the company currently does not have a formal program in place. Employees receive an in-house questionnaire focusing on occupational asthma, but there's no audiometry testing provided. Additionally, there was no evidence of toolbox talk or noise awareness training being given to the workshop operatives.

Finally, it was observed that the employees are unlikely to be exposed to chemical substances with an ototoxic effect within the workshop.

Findings

Our findings indicate that Workshop Operatives may be exposed to daily or weekly personal noise levels at or above the Upper Action Value of 85 dB(A) when using certain equipment such as the Arrow PT18G Pneumatic Nail Gun.

Additionally, they could potentially encounter daily or weekly personal noise exposure levels at or above the Lower Action Value of 80 dB(A) while operating equipment such as the SCM Si300n Circular Saw. However, employees working in other areas are generally expected to be exposed to noise levels below the Lower Action Value of 80 dB(A) during their regular activities.

Regarding peak noise levels, Workshop Operatives are likely to face levels at or above the Upper Action Value of 137 dB(C) when using the Arrow PT18G Pneumatic Nail Gun. Interestingly, we noted peak exposure levels exceeding the UEAV of 137dB(C) for one of the operatives. Yet, upon observation and discussions, no obvious events could explain these high peak readings. We believe that these readings may have been due to accidental knocking of the dosebadge microphone and thus consider them as false positives.

Recommendations

We recommend implementing the following measures based on our observations and compliance requirements under The Control of Noise at Work Regulations (CoNAW) 2005:

For Workshop Operatives, personal monitoring should be mandatory given the noise levels observed, ranging between 83-90 dB(A) with peaks at 138 dB(C). Employers must ensure to adhere to the guidelines if the Lower Exposure Action Value (LEAV) is likely to be exceeded, i.e., LEP,d is at or above 80dB(A) but less than 85dB(A) and LCpeak is at or above 135 dB(C) but less than 137dB(C).

Compliance includes conducting a noise risk assessment (reviewed at least every two years), providing suitable hearing protection upon request, and supplying personnel with relevant information, instruction, and training related to noise and its risks.

If the Upper Exposure Action Value (UEAV) is likely to be exceeded, i.e., LEP,d is at or above 85dB(A) and LCpeak is at or above 137 dB(C), additional actions must be taken. These involve developing a Noise Action Plan to reduce exposure to as low a level as reasonably practicable, providing and enforcing the use of suitable hearing protection, designating and demarcating hearing protection zones, and conducting appropriate health surveillance.

10 Steps for developing and comprehensive noise control action plan

Creating a noise control action plan is crucial for minimizing the risks associated with excessive noise exposure in the workplace. Here are some key points to consider:
 
1. Risk Assessment: Conduct an in-depth risk assessment to identify sources of noise, workers exposed to these sources, and times during which exposure is likely to occur. This should be done with the help of qualified professionals and must take into consideration both the level of noise and the duration of exposure.
 
2. Noise Monitoring: Regularly monitor noise levels in different areas of the workplace, particularly those identified as high-risk areas during the risk assessment. The monitoring should be carried out by trained personnel using calibrated equipment.
 
3. Engineering Controls: Explore possibilities of implementing engineering controls to reduce noise at the source. This can include modifications to machinery, using noise-absorbing materials around the source, or changes in the work process to reduce noise generation.
 
4. Administrative Controls: Consider administrative controls such as rotating workers among different jobs to limit individual exposure time, scheduling noisy tasks for times when fewer people are present, and establishing quiet zones where noise levels are kept below certain limits.
 
5. PPE Provision and Use: Provide appropriate personal protective equipment (PPE) such as earmuffs or earplugs, and enforce their usage in designated areas or during specific tasks. Regular training on the correct use of PPE is also critical.
 
6. Training and Awareness: Regularly train workers on the risks associated with noise exposure, the importance of using PPE, and other preventive measures. Encourage reporting of issues related to noise exposure and maintain open communication channels for this purpose.
 
7. Health Surveillance: Implement a regular health surveillance program to identify early signs of hearing damage. This can include audiometric testing and regular check-ups.
 
8. Noise Action Plan Review: Regularly review and update the noise control action plan to ensure it remains effective. This should be done at least every two years, or whenever there are significant changes to work processes or equipment.
 
9. Documentation: Keep detailed records of risk assessments, noise measurements, actions taken to reduce noise exposure, PPE provided, and health surveillance results. This is important not only for regulatory compliance but also for reviewing the effectiveness of control measures and planning future actions.
 
10. Consultation: Involve workers and their representatives in the decision-making process. They can provide valuable insights into practical aspects of noise exposure and control measures.
 
Remember, the key objective of a noise control action plan is to reduce noise exposure to a level that's as low as reasonably practicable, and to comply with the regulations laid out by the appropriate regulatory body.

Value Delivered

In this project, we have delivered significant value to our client by providing a comprehensive evaluation of the noise exposure in their workshop. We have identified areas where noise levels exceed regulatory action values, thereby posing potential risks to employee health. Based on these findings, we have also provided detailed recommendations on how to control and manage these risks effectively. This includes mandatory monitoring requirements, necessary compliance under the Control of Noise at Work Regulations (CoNAW) 2005, and the development of a comprehensive Noise Action Plan. Additionally, we have recommended regular health surveillance and provided insights on how to implement it. As a result of our work, the client is now empowered to create a safer, more compliant working environment, protect their employees from potential hearing damage, and reduce the risk of future liabilities and penalties.