A Step-by-Step Guide to Preventing Hearing Damage in Manufacturing

Manufacturing facilities are loud, and the most common culprit is the machinery itself.

By: Doug Backinger, Contributor

The absorption system on these patented CasterShox® Casters minimize and even eliminates vibration that causes cart noise. Image courtesy of Caster Concepts.

Hearing loss is a pervasive problem in the workplace, affecting millions of workers annually.

In the U.S., it ranks as the third most common chronic physical health condition among adults, trailing only high blood pressure and arthritis.¹ Across all industries, about 22 million workers are exposed to hazardous noise at work each year.²

The problem is particularly acute in manufacturing facilities, where nearly half of all manufacturing workers have been exposed to hazardous noise.

Fortunately, this is a solvable problem. Here is your step-by-step guide to preventing hearing damage in manufacturing.

1. ASSESS YOUR CURRENT NOISE LEVELS

What gets measured is managed, and manufacturers can’t solve problems they don’t understand.

That’s why protecting employees’ hearing starts with understanding existing volume levels throughout a manufacturing facility.

Noise monitoring technology will determine the decibel levels across a manufacturing facility, allowing leaders to identify problem areas where noise levels exceed OSHA’s allowed exposure limit of 85 decibels over an 8-hour period.³

2. UPGRADE OR MAINTAIN EQUIPMENT

Manufacturing facilities are loud, and the most common culprit is the machinery itself.

Machines, pneumatic systems, conveyor belts, hydraulic presses, and ventilation systems, can create a cacophony of noise that quickly creates an environment hazardous to employees’ hearing.

Upgrading or maintaining equipment can reduce noise pollution from squeaky wheels, rattling panels, and loose fasteners.

When a US-based auto manufacturer planned its new facility, the company prioritized employee safety by addressing workplace noise, creating a quieter and safer environment for its staff.⁴

During their assessment, they identified material handling carts as the primary source of noise in the plant. To tackle this issue, they introduced custom-designed wheel casters, which significantly lowered noise levels, reducing sound by as much as 15 decibels compared to other tested alternatives.

While the cost of noise reduction measures can vary widely between businesses, even simple changes, such as upgrading wheel quality or incorporating sound-dampening materials, can have a significant positive impact on the overall work environment.

3. PROVIDE AND PROMOTE PPE

Distribute advanced PPE, such as noise-canceling earmuffs or molded earplugs, to employees.

At the same time, train workers on how to use their equipment and stress its importance to their health and overall well-being.

In many manufacturing facilities, employees are not using this equipment. The CDC reports that more than a quarter of manufacturing employees say they don’t wear hearing protection.⁵

To effectively protect employees, manufacturers can’t just provide the equipment. They have to promote its use and foster a culture of safety where proper PPE usage is consistently encouraged, monitored, and reinforced.

4. CULTIVATE A SAFETY CULTURE

Manufacturers with a robust safety culture are stronger, more resilient, and more sustainable than their less conscientious counterparts.

According to the MIT Sloan Management Review, businesses that “fully embrace worker safety produce a higher-quality product; have more productive, loyal workers; and, most importantly, experience fewer work injuries.”⁶

Of course, if a robust safety culture was easy to achieve, every company would have one.

Cultivating a safety culture requires management to have a genuine commitment to worker well-being and education, positioning employees to protect their hearing and embrace other safety measures.

Critically, safety culture is taught and caught. When leaders model safety best practices, like wearing hearing protection, they demonstrate the solution’s efficacy and signal its importance.

At the same time, education and preventative measures can go a long way to achieve a safety culture.

For example, conducting regular hearing screenings to detect early signs of hearing damage can protect employees from further damage while reinforcing the importance of preventive measures before hearing damage is done.

5. MONITOR AND ADJUST STRATEGIES

Employees’ hearing health is too important to minimize or mitigate. It’s an urgent and important problem that the manufacturing sector should (and can) improve right now.

However, overnight success isn’t a guarantee. Progress is the goal, not immediate perfection.

To achieve this, regularly review the effectiveness of your noise reduction and hearing protection efforts. Use feedback from employees and data from noise monitoring systems to refine your approach.

PROGRESS WILL MAKE PERFECT

Whether manufacturers want to recruit and retain the best talent, maintain regulatory compliance, or protect their productivity and product quality, preventing hearing damage is part of the equation.

To achieve this, assess noise levels, maintain equipment, provide effective PPE, cultivate a culture of safety, and regularly monitor and adjust progress.

It’s the best way to foster the most productive, sustainable and employee-oriented workplace possible. WMHS

Doug Backinger is Senior VP, Solutions Engineering & Innovation of Caster Concepts. With the ability to integrate a lean Six Sigma methodology combined with his intuitive knowledge of solving material handling challenges, Doug ensures Caster Concepts’ quality products meet the specific needs of a wide range of applications and industries. He was instrumental in leading advanced processes as head of the quality department at Caster Concepts. He also led the team to secure ISO 9001 and AS 9100 certifications for Aerol, the company’s latest acquisition of precision casters and ground support equipment for the military and other industries. www.casterconcepts.com