Shaking off vibrations: enhancing operator safety with ergonomic industrial tools

Vibration-induced injuries are some of the most common yet preventable occupational injuries. However once manifested they can become permanent and irreversable. In Sweden, 30% of declared workplace injuries are attributed to vibrations, and the figure is likely to be higher. 

Vibration injuries can be categorized into three main types:

• Vascular Disorders: These include conditions such as hand-arm vibration syndrome (HAVS), which can lead to blanching of fingers and decreased blood circulation.
• Nerve Injuries: Prolonged exposure to vibrations can cause nerve damage, resulting in numbness, tingling, and loss of dexterity.
• Musculoskeletal Disorders: These involve damage to muscles, joints, and tendons, leading to chronic pain and reduced mobility.

Further these injuries have an economic impact on production. The cost of vibration induced injuries is substantial. Companies in Sweden and the UK have estimated that a single vibration injury can cost approximately €50,000. This figure includes costs related to decreased productivity, hiring and training new operators, and finding alternative tasks for injured workers. Poor ergonomics and vibrations significantly impact overall production quality, with the risk of quality issues tripling when ergonomic standards are not met.

To manage vibration exposure, employers within the European Union are mandated to use two critical metrics: action value and limit value, with both in reference to 8 hours of trigger time. The action value—2.5 m/s², is a threshold that, once reached, necessitates the implementation of measures by the employer to reduce vibration exposure.

The limit value—5m/s², represents the maximum allowable vibration exposure for operators that cannot be surpassed under any circumstance. However, the vibration levels measured in real workplace conditions often differ from those declared by manufacturers. This discrepancy arises from factors such as the quality of inserted tools and the operator's skill level. Real-time exposure, or "in-use" vibration, reflects the actual conditions experienced by workers, emphasizing the need for consistent, accurate monitoring and tailored interventions. Check out our matrix to get an accurate outlook on how long tools experiencing varying vibration levels can operate.

These vibrations in industrial tools stem from various sources and are categorized into internal and process forces depending on their origin. Internal forces are independent of the work process and include imbalances within rotating machine parts or inserted tools. For example, our pulse assembly tools utilize technology to convert reaction forces into vibrations. Process forces, on the other hand, arise from the interaction between the tool and the workpiece, such as the contact between a grinding wheel and the material being worked on.

By neglecting the importance of vibrations in your manufacturing processes, you are likely sacrificing several critical aspects that you would otherwise strive to preserve. This oversight can inadvertently harm your operations. One of the key trade-offs is the health and safety of your operators. Ignoring vibrations poses a silent threat, gradually reducing their efficiency. Imbalanced internal and process forces can cause vibrations, leading to imprecise and unplanned actions. This not only affects operator performance but also impacts overall operational efficiency. Additionally, vibrations compromise quality control and introduce inconsistencies, resulting in variations that undermine precision and reliability in production. Therefore, addressing vibrations is crucial for maintaining high standards in both operator well-being and production quality.

Should you accept vibrations as an inevitable aspect of production? Absolutely not. There are numerous strategies available to mitigate and control vibration exposure.

Firstly, adopting a long-term perspective when selecting tools is essential. Tools should not only be viewed as instruments for completing tasks but also as investments in operator well-being. This means proactively considering ergonomics and the effects of vibrations. High-performing, durable tools can enhance longevity of tools and reduce disruptions in your production lines, fostering overall more sustainable operations.

Begin by conducting a vibration exposure assessment to pinpoint areas that are at low and high risk. Head over to our pocketguide to learn how to carry out this assessment. Our calculator can assist you in this process, providing an estimate of the vibration levels your operators may encounter.

Since vibrations are primarily experienced in hand-held tools, both operators and employers must take extra steps to reduce vibration exposure. Employers could select processes and tools with lower declared vibration values and ensure the use of quality consumables such as a sharp drill bit over a worn one. Thus, understanding the task at hand and choosing an appropriate tool is vital. Today, most tools are available in versions with lower vibrations, which can significantly reduce exposure when suitable. However, it is important to ensure these tools maintain equal or better performance to avoid longer exposure times that negate the benefits of reduced vibration levels. Employers can also plan job rotation to distribute vibration-intensive tasks among more operators. Lastly, selecting tools with good ergonomic design can reduce operator fatigue, lessen the impact of vibrations, and enhance productivity.

For more detailed information on these mitigation strategies read our article on vibration injuries.

Since the 1970s, Atlas Copco has been at the forefront of efforts to reduce vibrations in industrial tools. Integrating innovations such as springs, autobalancers, differential pistons, and oil pulse technologies to dampen vibrations. By prioritizing ergonomics and tool performance equally, Atlas Copco continues to lead the industry in setting new standards for vibration control.

Atlas Copco builds upon three principles when designing tools, to ensure least vibration exposure for your operators:

1. Control the Magnitude of Vibrations: Implement tools and technologies that minimize vibration levels.

2. Make Tools Less Sensitive: Design tools to be less responsive to external vibrations.

3. Isolate Vibrations from Grip Surfaces: Use materials and designs that dampen vibrations before they reach the operator's hands.

Looking ahead, the industry is moving towards establishing new standards for high-frequency vibrations. The International Organization for Standardization and the European Committee for Standardization are collaborating with private companies such as Atlas Copco to set these benchmarks. This new approach to measuring high-frequency vibrations will present a relative scale rather than fixed values, and is expected to be implemented by 2027, further refining vibration assessment and management.

Controlling vibrations in industrial tools is crucial for protecting worker health, ensuring safety, and maintaining operational efficiency. By investing in ergonomic designs and advanced technologies, you can reduce the adverse effects of vibrations, leading to a safer and more productive work environment. Bear in mind—2.5 m/s² to safeguard operator well-being and maintain uninterrupted, quality production.