CASE STUDY-1

Posted on August 31, 2018September 1, 2018 by

STAYING IN THE SAFE ZONE WITH VIBRATION AND SOUND ANALYSIS, MONITORING AND CONTROLLING

(Impact of Vibrations and Sounds in Plant and Machinery)

About Company:

A soft drink manufacturing company employs over 5,000 people in sites, warehouses and offices all over the country. The company Is responsible for manufacturing and distributing a wide range of different drinks products to customers throughout the country and some neighbor countries also. The following measurements were taken at the Mysore road facility in Bangalore.

Soft Drink MAnufacturing process — Soft Drink Manufacturing

The regional service station is the largest warehouse in the Manufacturing network. It occupies 2, 50,000sq.ft holds over 100 different products.

Problem:

The company has the following concerns:

The maintenance manager has the following concerns:

The excess vibration of some machines.
Employee’s health issues associated with the vibration and sound.
Level of vibration in the plant will affect the quality of the product.
Overall Vibration level should be according to the standards.

Control of vibration at work regulations (2005)

Table of exposure limits according to Government Regulations


	Daily exposure Average	Daily exposure limit
Hand arm vibration	2.5m/s²	5 m/s²
Whole body vibration	0.5m/s²	1.15 m/s²

Control of noise at work regulations (2005)


	Average level of exposure dB (A)	Peak level of exposure dB(C)
Lower exposure limit	80	135
Upper exposure limit	85	137
Exposure limit value	87	140

.The regulations are designed to prevent the health risks associated with employees exposure to vibration and noise in the workplace, like back pain & hearing loss respectively.

Solution:

The company wanted to measure the vibration and noise frequencies on site using advanced portable devices like Digital vibration Analyzer and Sound level meter and Analyzer for frequency measurement and analysis to know the levels at the site boundary.

The obtained data was further analyzed in vibration analysis PC software and compared with the limit values defined in the regulations.

The values are as follows:

Vibration:


Hand arm vibration	5.2m/s² >5m/s² (daily exposure limit)
Whole body vibration	1.28m/s²>1.15m/s²(daily exposure limit)

Sound:


Lower exposure Limit	90 dB (More than Average level of exposure)
Upper exposure Limit	97 dB (More than Average level of exposure)
Exposure Limit value	92 dB (More than Average level of exposure)

Vibration Measurement in SV Vibration Analyzer

Octave Analysis in SV Vibration Analyzer

Sound/Noise Analysis in SV Vibration Analyzer

The Quality manager analyzed the data and suggested the staff to implement few changes in the machinery according to the Analysis

Following the vibration and noise measurements, The Company has issued new hearing protecting systems and also replaced some equipment and accessories.

A few weeks later, the company repeated the same measurement with the Vibration and Sound meter. The results showed the reduced and balanced level of vibration and sound on site after changing the new equipment and implementing protection.

Vibration:


Hand arm vibration	3.5m/s² <5m/s² (daily exposure limit)
Whole body vibration	0.95m/s²<1.15m/s²(daily exposure limit)

Sound:


Lower exposure Limit	71 dB (Near to Average level of exposure)
Upper exposure Limit	74 dB (Near to Average level of exposure)
Exposure Limit value	76 dB (Near to Average level of exposure)

The company was pleased with the results of the devices

Outcome/Benefits:


Financial loss/benefits
Daily Production = 100 tons
Price/ton= 1 million ₹(10Lakhs) i.e. 100 tons= 100 million₹ (10 crore)
Resource loss/benefits
Machinery replacement cost =5-10 lakh ₹ * Maintenance persons wages = 1 lakh₹ * Cost of time delay and order losses =2-5 lakh₹ * All these losses will be avoided if the vibration and sound levels are in control according to the standards .Regular monitoring is necessary to avoid this.

In the above table *=Approximate

From the above table, we can predict how much loss the company would have faced if the sounds and vibrations are not monitored at regular basis; it will cost both the financial and resource loss to the company.

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