uvex solves overprotection problem for leading aerospace manufacturer

A leading manufacturer of aircraft equipment, including landing gear, wheels, brakes, and wiring, was experiencing ongoing challenges with hearing protection compliance across its UK site.

Employees reported that existing earplugs from another leading earplug manufacturer were uncomfortable and provided excessive attenuation, while the Health and Safety Manager identified additional problems with fit and sizing. This impacted compliance and increased PPE waste.

Through distribution partner Rubix, uvex was invited to take part in a site-wide safety day to address these issues and provide practical, sustainable solutions.

The site operates a mix of manufacturing and assembly environments, with measured noise levels ranging from 85 to 90 decibels in production areas. Around 60 office-based staff also require intermittent hearing protection when entering the shop floor.

Key challenges included:

• Overprotection and discomfort from existing foam plugs.
• Poor compliance due to one-size products and poor fit.
• The need for tailored protection across different noise zones.
• Intermittent noise exposure for some roles.
• A desire to reduce waste and improve sustainability.

uvex reviewed the site’s noise survey to map appropriate attenuation levels to each work area. During the safety day, uvex presented to more than 300 employees, including the nightshift, on correct fitting, maintenance, and the basics of ear anatomy to build understanding of why proper protection matters.

A tailored trial was set up for around 100 employees using:

• uvex hi-com – disposable plugs for general use.
• uvex xact-fit – reusable plugs in two sizes for improved comfort and fit, ideal for both production and intermittent-use office staff.
• uvex whisper – reusable plugs for lower attenuation needs.
• Earmuffs – for high-noise processes.

The uvex xact-fit plugs, with a lifespan of three to four weeks, offered a comfortable, consistent fit while reducing the volume of disposables used. Feedback from the trial was unanimous with 100% of participants reporting improved comfort, better fit, and protection levels more suited to the task.

To maintain compliance and control usage, the company introduced a vending system that dispenses only the correct hearing protection for each employee’s designated area.

• Improved compliance: 100% positive feedback on comfort, fit, and protection levels.
• Cost savings: Reusable plugs reduced consumption and savings of £8,000 on the company’s PPE spend.
• Sustainability gains: Significant reduction in disposable waste and improved site cleanliness.
• Workforce education: Over 500 employees, comprising technical and office functions, were trained on hearing protection and ear health.

The success of the hearing protection programme led to a footwear trial for 15 female employees, testing the uvex 1 x-cite range which was chosen for its comfort, style, and suitability for both office and shop floor environments. The trial was co-funded by uvex and the company, with plans to potentially roll it out to a further 60 employees.

By matching protection to noise levels, improving fit, and delivering education, uvex significantly improved hearing protection compliance and comfort across a complex aerospace site. The programme also supported sustainability objectives and opened the door to wider PPE improvements, demonstrating the benefits of a targeted, collaborative approach to safety equipment.