Case Study:
BEL Engineering
HAVS Management
Strengthening HAVS Management Within a Highly Regulated Engineering Environment
BEL Engineering operates as a project-managed CNC machining business, working across multiple regulated sectors including nuclear, defence, aerospace, oil and gas. With two sites in the North East at St Peters in Newcastle and Cramlington, the business supports a wide variety of customers and component types, each with its own demands on precision, traceability and compliance.
While hand arm vibration exposure is not a dominant risk across the business as a whole, it is a known factor within specific finishing and deburring operations. These tasks typically involve short but repeated use of hand-held tools such as grinders, sanders and polishers. They are often carried out by a small number of experienced operators. Although exposure durations are measured in minutes rather than hours, BEL recognised that even repeated low-level exposure warranted careful management, particularly where individuals had raised concerns around hand comfort and fatigue.
Prior to introducing HAVSense, BEL relied on a paper-based monitoring process supported by annual independent tool testing. Each tool was tested, documented and communicated to operators, with exposure logged manually during use. While the system was well intentioned and compliant in principle, it placed a heavy administrative burden on supervisors and relied on handwritten records that could vary in clarity and consistency. Follow up actions were sometimes delayed simply because reviewing and interpreting the paperwork took time.
The decision to introduce HAVSense was not driven by a desire to replace independent testing or reduce oversight, but to add real time exposure visibility alongside existing controls. BEL wanted to understand how tools were being used between service intervals and how operator technique and task variation influenced exposure on the shop floor. In one instance, HAVSco data highlighted that a newly purchased palm sander was producing higher vibration exposure than the older model it replaced. This would not have been apparent through periodic testing alone.
Following delivery, the HAVSense system was fully integrated within two to three weeks without requiring changes to BEL’s wider health and safety processes. Tools within the finishing area were identified and labelled to allow meaningful comparison. Operators were introduced to the system as part of normal work rather than as a separate monitoring exercise. Where one operator found prolonged wear uncomfortable, the dosimeter was mounted directly to the tool using a strap. This allowed monitoring to continue without disruption.
From a management perspective, the most significant change has been confidence in the data. Instead of relying solely on annual test results and estimated exposure, supervisors can now review tangible, task-specific information. Monthly reviews allow operators to see their own exposure levels. Where something appears unusual, additional investigation can take place immediately. This has made conversations on the shop floor clearer and more constructive, with data used as a shared reference point rather than an abstract calculation.
Over seven months of monitoring, exposure levels have remained well controlled, with recorded peaks reaching 28 to 30 points. While these figures have not raised compliance concerns, they have reinforced the value of ongoing visibility and operator involvement. Rather than feeling monitored in isolation, operators have engaged with the process and gained a better understanding of how their own working methods influence exposure.
HAVSense now sits alongside BEL’s independent testing, servicing and repair regime as part of a layered approach to HAV management. Together, these systems provide both assurance and accountability, supporting internal decision making and strengthening BEL’s ability to demonstrate good practice within highly scrutinised industries.
Reflecting on the change, BEL described the system as giving operators greater confidence in the tools they use and in how workforce exposure is being managed. By combining real time data with established testing processes, HAV management has become more robust, more transparent and easier to record without increasing administrative load.
“It has given the guys greater confidence in using the tools and knowing that they are being tested. Not just the tools, but also how they are being used. They understand their exposure levels and feel involved in the process, which makes a real difference on the shop floor.”
Michael Fenton, HS&E Manager – BEL Engineering
Before HAVSense |
After HAVSense |
| Paper based exposure logs and handwritten records | Automated capture of task specific exposure data |
| Exposure assessments reliant on estimates and judgement | Real time visibility of vibration exposure |
| Annual independent tool testing only | Ongoing monitoring alongside independent testing |
| Time consuming administration for supervisors | Significantly reduced daily administrative effort |
| Limited visibility between service intervals | Clear insight into tool performance over time |
| Difficult to share exposure data with operators | Exposure data used as a shared reference on the shop floor |
| Follow up actions sometimes delayed | Faster, evidence-based decisions when review is needed |
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