Workers Only Complain During Production How to Find the Cause Malaysia

Workers Only Complain During Production How to Find the Cause Malaysia The factory seems normal before production starts. Then the machines begin operating. Workers start saying: “There is a smell.” “The area becomes dusty.” “It gets very hot.” “The noise becomes unbearable.” “The air feels stuffy.” “My eyes feel uncomfortable near this process.” After production stops, the complaint reduces or disappears. This is an important clue. Instead of asking: “Which environmental meter should we buy?” ask: What changes when production starts? The process itself may be creating or changing: Dust → Gas / Vapour → Heat → Noise → Airflow → Ventilation Demand → Machine Condition A very effective troubleshooting method is therefore: Production OFF → Establish Baseline → Production ON → Measure Change → Locate Source → Correct → Measure Again 1. The Timing Is Already Telling You Something If workers complain: Only during production then production activity becomes a major investigation lead. Ask: Which machine starts? Which material is processed? Which chemicals are used? Does heating begin? Does grinding or cutting begin? Does extraction start automatically? Does forklift activity increase? Does the number of workers increase? Does the complaint begin immediately or after several hours? Timing can narrow the problem dramatically. 2. Don't Measure Only When Production Is Stopped This is a common mistake. A technician visits during lunch. Production is stopped. Measurements look normal. The conclusion becomes: “No problem found.” But workers complain during full production. The measurement condition must represent the actual problem. 3. Establish a Production-OFF Baseline Before the process begins, record appropriate conditions. Depending on the complaint, this may include: PM VOC Relevant Gas Temperature Humidity Noise Air Velocity The purpose is not to measure everything. Measure what is relevant to the complaint. 4. Repeat During Production Then repeat comparable measurements when the process is operating. Now the factory can ask: What changed? For example: PM increased VOC increased Temperature increased Noise increased Airflow decreased That gives the investigation direction. 5. Dust Appears When Machine Starts Suppose workers say: “Every time this machine starts, the area becomes dusty.” Possible pathway: PM Screening Where Appropriate ↓ Compare Machine OFF / ON ↓ Measure Near Source ↓ Measure Worker Position ↓ Check Extraction Airflow ↓ Investigate Hood / Filter / Duct ↓ Correct ↓ Measure Again The problem is not simply: “We need a PM meter.” The real problem is: Why isn't the dust being controlled? 6. Chemical Smell Appears During Production Suppose workers say: “There is no smell before production. Once coating starts, the smell appears.” Ask: Which chemical is used? Can the SDS be reviewed? Was the chemical recently changed? Has production volume increased? The measurement may involve appropriate: VOC or: Specific Gas / Vapour depending on the process and identified substance. 7. Check Local Exhaust at the Same Time If the process generates vapour, fumes or dust, ventilation performance may be critical. Measure appropriate air velocity at relevant: Hood Extraction Point Duct Exhaust The key question becomes: Does extraction performance match the production condition? 8. Extraction Can Be Running but Still Be Inadequate Production starts. The exhaust fan also starts. Workers still complain. Possible reasons include: Insufficient airflow Dirty filter Blocked duct Hood too far from source Increased production load Changed machine layout Poor make-up air Therefore: Extraction ON does not automatically mean: Contaminant Controlled 9. Factory Becomes Hot Only During Production Machines generate heat. Motors generate heat. Ovens generate heat. Compressors generate heat. Processes may release steam or hot air. If the factory is comfortable before production but hot during operation, compare: Temperature / Humidity Before versus During Production Then investigate appropriate: WBGT Air Velocity Heat Source depending on the problem. 10. Noise Appears Only When Certain Equipment Runs Suppose: Normal production = acceptable but: Machine No. 5 starts = noise complaint Now the investigation becomes much easier. Compare appropriate: Machine OFF versus Machine ON and: Near Machine versus Worker Position A sound level meter can help quantify the change. 11. Abnormal Noise May Also Indicate Machine Condition If the machine suddenly became noisier than before, do not stop with sound measurement. Consider whether maintenance should investigate appropriate: Vibration Temperature RPM and equipment condition. Now Environmental / Safety connects directly with Predictive Maintenance. 12. Workers Feel Stuffy Only During Full Production This may happen because: More workers are present Ventilation demand increases Heat load increases Process emissions increase Doors are closed Air-conditioning cannot keep up Extraction affects room air balance Appropriate measurements may include: CO Temperature Humidity Air Velocity depending on the workplace. 13. Look for Delayed Problems Not every problem starts immediately. Example: 8:00 AM Production starts 10:00 AM Conditions still acceptable 1:00 PM Workers begin complaining 3:00 PM Complaint becomes severe This suggests accumulation or changing environmental conditions. A spot measurement may miss this. 14. Data Logging Can Reveal Accumulation Where supported parameters are suitable for logging, continuous measurements can help identify: Start ↓ Rise ↓ Peak ↓ Recovery This is particularly useful for conditions that change over the shift. 15. Compare Production Load “Production ON” may still be too broad. Try comparing: No Production ↓ One Line Running ↓ Several Lines Running ↓ Full Production This may show whether the environmental problem scales with production load. 16. Example: One Machine Creates the Dust Complaint Factory: “Workers complain only when Machine 3 operates.” Possible investigation: PM Screening ↓ Machine 3 OFF / ON Comparison ↓ Source vs Worker Position ↓ Extraction Air Velocity ↓ Filter / Duct Investigation ↓ Corrective Action ↓ Repeat Measurement Now the source has been narrowed dramatically. 17. Example: Painting Process Creates Strong Smell Factory: “The room is fine until painting starts.” Possible pathway: Identify Coating / Solvent ↓ Review SDS ↓ Determine Appropriate Vapour / VOC Measurement ↓ Compare Process OFF / ON ↓ Check Local Exhaust ↓ Check Adjacent Worker Area ↓ Correct ↓ Measure Again This is a process-based environmental investigation. 18. Example: Full Production Makes the Factory Too Hot Customer: “With two lines running it is okay. With all six lines running, workers complain about heat.” Possible pathway: Temperature / Humidity ↓ Compare Production Load ↓ WBGT Where Appropriate ↓ Air Velocity ↓ Identify Major Heat Sources ↓ Ventilation Investigation ↓ Corrective Action ↓ Re-Test at Full Production The final verification must reproduce the problem condition. 19. Example: Compressor Creates Noise Complaint Customer: “Workers complain only when Compressor B runs.” Possible pathway: Sound Measurement ↓ Compare Compressor A / B ↓ Vibration Measurement ↓ Temperature ↓ Maintenance Investigation ↓ Corrective Action ↓ Measure Again One complaint can now serve both: Safety and: Machine Reliability 20. Example: Workers Feel Bad Only Near One Production Process Do not immediately conclude: “The whole factory has poor air quality.” Map the complaint: At Source ↓ Operator Position ↓ Nearby Worker ↓ Adjacent Department ↓ Reference Area Then measure the parameters relevant to that process. This helps identify whether the problem is: Localized or: Factory-Wide 21. Ask Whether the Process Recently Changed Even if the machine is old, ask: New raw material? New chemical supplier? Higher production speed? Longer operating hours? New tool? New temperature setting? New product? A process change may explain a new environmental complaint. 22. Ask Whether the Ventilation Recently Changed Likewise: New partition? Moved machine? Added rack? Changed exhaust duct? Filter replacement? Closed door? New production line? Factory airflow can change even when the fan itself has not changed. 23. Don't Forget Instrument Verification Suppose previous measurements were normal. Now a meter suddenly shows a much higher value. Before concluding: “Production has become dangerous.” or: “The meter is broken.” investigate both possibilities. Where appropriate: Repeat Measurement ↓ Check Instrument Condition ↓ Compare With Suitable Reference / Second Instrument ↓ Review Calibration / Sensor Condition This creates another link to MTM service. 24. Corrective Action Is Not the End Suppose the factory: Changes filter Repairs exhaust Moves hood Installs fan Services machine Changes process The next step should be: Measure Again Under Full Production. Otherwise, the factory does not know whether the original problem has actually been solved. 25. Keep the New Baseline After successful improvement, record the normal operating condition. For example: Normal PM Normal Air Velocity Normal Temperature Normal Noise depending on the process. Next time workers complain, the factory has something to compare against. What Instruments Might Be Needed? Depending on what changes during production, a solution may include: PM2.5 / PM10 Meter For suitable particulate screening. VOC Meter For appropriate VOC screening. Specific Gas / Multi-Gas Detector Where identified atmospheric hazards require measurement. Temperature & Humidity Meter For environmental measurements. WBGT Meter For appropriate heat-stress investigation. Sound Level Meter For area and process-noise measurements. Vibration Meter Where abnormal machine condition may be contributing to the complaint. Anemometer For ventilation and extraction troubleshooting. Differential Pressure Meter For appropriate filter / pressure investigations. Data Logger For supported parameters that change over the production cycle. The solution follows: The symptom. Not the catalogue. Don't Search Only for “Factory Environmental Meter” If workers complain only during production, ask: Which process starts? Which machine runs? Which material is used? Which chemical is introduced? What becomes hotter? What becomes noisier? Does dust appear? Does extraction performance change? The production process is giving you clues. From Production Complaint to Measurement Solution The better pathway is: Workers Complain ↓ Confirm It Happens During Production ↓ Identify Machine / Process ↓ Establish Production-OFF Baseline ↓ Measure During Production ↓ Identify What Changes ↓ Locate Source ↓ Check Ventilation / Machine Condition ↓ Correct ↓ Re-Test Under Full Production ↓ Keep Baseline This is how environmental monitoring becomes troubleshooting. One Production Complaint Can Connect the Whole MTM Portfolio Environmental PM → VOC → Temperature → Humidity Safety Gas → Noise → Heat Stress Facility Airflow → Differential Pressure → Ventilation Predictive Maintenance Vibration → Temperature → RPM Service Instrument Verification → Calibration This is exactly the position MTM wants: Not: “We have many instruments.” But: “Tell us what changes when production starts.” From there, MTM can help determine what needs to be measured. Factory Production Environmental & Safety Troubleshooting Solutions Malaysia MTM Precision supports: Manufacturing plants Production departments EHS teams Safety officers Maintenance departments Facility managers QA/QC teams Warehouses Industrial contractors with measurement solutions covering: Dust VOC Gas Temperature Humidity Heat Stress Noise Vibration Airflow Differential Pressure Data Logging Calibration & Verification Workers Only Complain When Production Starts? Don't start by buying another meter. Tell MTM: Which machine is running? Which process starts? What material or chemical is being used? What exactly do workers experience? How long after production starts does it happen? Is extraction or ventilation installed? Did anything recently change? MTM can help build the measurement pathway around the actual production problem. MTM Precision Sdn Bhd Showroom & Service Centre No. 29-1 & 29-2, Jalan Bandar 18, Pusat Bandar Puchong, 47160 Puchong, Selangor, Malaysia WhatsApp: +6016-660 7346 Email: mtmpre@yahoo.com Website: www.mtmpre.com.my Production OFF → Baseline. Production ON → Find what changes. Don't start with the instrument. Start with the process.