Project Overview:
Darren led a comprehensive vibration study for a high-precision manufacturing facility experiencing unexplained performance issues. Using sensors, a laptop, a DAQ card, and FFT spectrum analysis software, he identified and resolved critical vibration sources that were affecting both facility infrastructure and equipment operation.

Scope of Work:

1. Problem Identification:
   The facility’s engineers reported inconsistent performance in key production equipment and a higher-than-normal defect rate during metrology checks.
2. Field Survey:
   Darren performed an on-site vibration survey using precision sensors placed across critical locations (machinery bases, foundation points, and surrounding infrastructure).
   • Tools Used:
     • FFT spectrum analysis software for frequency diagnostics.
     • DAQ (Data Acquisition) card for accurate, real-time data capture.
     • Portable setup with a laptop and sensors to enable rapid deployment.
3. Data Analysis:
   Using FFT analysis, Darren isolated several vibration sources:
   • Harmonic vibrations caused by nearby HVAC systems.
   • Ground vibrations transmitted from truck traffic outside the facility.
   • Minor resonances from improperly mounted equipment.
4. Recommendations & Implementation:
   • Suggested passive isolation platforms for metrology tools to improve measurement consistency.
   • Recommended adjustments to equipment mounting to eliminate internal resonance.
   • Collaborated with the facility’s engineering team to reschedule heavy truck operations during off-peak hours.
5. Outcome:
   • Defect rates during metrology checks reduced by 30%.
   • Production output increased by 10% due to fewer operational disruptions.
   • The vibration study provided the foundation for long-term improvements in facility layout and machine maintenance schedules.