The challenge: Finding the right hearing protection for individual workers

In aircraft maintenance, teams work in loud, complex environments where hearing protection is critical. At Lufthansa technical fleet management, standard hearing protection wasn’t cutting it. Crews reported issues ranging from earplugs not fitting properly to overly strong hearing protection that blocked out sounds needed on the job.

This left the team with two important challenges:

1. Fit: Standard one-size-fits-all plugs didn’t work for everyone, especially employees with smaller ear canals who struggled to get a secure seal.
2. Protection level: High-NRR earplugs (>30 dB) were often mismatched to the actual environment. In moderate noise areas (80–95 dB), they made communication and signal recognition difficult. In quieter areas (<80 dB), employees had no suitable option at all.

The solution: A personalized approach with xact Fit™

Instead of selecting hearing protection based on compliance alone, Lufthansa chose to start with the needs of its employees. By assessing real-world fit and protection levels, the safety team was able to make meaningful changes to their program using the HexArmor® xact Fit™ test.

The xact Fit™ test shows exactly how much protection an employee is receiving from their hearing protectors, regardless of the brand or model, and provides real-time feedback on how earplug fit impacts performance. This not only helped employees choose the right size and protection level, but also educated them on the importance of proper use. Here's how:

• Better fit for every employee: The xact Fit™ highlighted the need for earplugs available in multiple sizes, allowing employees to finally achieve a comfortable, secure seal—even those with small ear canals. We recommended the ergonomic design of simpleFit® disposable earplugs with left and right paddles, which made insertion easier, even while wearing gloves.
• Protection matched to the environment: The simpleFit® range allowed employees to use earplugs with noise reduction levels appropriate to their actual work setting. By switching to simpleFit® disposable earplugs, overprotection was reduced, communication was improved, and workers in quieter zones gained access to suitable options.

With Bluetooth-enabled headphones and a fully portable tablet, this system lets you conduct hearing fit tests anywhere on site with no wires, no fixed stations, and no hassle. Pre-installed software and automatic data uploads make setup fast, simple, and more efficient than competing systems.

The results: Confidence and compliance

By taking a personalized approach to hearing protection, Lufthansa gave employees solutions they could rely on with protection that fit properly, matched their environment, and didn’t interfere with communication. Workers reported greater levels of comfort while wearing our simpleFit® earplugs, which led to more consistent use and compliance across the team.

With overprotection reduced, crews could stay connected and aware of important signals while still safeguarding their long-term hearing health. Hearing protection isn’t just about checking a compliance box; it’s about safeguarding one of our most vital senses. With the right approach and the right tools, Lufthansa’s crews can now do their jobs with greater comfort, confidence, and long-term protection.

See the xact Fit™ hearing protection system