The team at Georgia-Pacific's Augusta Corrugated facility has set a new standard for safety, earning the Fibre Box Association's 'Innovation in Safety' Achievement Award for creating a groundbreaking tool.
For years, workers encountered serious hazards while checking the gap between the glue roll and the corrugated roll on the single facer, a large machine that forms flutes on liner paper for corrugated board. Though the task may seem simple, the risks were considerable. Employees had to feed material just 4 thousandths of an inch thick into the running machine, forcing them to reach into dangerous areas near the machine's nip point, exposing themselves to extreme heat, pinch points, and potential crushing injuries. Despite the danger, the process had become routine.
"We had become complacent. People said, 'this is how it's always been done,' but that didn’t mean it was the right way," said Daryl Harris, corrugator supervisor.
Recognizing the need for improvement, the Augusta team acted swiftly. Collaborating with maintenance personnel and equipment operators, they developed a solution within just two months. The result was a gap check stand, a tool that significantly improves safety by keeping employees completely away from the machine. It eliminates the dangers of heat, pinch points, and crushing injuries and is securely bolted to the floor to avoid any risk of being pulled into the single facer.
The impact of this innovation has been tremendous. Employees appreciate the tool’s simplicity and effectiveness, and most importantly, it ensures their safety.
"The teamwork and quick problem-solving demonstrated by the Augusta team are remarkable," said Paul Guy, operations manager while adding, "When leadership engages with staff and offers a solution that enhances safety while empowering everyone, it not only improves the work environment but strengthens our overall success. I’m incredibly proud of this collaboration."
For years, workers encountered serious hazards while checking the gap between the glue roll and the corrugated roll on the single facer, a large machine that forms flutes on liner paper for corrugated board. Though the task may seem simple, the risks were considerable. Employees had to feed material just 4 thousandths of an inch thick into the running machine, forcing them to reach into dangerous areas near the machine's nip point, exposing themselves to extreme heat, pinch points, and potential crushing injuries. Despite the danger, the process had become routine.
"We had become complacent. People said, 'this is how it's always been done,' but that didn’t mean it was the right way," said Daryl Harris, corrugator supervisor.
Recognizing the need for improvement, the Augusta team acted swiftly. Collaborating with maintenance personnel and equipment operators, they developed a solution within just two months. The result was a gap check stand, a tool that significantly improves safety by keeping employees completely away from the machine. It eliminates the dangers of heat, pinch points, and crushing injuries and is securely bolted to the floor to avoid any risk of being pulled into the single facer.
The impact of this innovation has been tremendous. Employees appreciate the tool’s simplicity and effectiveness, and most importantly, it ensures their safety.
"The teamwork and quick problem-solving demonstrated by the Augusta team are remarkable," said Paul Guy, operations manager while adding, "When leadership engages with staff and offers a solution that enhances safety while empowering everyone, it not only improves the work environment but strengthens our overall success. I’m incredibly proud of this collaboration."