Innovation in Safety

Georgia-Pacific, Martinsville, VA 
The double backer section of a corrugator requires annual belt changes, posing significant safety risks due to suspended loads and elevated work surfaces. A revolutionary threader/winder machine was designed to address this, drastically improving safety and efficiency. This innovative solution reduces belt change time by 75%, labor hours by 92%, and eliminates employee contact with the running machine, enhancing safety exponentially. After a decade of development, the threader/winder was successfully installed in 2023, significantly improving operational efficiencies and safety standards.

Georgia-Pacific, Augusta, GA 
Checking the gap between the corrugator and glue roll on the MHI 50C single facer poses various risks, including thermal hazards and pinch points. An innovative solution was developed to allow operators to perform the gap check safely from outside the machine, eliminating exposure to potential injuries. The solution involved thorough problem analysis and collaboration to design and test a prototype. By implementing this tool, the plant significantly reduced high potential conditions associated with the gap check task, enhancing safety and operational efficiency.

WestRock - Town Mt Royal Plant 
The plant implemented a threading assist device for their corrugator's hotplate section, reducing the risk of thermal hazards and nip point injuries during threading. Working with an outside manufacturer and engineering company, the device underwent a thorough design process, including risk analysis and stakeholder discussions. Trials and adjustments were made to ensure proper functionality, leading to installing guarding and interlocked switches for safety. This Innovation has significantly improved safety by eliminating exposure to potential injuries associated with the previous manual threading method. 

Georgia-Pacific, Batavia, NY 
Employees can access powered conveyor systems throughout the facility without E-stop. After a near-miss incident, a light curtain system was engineered and installed to halt conveyor movement when breached automatically. Using Banner Engineering light curtains mounted on custom-built steel posts, the system is robust. It requires a manual reset, enhancing safety by eliminating human error and associated risks like slip hazards and pinch points. This proactive safety measure demonstrates a commitment to employee well-being and engagement.

Georgia-Pacific, Spartanburg, SC 
Addressed safety concerns in T-Car aisles by installing pause stations at pedestrian entry points, allowing smooth T-Car stops while in manual or automatic. Indicator lights signal pedestrian entry status, enhancing visibility and safety. Despite initial challenges in re-training employees and visitor comprehension, the initiative has heightened operator and pedestrian awareness and reduced T-Car stops due to pedestrian traffic. While statistical data on the effectiveness of the new protocol is not available, it has allowed for more engagement and conversation around employee safety.

Georgia-Pacific, Albion, MI 
The ElephantWall Topple Barrier System is a robust, load-rated wall designed to prevent paper rolls weighing up to 9,500 pounds from falling onto pedestrians or equipment. It features an integrated pedestrian walkway to address space constraints and ensure safe passage. Developed in collaboration with Miner Corp., it has significantly reduced risk in the roll room, inspiring similar safety measures in other facilities and fostering a solid partnership for ongoing safety improvements.

Greif, Inc., Massillon, OH 
Enhanced safety by adding extra lighting to their Yard and Fleet trucks, improving visibility for drivers during nighttime operations. This helps their team members identify potential hazards when entering or exiting the vehicle, ensuring safer working conditions.

Greif, Inc., Mason, MI 
They installed a Keyence distance sensor with a digital display and power converter on their clamp truck. This system alerts operators when they have reached a predetermined distance from the stacked roll stock, preventing premature lowering and potential damage and promoting production efficiency and safety by ensuring roll securement.

Royal Containers, Brampton, Ontario 
Royal Containers of Brampton, ON, developed a pioneering box hopper prefeeder robot, the first of its kind, to enhance the efficiency and safety of our high-speed folder-gluer operations. This innovative system addresses significant ergonomic hazards by eliminating the need for manual lifting of 7,000 to 9,000 pounds of cartons per hour, thus preventing repetitive strain injuries and allowing operators to be reassigned to other tasks. The robot mitigates mechanical hazards by operating within a fully fenced cell equipped with safety curtains and interlocks, ensuring operator safety from moving parts of the robotic arm. The development took 18 months and involved sophisticated adaptations, mainly designing a splitter assembly to handle heavy stacks without damage, ensuring high-quality standards. The robot has increased throughput from 13,500 to 15,000 cartons, reducing human error with a fault detection system that prevents jams, maintains consistent production speeds, and enhances overall efficiency.

Westrock, Milton, ON 
In Ontario, Canada, Musculoskeletal Disorders (MSDs) account for over 40% of lost-time compensation claims, prompting a proactive approach in Milton to address ergonomic risks. 

The Ergonomic Program focuses on assessing existing ergonomic hazards within our facility, educating and mindset shift among team members, and maintaining a sustainable program focused on continuous improvement. We have incorporated initiatives like a stretching cage, ergonomic mats, and a mandatory injury reporting system to reach our goal. 

Westrock, Maple Heights, OH Plant 
Implemented an automatic timer shutoff switch for the Hogger/Shredder to address instances of forgetting to power off the machine, enhancing safety and reliability. With guidance from an electrician, a photo eye and timer were integrated into the PLC system, ensuring the machine shuts down after a set period of inactivity. Additionally, an interlock switch was installed on the inlet door to enhance safety further, stopping all power to the Hogger in case of unauthorized access. These measures have bolstered our safety culture and demonstrated leadership's commitment to employee well-being.

Georgia-Pacific, Albion, MI 
A critical hazard between mobile equipment and pedestrians is in our shipping yard when an employee manually places a trailer stand once a truck arrives at the dock. We found a solution in the Shuntable Stand 1.0 to eliminate the hazard. While this specific stand could meet our requirements, we knew we could do better, so we partnered with the manufacturer to produce the Shuntable Stand 2.0 – now front-mounted on yard jockey trucks for enhanced functionality. With implementation taking over three months, adjustments were made to ensure stability and reliability, ultimately eliminating the need for manual placement of stands, wheel chocks, and glad hand locks, thus eliminating pedestrian risks and improving safety, even in harsh winter conditions.

Georgia-Pacific, Denton, TX 
Revamped their Lock Tag Verify (LTV) program from paper to electronic format to reduce waste, enhance safety, and utilize team suggestions. Using handheld tablets and an online system, they streamlined procedures with QR codes for easy access and tracking, requiring completing each step before progressing. The phased rollout incorporated stakeholder feedback, facilitated cross-functional collaboration and inspired other facilities to adopt the system. The digital platform has improved safety by ensuring thoroughness in the lockout process and facilitated data analysis for identifying areas of improvement.