Safety Innovation Summary:
During a liner tear-out on a splicer, an employee sustained a thumb injury while attempting to stop a free-spinning idle roller by hand. These rollers retain significant momentum and cannot be stopped by lock, tag, verify (LTV) or alternative protective measures (APM). With no mechanical brakes and no feasible OEM solution, the site developed a custom tool—“the Roll Stopper”—to safely and effectively stop the dancer rollers.

 

Implementation and Impact:
Initial prototypes faced alignment and stopping-force challenges, but through collaborative testing with the maintenance team and EDP, adjustments were made to size, shape, and material. The final Roll Stopper proved effective and durable, while remaining compliant with BRC standards. To ensure safe adoption, the team conducted hands-on training, created a new SOP, and integrated the tool into LTV procedures.

The result is a significant reduction in hand and finger injury risk, improved LTV compliance, and a strengthened safety culture through proactive hazard mitigation.

 

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