Safety Innovation Summary:
The corrugator roll handling process required multiple employees to work in close proximity, creating a risk where one person could activate roll arms while another remained in the danger zone. Past industry incidents highlighted serious injuries caused by struck-by and pinch point hazards, often due to reliance on communication and timing. To address this, pressure-sensitive safety mats were installed in the roll handling area. These mats automatically disable all roll arm movement whenever a person is detected within the hazard zone, ensuring that equipment cannot operate until the area is clear. 

 

Implementation and Impact:
This solution introduced an engineered control that removes dependence on human behavior and communication. The mats provide a consistent and automatic safeguard by preventing any arm movement while personnel are present in the area. As a result, the risk of struck-by and pinch point injuries is significantly reduced. This improvement establishes safe operation as the default condition and reinforces the principle of eliminating hazards through engineering controls rather than relying solely on administrative practices.

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