why equipment simulators ?
DESCRIPTION
Why Equipment Simulators ?. Caterpillar Equipment Training MISSION Assist our customers in improving their return on investment from the use of Caterpillar products and services. Situation: World equipment fleet not safely / effectively utilized New equipment not used as designed - PowerPoint PPT PresentationTRANSCRIPT
Why
Equipment Simulators
?
Caterpillar Equipment Training
MISSION
Assist our customers in improving their return on investment from the use of
Caterpillar products and services
• Situation:– World equipment fleet not
safely / effectively utilized– New equipment not used as
designed– Equipment abused /accidents– Licensing and regulatory
pressures building– Deepening skill vacuum:
• Exit bubble• Entry shortage
• Consequence:– End-user ROI potential
capped– Negative effect on
perception of value– Loss - all parties– Conflicting, costly,
confusing standards– Work delayed, not
started, purchases delayed
User sees need, wants to change, but . . .- perceives costs of correction as too high- feels no regulatory “force majeur”- competitors have same problem
Actual costs of correction are high:- equipment - time - production loss
- effectiveness of training is low
“There is no help!”
Some users do not see need ( ! )
What’s the Reaction?
Traditional training programs targeted on some basic level of competency that may, or may not be defined in regulations, policies, etc. All too widely, these efforts are viewed as pure cost.
The focus is not on proficiency and the surety that knowledge and skill underlie safety and profit.
What’s at the core?
Traditional training programs targeted on proficiency
Employment of tools and techniques from similar * industries: aircraft, shipping, heavy lifting, railroads, surgery, military vehicles
*Definition of similar: high capital cost, high operating cost, critical nature of emergency techniques, high risk to human and equipment
Technological advances have lowered costs of these tools, SIMULATORS, dramatically-10 years
plus
How is this to be addressed ?
Caterpillar Equipment Training Sim I
Increasingly employed on a commercial basis:Cranes, trains, ships, emergency vehicles
Interest turning to earthmoving/mining equipment:Skill development efficiencyEffective at all levels of skill development“Infinitely” flexibleConsistentRisk freeSystems integration
Simulator Evolution
• Candidate aptitude• Perform all operations
before put on truck• Periodic booster
– Reinforce new hands
– Refresh/correct old
– Rain, ice, snow
• Pits, hauls, night/day• Systems, features• Awareness
• Evaluation • Basic training
• Production refresher– every 6 months– old & new hands– seasonal prep
• New mine situations• New equipment• Supervisor training
Simulator Application
Simulator - Series I
Simulator Series II
Air conditioning
Air compressor
Operator station on long axis - floor to ceiling view
Truck setup
Shovel setup
Installing shovel module
Arctic package for Nuna Logistics
• Print out an operator's detailed report, and log or "play back" the operator's session to evaluate performance
Feedback
VIDEO
Most common benefit mentioned Increased equipment availability
Most commonly observed errors:
Improper service brake useFailure to use/don’t know how to use retarderEngine overspeedFailure to react correctly to emergenciesDo not react to/know levels of warningWide variety of traffic/safety violations
Results?
Experience - I
USA December, 2000
35 operators 1 hour each
Long history of brake problems - 190 ton truck fleet
Not one operator used the retarder
Mine management initiated complete retraining program for 2001 and 2002
Experience - II
USA 2001
42 operators 2 1/2 hours each
Service brake used incorrectly 2028 times/12 hr
Shift fwd while moving backwards 156 “ “
Shift reverse while moving forward 234 “ “
Service brake not engaged 936 “ “
when park brake released
Experience - III
Labrador September, 2001
182 operators I hour each
5761 faults recorded 85% among 6 faults
66% in one fault - Service Brake used incorrectly
Emergency tests
40% failed to extinguish fire
Employee morale
Initial concern, turned very positive - “high tech"
Experience - IV
British Columbia October, 2001
85 operators 3 hours each
Program any road condition, truck problem without risk
Common criteria for evaluation
Neutral “instructor” - the computer
Objective basis for comparison and seeing improvement
40 trucks 160 operators 20% turnover
32 new operators per yr @ 20 hrs each 640 hrs
128 experienced operators at 4 hours each 512
64 op candidates @ 2 hrs each 128
Total hours 1280 hrs
Sim interest and depreciation $50,000/yrSim operating expense 10,000
Instructor @ $30/h 38,700
Total annual expense $98,700
Cost per hour $77
Simulator Training Cost Strawman
20 trucks 60 operators 20% turnover
12 new operators per yr @ 20 hrs each 240 hrs
48 experienced operators at 4 hours each 192
24 op candidates @ 2 hrs each 48
Total hours 480 hrs
Sim interest and depreciation $50,000/yrSim operating expense 5,000
Instructor @ $30/hr $14,400
Total annual expense $69,400
Cost per hour $147
Simulator Training Cost Strawman
• Candidate aptitude• Perform all operations
before put on truck• Periodic booster
– Reinforce new hands
– Refresh/correct old
– Rain, ice, snow
• Pits, hauls, night/day• Systems, features• Awareness
• Evaluation • Basic training
• Production refresher– every 6 months– old & new hands– seasonal prep
• New mine situations• New equipment• Supervisor training
Simulator Application
Integrated Training ProgramEvaluation Current and candidates
Foundation skills Proficiency, emergency
Re-qualification After an incident
“Check ride” Semi-annual
New conditions Layout, equipment, seasonal
Effective program requires use of simulator and actual equipment - simulator not a “silver bullet”
What Can Proper Operator and Supervisor Training Deliver?
• Increased Production• Lower Repair Costs• Longer Power Train Life• Fewer Sudden Death Tire
Failures• Reduction in Injury Rates• Fewer Safety Citations• Lower Employee Turnover
• Reduced Downtime• Increased GET Life• Reduction in Structural Failures• Longer Tire Life• Higher Resale Value• Reduced Insurance Costs• Improved Employee Morale
Greater Safety & Profit
Caterpillar Equipment Training
Get the most out of your investment
Truck Operational
Video
Written Test
PassWatch Video
with TestPass
Simulator Evaluation
Simulator Review
Simulator Performance
Training
FinalSimulator Evaluation
Acceptable?
General Evaluation and
Training Complete
More Training
Special Training
Yes
No
No
Yes Yes
No
Simulator
Operator techniquesService brakeThrottle controlRetarderSpecial Hazard Training- Flat tires- Slippery conditions- Defensive driving- Fog / Night time conditions- Fire
Video
General safety practicesWalk-around InspectionStartup proceduresSetting the transmission controlProper braking & retardingLoadingTraveling & dumpingShut down procedures
Top 5% Performers
Good attitudeProper skill setWillingness to shareLeader / exampleCertified Operator TrainingStretch capabilitiesBuild teamworkIncrease skill levelIncrease moraleSet examplesTalk Performance
Pit Bosses / Foreman / SupersMachine App. & Performance Sem.
Analyze job conditionsProduction requirementsProduction costsMachine versatilityMachine sizing & attachments
Off Highway TruckPerformance & Safety Training Plan
Machine Operational
Video
Written Evaluation
Pass
Watch Video with
EvaluationPass
General Evaluation and
Training Complete
Special Training
No
No
Video
General safety practicesWalk-around InspectionStartup proceduresMachine operation fundamentalsShut down procedures
Top 5% Performers
Good attitudeProper skill setWillingness to shareLeader / example
Certified Operator TrainingStretch capabilitiesBuild teamworkIncrease skill levelIncrease moraleSet examplesTalk Performance
Pit Bosses / Foreman / Supers
Machine App. & Performance Sem.
Analyze job conditionsProduction requirementsProduction costsMachine versatilityMachine sizing & attachments
General MachinePerformance & Safety Training Plan
Operator Training (Non
Certified)
Yes
Performance Evaluation
Pass Special Training
No
Yes
Operator Training (Non Certified)
General safety practicesWalk-around InspectionStartup proceduresMachine operation fundamentalsShut down procedures
On The Iron