Findings reveal that the average cost per major incident related to Operator error exceeds $80M. In order to avoid this, many industries are opting for Operator Training solutions that help companies to rise above the challenges of designing, controlling and operating their plants safely, reliably and profitably.
Humans are visual learners, who learn more easily by seeing how something works, rather than just reading about it. This can be further improved by actually performing the actions. That is why PC-based simulation trainings are much more trusted in industries like Mining, Construction and Forestry and it is a cost-effective way of improving traditional operator training. They provide hands-on experience, more quickly and efficiently, to operators in a safe environment.
PC-based Simulation training is important for preventing accidents at work places. It is proven to reduce training costs, increases productivity, and minimizes the risks. The PC-based simulation has made simulation training affordable to industries. There are three levels of simulations.
3 Levels of Simulations
The 3 levels of simulations describe how close the simulation process is and equipment reacts to the actual plant.
1. Low Fidelity: It is the basic process simulator that is a part of the software with the control system.
2. Medium Fidelity: It uses 2 PCs, one for running the control software program, and the second for supplying process responses.
3. High Fidelity: It mimics the actions of the process.
Benefits of using PC-based Simulators
A well-designed and operated simulation training program has many benefits. These are:
1. Cost-Effective: PC hardware is inexpensive, and graphical programming methods created for the Operating System now enable plant personnel, to configure the simulator.
2. Improves Quality: Simulators create scenarios, which depict the actual problems in the work place. It improves the quality of operator by recording their responses. Senior operator’s responses can act as best practices, which can be used to measure the improvements of new trainees.
3. Practical Training Method: It helps trainees, to make a transition to field training on an actual machine, much easier.
4. Mitigating Factor: When the operators confront a problem in real life, simulation training programs act as a mitigating factor and take precautions to prevent the damage.
5. Leads to Process Improvements: It enhances operator actions, reducing risk of accidents and increase operator productivity.
The goal of training via Simulations is to get the trainer close to the real situation and when they experience a worst-case in real life, simulation programs help them to take the precautions, as they have already realized this solution through simulation.