A Unique and Cost Effective Approach to Simulation Training

1
A Unique and Cost Effective Approach to
Simulation Training

• Presented by
• Dave Young- Simtronics Corporation
• Chris Dannenmaier- KBC Human Performance
  Improvement

2
The Current Landscape of Simulator Training
Options

• Generic- Ideal for principle level training.
• Custom- Unit optimization, management of Advanced
  Controls, Start up/Shut Down.
• Semi-Custom- A variation of generic with some
  tweaks. Mostly graphical and user interface
  changes.

3
In a Perfect World

• We would have no issues with budgets, staffing,
  time management, department communications,
  turnover, etc.
• Training would be a high priority for management.
• A long term structured two-stage simulation
  training program would be developed and
  implemented.

4
Perfect World Simulation Program Stage 1

• A full library of generic simulation would be
  deployed to operators for rigorous principle
  level training.
• Troubleshooting skills- eliminate rote responses.
• Start Up/ Shut Down.
• Plant safety.
• Structured curriculum and evaluation of process
  skills.
• Builds the foundation for meaningful training on
  a custom simulator.

5
Stage 1 Generic

• Low entry cost.
• Very low maintenance cost.
• PC Based- Easy accessibility.
• Commercial curriculum is becoming more readily
  available.
• Minimizes rote learning in favor of principle
  level understanding.

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Perfect World Simulation Program Stage 2

• Stage 1 complete- Operators have a solid
  principle level understanding of process.
• Evaluate results of Stage 1 to determine priority
  list for custom simulators.
• Major design differences- generic doesnt
  translate well.
• Advanced Controls significantly change how the
  unit operates.
• Where a suitable business case can be made,
  custom simulators would be built.

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Perfect World Simulation Stage 2 Continued

• Curriculum would be developed surrounding the
  custom simulator.
• Production optimization.
• Management of Advanced Controls.
• Procedure validation.
• Proprietary Units.

8
Results of a Perfect World Simulation Program

• Blended Approach offers the best of both worlds.
• Knowledge that operators are mastering principles
  of operation- not simply memorizing procedures.
• True optimization of high value units.
• Applying solid foundational skills to real job
  duties.
• Turning knowledge into skill.
• Structured curriculum and evaluation-
  documentation of operator competency.

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We Dont Live in a Perfect World

• Custom simulators carry a heavy upfront cost.
• Significant long term commitment of time/money to
  keep custom units evergreen.
• Trainers need to master 2 or more simulator
  systems.

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We Dont Live in a Perfect World Continued

• Costly and difficult to develop curriculum for
  large numbers of unit specific simulators.
• There is great pressure to limit time for
  operator training.

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To Achieve a Perfect World Scenario.

• A major long-term commitment would be needed from
  all levels of management.

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Custom Simulation Obstacles

• Very high initial cost.
• Building and maintaining a custom simulator is a
  major strain on already stretched resources.
• Engineering data.
• Quality reviews/ vendor communication.
• The strain is ongoing if the unit is to be
  maintained correctly.
• May take the best console operators off the
  board.

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Custom Simulation Downfalls

• Projects are shelved due to emergencies,
  turnarounds, etc.
• Management long term commitment.
• Many will lose focus and support will wane.
• Management changes.
• Will a new manager have the same commitment?
• Inactivity.
• Hard to access, easily forgotten.

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An Outdated Custom Simulator is a VERY EXPENSIVE
Generic Simulator
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The Perfect World is Not Viable at All Sites

• Custom Simulators are not always an option.

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Business realities do NOT decrease the need for
knowledgeable, safe operators on ALL units.

• Accidents can happen anywhere- not just in high
  value units.
• Lack of a pure business case does not decrease
  the need to ensure safety and efficiency.
• The benefits of automation investment are limited
  by lack of operator skill.

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When Custom Simulators are not an option, are we
forced to settle for generic only?
18
There is another option.
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Enhanced Semi-Custom Simulation

• A generic unit based on your units technology is
  used as a base simulation.
• The unit may be tweaked to customize graphics or
  interface.
• Site specific control strategies, including
  Advanced Controls are overlaid on the generic
  unit.

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Benefits

• Provides much of the benefit of full custom
  simulation at a fraction of the cost.
• Greatly reduces the time commitment needed to
  manage the development of custom simulators.
• Trainee can run simulations with and without
  Advanced Controls- managing the process
  appropriately.

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Benefits Continued

• Easy to teach, easy to learn.
• Quickly illustrates gaps in operators base
  knowledge.
• Can be PC-Based for easy universal access.

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Trend Toward Corporate Wide Training Initiatives

• New technology is enabling more standardization.
• Cost considerations/ economies of scale.
• Decrease re-inventing the wheel.
• Corporate wide quality control of training.

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Enhanced Semi Custom as a Corporate Wide solution

• A base generic unit will be selected.
• The base generic unit may be off the shelf or
  specifically developed for a particular group of
  sites.
• Perhaps multiple base designs.
• Each site will have its specific Advanced
  Controls overlaid on the pre-approved base
  design.
• A basic level of console and control mastery can
  be easily taught and evaluated.

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Training with Enhanced Semi Custom Simulation

• As with any tool, effective simulation training
  is dependant on a solid, structured delivery
  program.
• Relevant and well presented curriculum.
• Simulation exercises to augment written
  curriculum and theory.
• Objective evaluation.
• Gap training.
• Time for practice.

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Enhanced Semi Custom Simulation Curriculum

• A standard curriculum would be developed for each
  base unit on a corporate wide basis.
• Can be Paper Based, CBT, Instructor led.
• Curriculum would include
• Job Duty Training.
• Process Control Training.
• Process Troubleshooting.
• Console Strategy Training
• Process Optimization.

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Enhanced Semi Custom Simulation Curriculum

• Unit curriculum would leave some room for site
  specific modifications.
• Start up/Shut down procedures.
• Unit specific nuances.

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Results

• Not to be mistaken for the Perfect World.
• But significantly better than doing nothing.
• Far greater unit specific knowledge than with
  generic alone.
• Provides a means of building basic operator skill
  sets.
• Higher level than generic alone.
• Consistent corporate wide operator competency can
  be achieved and documented.
• Present and future regulatory considerations.

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Individual Site

• Not all process facilities are part of a
  corporate simulation training initiative.
• May therefore have a smaller budget.
• Benefits of Enhanced Semi Custom Simulation apply
  equally
• Lower up front cost.
• Lower maintenance cost.
• Easier to justify to management.
• Curriculum may be more costly.

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Questions
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Thank You!

• Dave Young
• Simtronics Corporation
• dyoung_at_simtronics.com
• 908-537-6734
• Chris Dannenmaier
• KBC Human Performance Improvement
• cdannenmaier_at_kbcat.com