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