The mining training processes of large African companies is made more efficient and cost effective with advanced simulator training technology, says simulator training equipment company Immersive Technologies marketing coordinator Don Forbes.

Mining companies operating in Africa as BHP Billion (Middelburg Mine), Xstrata mining (South Africa) and Aveva (Niger), have all invested in the simulator technology and equipment in a plight to enhance productivity, safety and cost efficiency in improving operator training programmes, states Forbes.

"These customers join the growing number of African companies such as Geita Gold Mine, Tanzania who reportedly have reduced training time by 50% resulting in substantial savings from not having to remove equipment from the production cycle, but also in reduced unscheduled maintenance costs through better trained operators," he says.

Simulation-based training has been used in the space and aviation industries for many years, owing to the benefits of training for pilots for this highly technical environment.

Immersive Technologies have since become a leading provider of heavy equipment simulator training products to the mining and earthmoving industries.

The company has supplied its simulation products to biggest mining companies across the world with 330 of its simulator modules used in 130 location in 21 countries, including Africa.

ENABLING EFFICIENT IN-HOUSE TRAINING AND RECUITMENT
Forbes says that the simulator provided its African customers with the opportunity to add to existing skills of its personnel.

"The simulator provided much need structure to their training program, and its ability to up-skill local workers, who have little to no experience driving any vehicles at all, resulting in higher productivity and increased levels of safety on site," he says.

The simulator equipment supplied by Immersive Technologies enables training of staff in a highly realistic simulator instead of undergoing training in the actual equipment.

The simulator has real function original equipment manufacturers (OEM's) cab controls and instrumentation, photo realistic 3D graphics, digital surround audio, and a motion base replicating the true feel of the mining equipment.

Immersive Technology reports that simulator technology assists mining organisations in lowering cost per tonne in the safest possible way, with advanced equipment (AE) simulators being used by leading mining companies in recruiting, training and implementing refresher tests for heavy equipment operators.

Forbes says that simulator technology provides the ability to train in a multitude of different scenarios and environments to efficiently prepare operators for future working conditions.

"Many of the scenarios within the simulator are not possible, or feasible to train within real equipment. Engine and tire fires, loss of steering/brakes, and environmental conditions are just some of the many events, to which the trainer can expose a trainee," adds Forbes.

The simulator can be used in a variety of different training areas, and this includes pre-employment qualification, basic equipment skills, periodic emergency training, site orientation and new equipment model training, explains Forbes.

BENEFITS IN THE PRODUCTION LINE
Forbes says that trainees are able to repeatedly practice difficult scenarios without holding up the production circuit and reducing the productivity of the mine.

"The combination of onscreen errors, pre-recorded multimedia lessons, together with the close tuition of the trainer ensures the operator has a thorough understanding of the correct operational procedures of the equipment and their role in the production cycle," he adds.

Training operators using the AE simulator ensures that trainees become familiar with machine controls and instrumentation in a safe environment.

The ability to practice realistic emergency situations is unparalleled and can be the deciding factor in a dangerous situation, reports Immersive Technologies.

Benefits of a simulator include minimizing machinery downtime, fewer production interruptions by reducing the amount of time an inexperienced operator is in the circuit, wear and tear reduction, owing to operators with high-level equipment handling skills, increased handling of machine operation, and effective prospective employee assessment, reports Immersive Technologies.

"It allows trainees to enter the actual work environment at a much higher level of competency right from their first shift, increasing their overall confidence, which acts to reduce stress related incidents," corroborates Forbes.

He says that better trained operators provide better cycle times, less wear on equipment, reduced unscheduled maintenance and a safer working environment.

SIMULATORS IN AFRICAN MINING OPERATIONS
Immersive Technologies count BHP Billiton, Rio Tinto, Freeport McMoRan, Anglo Coal, Xstrata, Equinox Minerals, and Geita Gold, among the mining houses to have implemented simulators in its mining operations.

"Equinox Minerals site at Lumwana, Zambia purchased 4 base simulators and a range of machine modules to rapidly train their predominantly indigenous operator workforce, many who have not previously driven a vehicle of any type," states Forbes.

"These are among a growing number of African companies, that includes Geita Gold Mine, Tanzania, who reportedly have reduced training time by
50%, resulting in substantial savings from not only having to remove equipment from the production cycle, but also in reduced unscheduled maintenance costs through better trained operators," adds Forbes.

ORIGINAL EQUIPMENT MANUFACTURERS
Alliances with many OEM's as Caterpillar, Hitachi, Komatsu, Liebherr, Bucyrus, and P&H Minepro, ensures that the Immersive Technologies receive the essential technical information necessary to accurately replicate their equipment, says Forbes.

"Through our large customer base we continue to actively collect feedback and industry information to ensure the simulators are acting on the industries most pressing requirements. Most recently a large amount of resources have been placed in developing simulation scenarios of tire preservation, which have been received very positively by our customer base. We meet on regular intervals with as many customers as possible to share ideas, and continually learn from each other," he concludes.